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Question:  1996 Plymouth Grand Voyager  mileage: 100,000.  This is what I've done to our van so far:  1.  Compression test of 150-160 (all six cylinders) 2.  Fuel pressure is good (50 psi) 3.  Timing good---mechanical and ignition 4.  Igniters---continuity check was good; Noid light check was good  5.  Idle air control valve resulted in lowering of RPM when disconnected 6.  Removed exhaust pipe, which took catalytic converter out of play--no change 7.   Replaced:  O2 sensor; map sensor; plugs; wires; fuel filter; air filter.  Van still runs rough at idle, burns rich (black smoke), lacks power and stalls if driven.  Self-diagnostic shows no codes except for battery disconnect.

Answer:  Scan the computer with an OBDII scan tool.  This will check for soft fault codes that do not show up on the self-diagnostic check.  Also, check the fuel injectors for proper spray pattern and flow volume.

Question: 1992 Plymouth Voyager mileage: 178,085. My car recently broke down. I replaced the fuel pump, filter, relay; complete tune up all 6 injectors, distributor, and computer and it still would not run on its own. Took it to the dealer and was told the MAP sensor was bad. I had them replace it. Since I got it back the car has a bad hesitation and when I pulled up the codes it has a code 12 and 14. I haven’t disconnected the battery lately but have code 12. Now tonight on my way home it broke down again. I disconnected the MAP sensor and it fired right up and ran pretty well all the way home. I am in desperate need to have this problem resolved.

Answer: We suggest checking the vacuum hoses, especially the one to the MAP sensor. If they check okay, next check the wiring harnesses for resistance or bad connections.

Question: 1985 Plymouth Voyager  mileage: 125,000. You fellows have a really great site! I hope you have an answer to my problem. I bought the above-mentioned van used. About six months later, the a/c compressor quit. I replaced the whole assembly not knowing the history of the vehicle. Upon further checking, the compressor clutch coil had fried. This was with R-12. After replacing the whole compressor using 134a, the van cooled fine for a couple of months. Then the coil went out again. The compressor was still under warranty, so it was replaced. This coil lasted about two years. About a month ago, this coil went out. It also took the clutch plate, so I thought that maybe that was the real problem. I replaced the whole clutch assembly. It didn't last three weeks. This time it was so bad, the compressor bearing was in pieces when I took the assembly off. Please help if you can. This is getting really nerve racking, not to mention expensive! The head pressures appear to be correct. I am installing about 30 oz of 134a when I evacuate and recharge the system. I hope this is enough info for you to give me at least an idea of where to start.

Answer: Try flushing out the entire air-conditioning system and replacing the receiver-drier and the expansion valve.

Question: 1991 Plymouth Voyager mileage: 140,000. My 1991 Plymouth Voyager has developed an intermittent problem. While driving suddenly the speedometer, tach and other gauges flip out and bounce all over the scale. The electric door looks pop up and down. It happens frequently but intermittently. It's funny but, I'd swear that the action gets more fast and furious when I accelerate during these episodes. Can you be as specific as you can because I'm the poor sap that has to fix this?

Answer: The first thing we would check is the body control module. Then check for loose or poor ground connections. Lastly, check the main power distribution box.

Question: 1998 Plymouth Grand Voyager mileage: 67,080.  I had my local roadside service give me a jump due to a "low battery". Since then, the "Rear Wiper", "Intermittent Rear Wiper", "Re-circulation", and the "A/C" buttons on the environmental control panel all blink in unison for approximately 16 -18 minutes immediately after starting the engine. These same 4 buttons also begin to blink when the key is in the "On" position. All 4 buttons function normally during this "blinking" phase. My only observation during this time has been the difficulty in "starting" the engine first thing in the morning when the engine is cold. The engine is slow to crank but does eventually turn over. I have checked the battery cells and they all seem to have enough fluid. The battery is the original Mopar battery and probably should be replaced. But, I wouldn't think this has anything to do with the blinking buttons. Any ideas as to why the buttons blink and then stop?

Answer: First, load test your battery and replace if necessary. Check all the fuses; if okay, scan the body control module as it may have been damaged when you had battery problems.

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Question: 1996 Plymouth Grand Voyager  mileage: 95,000. My heater fan stopped working. I put 12V across the motor and it ran. I checked the 40-amp fuse and it looks OK. I looked at the wiring diagram in the Haynes manual I have and it shows a relay, but I can't find the relay; I'd replace it if I could find it. It's not in the "power distribution center" under the hood, and it's not in the "junction box" under the dash. Do you know where to find this relay?

Answer: It is located on the junction box behind the left side of the dash.

Question: 1996 Plymouth voyager  mileage: 75,000. I have an intermittent gas smell when I have the heat on. It seems to be worse when the re-circulation button is off. The dealer has checked the problem three times with no resolution. Any thoughts?

Answer:  Make sure you don't have a fuel leak immediately, you don't want to have any cracked fuel lines. We have found leaky heater cores that give off an odor similar to gasoline. Have your car check to see if yours is leaking.

Question: 1997 Plymouth Grand Voyager  mileage: 55,000. Steering wheel vibration at 70 mph. Brought the van in 3 times for wheel balancing but vibration still exists when I reach 70. Last time in for balancing they told me that they saw some tire feathering and that perhaps I needed new struts and shocks. Is this possible with only 55,000 carefully driven miles?

Answer: CV joints that are starting to fail will cause a vibration like what you are experiencing. Your struts and shocks are not the cause of the feathering. Improper wheel alignment can cause tires to feather, however. There are three adjustments for wheel alignment, caster, camber and toe in/toe out. The toe in/toe out is most likely your problem.

Question: 1996 Plymouth Voyager  mileage: 65,000. Intermittent problem, turn key, dash lights up, starter does nothing. PCM, automatic shutdown relays, and starter have been replaced. PCM does not capture code when this happens. Have used a co-pilot, this does not capture any malfunction codes. The dealer and Plymouth are stumped. Can you help?

Answer: From what you have explained, the starter would have been the first suspect. However, since you have had it replaced, we would next check the ignition switch and the neutral safety switch. If your battery is the original one, take a look at it also as there could be an intermittent short occurring.

Question: 1995 Plymouth Voyager  mileage: 93,000. I put on pads and rotors on my van last week and I drove it about two miles and saw little wisps of smoke coming from the front right side when I stopped at a stoplight. I pulled over first chance and saw no smoke but did smell hot smell. Every time I drive it, I smell this hot smell when I stop. I don't have any noise or pull while driving or stopping. The brake pedal feels good. I read your Q&A and saw that some people sand their pads could this help my problem or is it something worse?

Answer: Sounds like the brake calipers are hanging up. You will have to remove them and either replace or rebuild them.

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Question: 1995 Plymouth Voyager  mileage: 80,000. Intermittent stalling (becoming less intermittent as time goes by) when slowing down to a stop. No problems at all on the highway etc. but in town it is a nightmare. At every stop sign, the car stalls. It starts right up again and then will stall at the next stop. It doesn't happen every day. For a while, it seemed to happen only when the tank had just been topped off. Recently happened again at half a tank. I've replaced the fuel filter, and had the fuel injection system cleaned. What next? Fuel pump?

Answer: Check the idle speed motor, as it may not be functioning properly. Also, check the engine for vacuum leaks.

Question: 1991 Plymouth Grand Voyager  mileage: 116,304. My compass/trip computer quit working. First, it started intermittently then went completely dead. Is there a relay that powers it? If so, where is it located?

Answer: There is no relay for your trip compute. Try checking all of the fuses. If they all check okay, then you may have to replace the trip computer.

Question: 1991 Plymouth Voyager  mileage: 96,000. Rough idle when starting cold or hot and when put into gear it stalls out. When it's idling, rough it also smells like it's running very rich. If you let it run for several minutes the idle smoothes out then you can put in gear and it doesn't stall. It runs great after you get it going. I have had it scoped, probed and fondled by several different mechanics and they can't seem to find anything wrong. I had a tune-up with new wires and the whole 9 yards done and it ran perfect for about 2 months but then went back to it's old ways. Seems to be a little worse in the summer months.

Answer: Check the fuel pump and filter and also the fuel pressure regulator.

Question: 1999 Plymouth Voyager mileage: 30,000. The door ajar indicator light comes on at unpredictable intervals even when we have shut all possible doors and made sure that no door is ajar. It goes away for several days and then for no reason if starts doing it again and does it for a day or two, then stops. Any idea what's wrong?

Answer: You may have a door switch that is out of adjustment. Try opening and closing each of the doors and giving each door a little extra push to see if the light will go out. If it does that door switch needs adjusting or replacement. If the light continuous to stay on, you probably have a faulty body control module (BCM).

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Question: 1997 Plymouth Voyager  mileage: 52,000. The exterior rubber gasket at the bottom of the windshield keeps coming loose. There is about 12"-15" that keeps popping up. It pushes back in place quite easily, and it remains in place for a little while, but then pops back up again. I was told that the only way to fix it was to remove the windshield. Isn't there an easier fix, perhaps an adhesive of some kind?

Answer: It is our opinion  that the best fix would be to remove the windshield and replace the rubber gasket. As far as using some kind of an adhesive, you could go down to your local hardware store and see if you can find a good rubber cement and give it a try.

Question: 1993 Plymouth Voyager  mileage: 162,000. After doing, a valve job on this van I came up with a code 27, (inj #1& 2 not receiving signal). I got the signal back to all injectors now, but it still runs rough & the problem seems to be that the connector from the fuel injector harness to the main harness is badly corroded. Can you help me locate a repair harness or the necessary connector, terminals, wiring I need to fix this? The dealers have been no help. Thanks

Answer: Your best bet is to find an auto dismantler (wrecking yard) to see if they have the part or can locate one for you from the network of wrecking yards.

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