engine CHRYSLER VOYAGER 2005 Service Manual

Fig. 2 LEFT FRONT ENGINE COMPARTMENT
Fig. 3 WASHER PUMP CONNECTORS
8W - 91 - 18 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

Fig. 6 LEFT SIDE ENGINE COMPARTMENT
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-21
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

Fig. 10 2.4 LITER ENGINE CONNECTORS REAR
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-25
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

Fig. 11 2.4 LITER ENGINE FRONT
8W - 91 - 26 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

Fig. 15 2.5 LITER DIESEL ENGINE FRONT
8W - 91 - 30 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

Fig. 16 2.5 LITER DIESEL ENGINE REAR
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-31
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

Fig. 17 3.3-3.8 LITER ENGINE REAR
8W - 91 - 32 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

Fig. 18 3.3-3.8 LITER ENGINE FRONT
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-33
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

8W-97 POWER DISTRIBUTION SYSTEM
TABLE OF CONTENTS
page page
POWER DISTRIBUTION SYSTEM
DESCRIPTION..........................1
OPERATION............................1
SPECIAL TOOLS
POWER DISTRIBUTION SYSTEMS.........1
INTEGRATED POWER MODULE
DESCRIPTION..........................1
OPERATION............................2
REMOVAL.............................2
INSTALLATION..........................2IOD FUSE
DESCRIPTION..........................3
OPERATION............................3
POWER OUTLET
DESCRIPTION..........................3
OPERATION............................3
DIAGNOSIS AND TESTING
DIAGNOSIS & TESTING - POWER OUTLET . . 3
REMOVAL.............................4
INSTALLATION..........................4
POWER DISTRIBUTION
SYSTEM
DESCRIPTION
The power distribution system for this vehicle con-
sists of the following components:
²Integrated Power Module (IPM)
²Front Control Module (FCM)
²Power Outlets
Refer to Wiring Diagrams for complete circuit sche-
matics.
The power distribution system also incorporates
various types of circuit control and protection fea-
tures, including:
²Automatic resetting circuit breakers
²Blade-type fuses
²Bus bars
²Cartridge fuses
²Circuit splice blocks
²Flashers
²Fusible links
²Relays
OPERATION
The power distribution system for this vehicle is
designed to provide safe, reliable, and centralized dis-
tribution points for the electrical current required to
operate all of the many standard and optional facto-
ry-installed electrical and electronic powertrain,
chassis, safety, security, comfort and convenience sys-
tems. At the same time, the power distribution sys-
tem was designed to provide ready access to these
electrical distribution points for the vehicle techni-
cian to use when conducting diagnosis and repair of
faulty circuits. The power distribution system can
also prove useful for the sourcing of additional elec-
trical circuits that may be required to provide theelectrical current needed to operate many accessories
that the vehicle owner may choose to have installed.
SPECIAL TOOLS
POWER DISTRIBUTION SYSTEMS
INTEGRATED POWER MODULE
DESCRIPTION
The Integrated Power Module (IPM) is a combina-
tion of the Power Distribution Center (PDC) and the
Front Control Module (FCM). The IPM is located in
the engine compartment, next to the battery. (Fig. 1).
The PDC mates directly with the FCM to form the
IPM. The PDC is a printed circuit board based mod-
ule that contains fuses and relays, while the FCM
contains the electronics controlling the IPM and
other functions. This IPM connects directly to the
battery positive through a four pin connector. The
ground connection is through two other connectors.
Terminal Pick Kit 6680
RS8W-97 POWER DISTRIBUTION SYSTEM8W-97-1

ENGINE
TABLE OF CONTENTS
page page
ENGINE 2.4L.............................. 1ENGINE 3.3/3.8L......................... 76
ENGINE 2.4L
TABLE OF CONTENTS
page page
ENGINE 2.4L
DESCRIPTION..........................3
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION............3
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - PERFORMANCE............4
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - MECHANICAL..............6
DIAGNOSIS AND TESTING - ENGINE OIL
LEAK INSPECTION.....................8
DIAGNOSIS AND TESTING - CYLINDER
COMPRESSION PRESSURE TEST.........9
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE
TEST................................9
STANDARD PROCEDURE
STANDARD PROCEDURE - ENGINE CORE
AND OIL GALLERY PLUGS..............10
STANDARD PROCEDURE - REPAIR OF
DAMAGED OR WORN THREADS.........10
HYDROSTATIC LOCKED ENGINE.........10
FORM-IN-PLACE GASKETS AND SEALERS . 11
STANDARD PROCEDURE - ENGINE
GASKET SURFACE PREPARATION........11
STANDARD PROCEDURE - MEASURING
BEARING CLEARANCE USING
PLASTIGAGE........................12
REMOVAL - ENGINE ASSEMBLY...........12
INSTALLATION - ENGINE ASSEMBLY........14
SPECIFICATIONS
SPECIFICATIONS - 2.4L ENGINE.........16
SPECIFICATIONS - TORQUE............20
SPECIAL TOOLS
2.4L ENGINE.........................21
AIR CLEANER ELEMENT
REMOVAL.............................24INSTALLATION.........................24
AIR CLEANER HOUSING
REMOVAL.............................25
INSTALLATION.........................25
CYLINDER HEAD
DESCRIPTION.........................25
DIAGNOSIS AND TESTINGÐCYLINDER HEAD
GASKET............................25
REMOVAL - CYLINDER HEAD.............26
CLEANING............................26
INSPECTION..........................27
INSTALLATION - CYLINDER HEAD..........27
CAMSHAFT OIL SEAL(S)
REMOVAL.............................28
INSTALLATION.........................29
CAMSHAFT(S)
DESCRIPTION.........................29
OPERATION...........................29
STANDARD PROCEDURE - MEASURING
CAMSHAFT END PLAY.................29
REMOVAL.............................30
CLEANING............................30
INSPECTION..........................30
INSTALLATION.........................31
CYLINDER HEAD COVER
REMOVAL.............................31
CLEANING............................31
INSPECTION..........................31
INSTALLATION.........................32
INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION.........................33
CLEANING............................33
VALVE SPRINGS & SEALS
REMOVAL
REMOVAL - CYLINDER HEAD ON.........33
REMOVAL - CYLINDER HEAD OFF........33
INSPECTION..........................33
RSENGINE9-1