heating CHRYSLER VOYAGER 2001 Owners Manual

inoperative heated seat switch(es) and a good ground.
There should be no continuity. If OK, go to Step 7. If
not OK, repair the shorted seat heater switch sensor
ground circuit as required.
(7) Check for continuity between the seat heater
switch sensor ground circuit cavities of the instru-
ment panel wire harness connector for the in opera-
tive heated seat switch and the instrument panel
wire harness connector for the BCM. There should be
continuity. If OK, go to Step 8. If not OK, repair the
open seat heater switch sensor ground circuit as
required.
(8) Check for continuity between the seat heater
switch mux circuit cavity of the instrument panel
wire harness connector for the inoperative heated
seat switch and a good ground. There should be no
continuity. If OK, go to Step 9. If not OK, repair the
shorted seat heater switch mux circuit as required.
(9) Check for continuity between the seat heater
switch mux circuit cavity of the instrument panel
wire harness connector for the inoperative heated
seat switch and the instrument panel wire harness
connector for the BCM. There should be continuity. If
OK, use a DRB IIItscan tool and the proper Diag-
nostic Procedures manual to test the BCM. If not
OK, repair the open seat heater switch mux circuit
as required.
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO THE RESTRAINTS SECTION OF
THIS MANUAL BEFORE ATTEMPTING ANY STEER-
ING WHEEL, STEERING COLUMN, SEAT OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the instrument panel center bezel.
Refer toInstrument Panel Center Bezelin the
Body section for the procedure.
(3) Remove the three screws (Fig. 4) that secure
the heated seat switch to the back of the instrument
panel center bezel.
(4) Remove the heated seat switch from the back
of the instrument panel center bezel.
INSTALLATION
(1) Position the heated seat switch onto the back
of the instrument panel center bezel.
(2) Install and tighten the three screws that secure
the heated seat switch to the back of the instrumentpanel center bezel. Tighten the screws to 1.5 N´m (13
in. lbs.) (Fig. 4).
(3) Install the center bezel onto the instrument
panel. Refer toInstrument Panel Center Bezelin
the Body section for the procedure.
(4) Reconnect the battery negative cable.
HEATED SEAT ELEMENT
DESCRIPTION
The heated seat system includes two seat heating
elements in each front seat, one for the seat cushion
and the other for the seat back. The two elements for
each seat that are connected in series with the
Heated Seat Module (HSM). The temperature sensor
is a Negative Temperature Coefficient (NTC) ther-
mistor. One temperature sensor is used for each seat,
and it is located on the seat cushion heating element
for all models.
The seat heating elements are sewn into the seat
cushion cover trim and seat back cover trim units.
The heated seat elements and the temperature sen-
sor cannot be adjusted or repaired and, if faulty or
damaged, the seat cushion or seat back assembly
must be replaced. Refer toSeat CushionorSeat
Backin the Removal and Installation section of
Body for the seat cushion and seat back service pro-
cedures.
Fig. 4 SWITCH RETAINING SCREWS
1 - HEATED SEAT SWITCH ASSEMBLY
2 - RETAINING SCREWS
8G - 10 HEATED SEAT SYSTEMRS
DRIVER HEATED SEAT SWITCH (Continued)

OPERATION
The heated seat elements resist the flow of electri-
cal current. When battery current is passed through
the elements, the energy lost by the resistance of the
elements to the current flow is released in the form
of heat. The temperature sensor is a NTC thermistor.
When the temperature of the seat cushion cover
rises, the resistance of the sensor decreases. The
HSM or MHSM supplies a five-volt current to one
side of each sensor, and monitors the voltage drop
through the sensor on a return circuit. The MSM or
MHSM uses this temperature sensor input to moni-
tor the temperature of the seat, and regulates the
current flow to the seat heating elements accordingly.
DIAGNOSIS & TESTING - HEATED SEAT
ELEMENT
The wire harness connectors for the seat cushion
and seat back heating elements are located under the
seat, near the rear edge of the seat cushion frame.
For circuit descriptions and diagrams, refer to Group
8W, Wiring Diagrams.
SEAT CUSHION
(1) Disconnect and isolate the battery negative
cable. Unplug the 4-way heated seat cushion wire
harness connector.
(2) Check for continuity between the two heated
seat driver circuit cavities of the seat cushion cover
half of the heated seat cushion wire harness connec-
tor. There should be continuity. If OK, go to Step 3. If
not OK, replace the faulty seat cushion cover.
(3) Check for continuity between one of the heated
seat driver circuit cavities of the seat cushion cover
half of the heated seat cushion wire harness connec-
tor and the seat cushion frame. There should be no
continuity. If OK, go to the Seat Back test. If not OK,
replace the faulty seat cushion cover.
SEAT BACK
(1) Disconnect and isolate the battery negative
cable. Unplug the 2-way heated seat back wire har-
ness connector.
(2) Check for continuity between the heated seat
driver circuit cavity and the ground circuit cavity of
the seat back cover half of the heated seat back wire
harness connector. There should be continuity. If OK,
go to Step 3. If not OK, replace the faulty seat back
cover.
(3) Check for continuity between the heated seat
driver circuit cavity of the seat back cover half of the
heated seat back wire harness connector and the seat
back frame. There should be no continuity. If OK,
test the heated seat sensor as described in this
group. If not OK, replace the faulty seat back cover.
HEATED SEAT SENSOR
DESCRIPTION
The heated seat temperature sensor is a Negative
Temperature Coefficient (NTC) thermistor. One tem-
perature sensor is used for each seat, and is inte-
grated into the seat cushion heating element.
DIAGNOSIS & TESTING - HEATED SEAT
SENSOR
For complete circuit diagrams, refer toWiring
Diagrams.
(1) Disconnect and isolate the battery negative
cable. Disconnect the 4-way heated seat cushion ele-
ment wire harness connector from the power seat
wire harness. The power seat wire harness connec-
tors for the seat cushion and seat back heating ele-
ments are secured to a bracket located under the
rear edge of the seat cushion frame.
(2) Using an ohmmeter, check the resistance
between the seat sensor circuit and the seat temper-
ature sensor input circuit cavities of the 4-way
heated seat cushion element wire harness connector.
The sensor resistance should be between 2 kilohms
at 15É C (60É F) and 200 kilohms at 30É C (85É F). If
not OK, replace the faulty seat cushion cover trim
and sensor unit.
PASSENGER HEATED SEAT
SWITCH
DESCRIPTION
The heated seat switches are mounted in the
instrument panel center bezel (Fig. 5). The two three-
position rocker-type switches, one switch for each
front seat, are incorporated into one large switch
assembly that also includes the hazzard, rear window
wiper and washer switches. The heated seat switches
provide a resistor multiplexed signal to the Body
Control Module (BCM) through separate hard wired
circuits. Each switch has an Off, Low, and High posi-
tion so that both the driver and the front seat pas-
senger can select a preferred seat heating mode.
Each switch has two Light-Emitting Diodes (LED)
which light to indicate that the heater for the seat is
turned on.
The heated seat switches and their LEDs cannot
be repaired. If either switch or LED is faulty or dam-
aged, the entire switch assembly must be replaced.
OPERATION
There are three positions that can be selected with
each of the heated seat switches: Off, Low, or High.
When the left side of the switch rocker is fully
RSHEATED SEAT SYSTEM8G-11
HEATED SEAT ELEMENT (Continued)

AUTO SHUT DOWN RELAY
DESCRIPTION
The relay is located in the Power Distribution Cen-
ter (PDC). For the location of the relay within the
PDC, refer to the PDC cover for location. Check elec-
trical terminals for corrosion and repair as necessary
OPERATION
The ASD sense circuit informs the PCM when the
ASD relay energizes. A 12 volt signal at this input
indicates to the PCM that the ASD has been acti-
vated. This input is used only to sense that the ASD
relay is energized.
When energized, the ASD relay supplies battery
voltage to the fuel injectors, ignition coils and the
heating element in each oxygen sensor. If the PCM
does not receive 12 volts from this input after
grounding the ASD relay, it sets a Diagnostic Trouble
Code (DTC).
When energized, the ASD relay provides power to
operate the injectors, ignition coil, generator field, O2
sensor heaters (both upstream and downstream), and
also provides a sense circuit to the PCM for diagnos-
tic purposes. The PCM energizes the ASD any time
there is a Crankshaft Position sensor signal that
exceeds a predetermined value. The ASD relay can
also be energized after the engine has been turned
off to perform an O2 sensor heater test, if vehicle is
equipped with OBD II diagnostics.
As mentioned earlier, the PCM energizes the ASD
relay during an O2 sensor heater test. This test is
performed only after the engine has been shut off.
The PCM still operates internally to perform several
checks, including monitoring the O2 sensor heaters.
CAMSHAFT POSITION
SENSOR
DESCRIPTION
The camshaft position sensorfor the 3.3/3.8L is
mounted in the front of the timing case cover (Fig. 7)
and the camshaft position sensor for the 2.4L is
mounted on the end of the cylinder head (Fig. 4).
OPERATION
The camshaft position sensor provides cylinder
identification to the Powertrain Control Module
(PCM) (Fig. 2). The sensor generates pulses as
groups of notches on the camshaft sprocket pass
underneath it (Fig. 3). The PCM keeps track of
crankshaft rotation and identifies each cylinder by
the pulses generated by the notches on the camshaftsprocket. Four crankshaft pulses follow each group of
camshaft pulses.
When the PCM receives 2 cam pulses followed by
the long flat spot on the camshaft sprocket, it knows
that the crankshaft timing marks for cylinder 1 are
next (on driveplate). When the PCM receives one
camshaft pulse after the long flat spot on the
sprocket, cylinder number 2 crankshaft timing marks
are next. After 3 camshaft pulses, the PCM knows
cylinder 4 crankshaft timing marks follow. One cam-
shaft pulse after the 3 pulses indicates cylinder 5.
The 2 camshaft pulses after cylinder 5 signals cylin-
der 6 (Fig. 3). The PCM can synchronize on cylinders
1or4.
When metal aligns with the sensor, voltage goes
low (less than 0.3 volts). When a notch aligns with
the sensor, voltage switches high (5.0 volts). As a
group of notches pass under the sensor, the voltage
switches from low (metal) to high (notch) then back
to low. The number of notches determine the amount
of pulses. If available, an oscilloscope can display the
square wave patterns of each timing event.
Top Dead Center (TDC) does not occur when
notches on the camshaft sprocket pass below the cyl-
inder. TDC occurs after the camshaft pulse (or
pulses) and after the 4 crankshaft pulses associated
with the particular cylinder. The arrows and cylinder
call outs on Figure 4 represent which cylinder the
flat spot and notches identify, they do not indicate
TDC position.
REMOVAL - 2.4L
The camshaft position sensor is mounted to the
rear of the cylinder head.
(1) Remove the negative battery cable.
Fig. 2 Camshaft Position Sensor
1 - ELECTRICAL CONNECTOR
2 - O-RING
3 - PAPER SPACER
RSIGNITION CONTROL8I-3

POWER MIRRORS
TABLE OF CONTENTS
page page
POWER MIRRORS
DESCRIPTION...........................45
OPERATION.............................45
DIAGNOSIS AND TESTING.................45
POWER MIRRORS......................45
AUTOMATIC DAY / NIGHT MIRROR
DESCRIPTION...........................46
OPERATION.............................46
DIAGNOSIS AND TESTING.................47AUTOMATIC DAY/NIGHT MIRROR..........47
REMOTE SWITCH
DIAGNOSIS AND TESTING.................48
REMOTE SWITCH......................48
REMOVAL..............................48
INSTALLATION...........................48
SIDEVIEW MIRROR
REMOVAL..............................48
POWER MIRRORS
DESCRIPTION
If equipped with power mirrors, the control switch
is located on the instrument panel to the left of the
headlamp switch.
OPERATION
The power mirrors are connected to battery feed at
all times. Each mirror head contains two electric
motors, two drive mechanisms, an electric heating
element, and the mirror glass. If the vehicle is
equipped with the optional memory system, each
mirror head also contains both a horizontal and a
vertical motor position sensor. One motor and drive
controls mirror up-and-down movement, and the
other controls right-and-left movement.
An optional driver side outside electrochromic mir-
ror is able to automatically change its reflectance
level. This mirror is controlled by the circuitry of the
automatic day/night inside rear view mirror. A thin
layer of electrochromic material between two pieces
of conductive glass make up the face of the mirror.
Two photocell sensors on the inside rear view mirror
are used to monitor light levels and adjust the reflec-tance of both the inside and driver side outside mir-
rors. This change in reflectance helps to reduce the
glare of headlamps approaching the vehicle from the
rear. (Refer to 8 - ELECTRICAL/POWER MIRRORS/
AUTOMATIC DAY / NIGHT MIRROR - DESCRIP-
TION) for more information on this system.
The motors which operate the mirrors are part of
the mirror assembly and cannot be serviced sepa-
rately.
DIAGNOSIS AND TESTING - POWER MIRRORS
(1) Remove Power Mirror Switch. (Refer to 8 -
ELECTRICAL/POWER MIRRORS/POWER MIRROR
SWITCH - REMOVAL).
(2) Disconnect wiring harness connector to the
power mirror switch and headlamp switch.
(3) Using two jumper wires:
²Connect one to a 12-volt source
²Connect the other to a good body ground
²Refer to the Mirror Test Chart for wire hookups
at the switch connector (Fig. 1).
(4) If results shown in table are not obtained,
check for broken or shorted circuit, or replace mirror
assembly as necessary.
RSPOWER MIRRORS8N-45

NOTE: Plastigage is available in a variety of clear-
ance ranges. Use the most appropriate range for
the specifications you are checking.
(4) Install the proper crankshaft bearings to
achieve the specified bearing clearances. (Refer to 9 -
ENGINE/ENGINE BLOCK/CRANKSHAFT MAIN
BEARINGS - STANDARD PROCEDURE) (Refer to 9
- ENGINE/ENGINE BLOCK/CONNECTING ROD
BEARINGS - STANDARD PROCEDURE)
REMOVAL - ENGINE ASSEMBLY
(1) Perform fuel pressure release procedure (Refer
to 14 - FUEL SYSTEM/FUEL DELIVERY - STAN-
DARD PROCEDURE)
(2) Disconnect battery negative cable.
(3) Remove air cleaner housing and inlet tube.
(4) Disconnect the fuel line from fuel rail. (Refer to
14 - FUEL SYSTEM/FUEL DELIVERY/FUEL LINES
- STANDARD PROCEDURE)
(5) Disconnect all vacuum hoses.
(6) Drain cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(7) Remove radiator fans. (Refer to 7 - COOLING/
ENGINE/RADIATOR FAN - REMOVAL)
(8) Remove radiator upper and lower hoses.
(9) Disconnect automatic transmission cooler lines
and plug.(10) Disconnect transmission shift linkage and
electrical connectors.
(11) Disconnect throttle body linkage.
(12) Disconnect engine wiring harness.
(13) Disconnect heater hoses from heater (Fig. 5).
(14) Discharge air conditioning system. (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING
- STANDARD PROCEDURE)
(15) Hoist vehicle and remove front wheels and
tires.
(16) Remove accessory drive belt splash shield.
(17) Remove accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)
(18) Remove axle shafts. (Refer to 3 - DIFFEREN-
TIAL & DRIVELINE/HALF SHAFT - REMOVAL)
(19) Drain engine oil and remove oil filter. (Refer
to 9 - ENGINE/LUBRICATION/OIL - STANDARD
PROCEDURE)
(20) Remove crossmember cradle plate (Fig. 6).
(21) Disconnect exhaust pipe from manifold (Fig.
7).
(22) Remove engine front mount and bracket from
engine. (Refer to 9 - ENGINE/ENGINE MOUNTING/
FRONT MOUNT - REMOVAL)
(23) Remove structural collar. (Refer to 9 -
ENGINE/ENGINE BLOCK/STRUCTURAL COVER -
REMOVAL)
Fig. 5 HEATER HOSES - 2.4L
1 - HEATER HOSES TO HEATER 3 - HEATER HOSE TO ENGINE - SUPPLY AND RETURN
2 - BOLT - HEATER TUBE SUPPORT
9 - 12 ENGINE 2.4LRS
ENGINE 2.4L (Continued)

OPERATION
The cylinder head closes the combustion chamber,
allowing the pistons to compress the fuel/air mixture
for ignition. The valves are actuated by the lobe pro-
files on the camshaft to open and close at specified
duration to either allow clean air in the combustion
chamber or the exhaust gases out; depending on the
stroke of the engine.
DIAGNOSIS AND TESTINGÐCYLINDER HEAD
GASKET
A cylinder head gasket leak can be located between
adjacent cylinders or between a cylinder and the
adjacent water jacket.
Possible indications of the cylinder head gasket
leaking between adjacent cylinders are:
²Loss of engine power
²Engine misfiring
²Poor fuel economy
Possible indications of the cylinder head gasket
leaking between a cylinder and an adjacent water
jacket are:
²Engine overheating
²Loss of coolant
²Excessive steam (white smoke) emitting from
exhaust
²Coolant foaming
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determine if an engine cylinder head gasket is
leaking between adjacent cylinders, follow the proce-
dures in Cylinder Compression Pressure Test (Refer
to 9 - ENGINE - DIAGNOSIS AND TESTING). An
engine cylinder head gasket leaking between adja-
cent cylinders will result in approximately a 50±70%
reduction in compression pressure.
CYLINDER-TO-WATER JACKET LEAKAGE TEST
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING WITH COOLANT PRES-
SURE CAP REMOVED.
VISUAL TEST METHOD
With the engine cool, remove the coolant pressure
cap. Start the engine and allow it to warm up until
thermostat opens.
If a large combustion/compression pressure leak
exists, bubbles will be visible in the coolant.
COOLING SYSTEM TESTER METHOD
WARNING: WITH COOLING SYSTEM TESTER IN
PLACE, PRESSURE WILL BUILD UP FAST. EXCES-
SIVE PRESSURE BUILT UP, BY CONTINUOUS
ENGINE OPERATION, MUST BE RELEASED TO A
SAFE PRESSURE POINT. NEVER PERMIT PRES-
SURE TO EXCEED 138 kPa (20 psi).
Install Cooling System Tester 7700 or equivalent to
pressure cap neck. Start the engine and observe the
tester's pressure gauge. If gauge pulsates with every
power stroke of a cylinder a combustion pressure
leak is evident.
CHEMICAL TEST METHOD
Combustion leaks into the cooling system can also
be checked by using Bloc-Chek Kit C-3685-A or
equivalent. Perform test following the procedures
supplied with the tool kit.
REMOVAL - CYLINDER HEAD
(1) Perform fuel system pressure release procedure
before attempting any repairs.(Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY - SPECIFICA-
TIONS)
(2) Disconnect battery negative cable.
(3) Drain cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(4) Remove air filter housing and inlet tube.
(5) Remove upper intake manifold. (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
REMOVAL)
Fig. 13 Cylinder Head and Camshafts
1 - CAMSHAFT BEARING CAPS
2 - PLUG
3 - CAMSHAFT
4 - CYLINDER HEAD
5 - CAMSHAFT OIL SEAL
RSENGINE 2.4L9-23
CYLINDER HEAD (Continued)

CYLINDER HEAD
DESCRIPTION
The aluminum cylinder heads (Fig. 15) are
designed to create high flow combustion chambers to
improve performance, while minimizing the change
to the burn rate in the chamber. The cylinder head
incorporates the combustion chamber. Two valves
per-cylinder are used with inserted valve seats and
guides. A multi-layer steel (MLS) type gasket is used
between the cylinder head and engine block.
OPERATION
The cylinder head closes the combustion chamber,
allowing the pistons to compress the fuel/air mixture
for ignition. The valves are actuated by the lobe pro-
files on the camshaft to open and close at specified
duration to either allow clean air in the combustion
chamber or the exhaust gases out; depending on the
stroke of the engine.
DIAGNOSIS AND TESTINGÐCYLINDER HEAD
GASKET
A cylinder head gasket leak can be located between
adjacent cylinders or between a cylinder and the
adjacent water jacket.
Possible indications of the cylinder head gasket
leaking between adjacent cylinders are:
²Loss of engine power
²Engine misfiring
²Poor fuel economy
Possible indications of the cylinder head gasket
leaking between a cylinder and an adjacent water
jacket are:
²Engine overheating
²Loss of coolant
²Excessive steam (white smoke) emitting from
exhaust
²Coolant foaming
Fig. 15 Cylinder Head and Components
1 - VALVE LOCKS 5 - SPRING SEATS
2 - RETAINERS 6 - CYLINDER HEAD
3 - VALVE SPRINGS 7 - VALVE - EXHAUST
4 - VALVE STEM SEALS 8 - VALVE - INTAKE
9 - 94 ENGINE 3.3/3.8LRS

(24) Disconnect egr solenoid vacuum line at brake
booster check valve.
(25) Disconnect fuel injector, cam sensor, boost
pressure/intake air temp sensor, fuel rail high pres-
sure, and egr solenoid connectors (Fig. 9).
(26) Disconnect generator electrical connectors.
(27) Disconnect coolant temp sensor and glow plug
electrical connectors.
(28) Disconnect injection pump and A/C compres-
sor electrical connectors.
(29) Disconnect starter electrical connectors.
(30) Disconnect ground wires at engine block.
(31) Raise vehicle on hoist.
(32) Disconnect oil temp sensor, oil pressure sen-
sor, engine speed sensor, and vehicle speed sensor
electrical connector (Fig. 10).
(33) Remove front wheels.
(34) Remove the suspension cradle assembly (Refer
to 13 - FRAME & BUMPERS/FRAME/ENGINE
CRADLE CROSSMEMBER - REMOVAL).
(35) Remove both axle shaft assemblies (Refer to 3
- DIFFERENTIAL & DRIVELINE/HALF SHAFT -
REMOVAL).(36) Disconnect the clutch slave cylinder quick dis-
connect line (RHD only)(Refer to 6 - CLUTCH/SLAVE
CYLINDER - REMOVAL).
(37) Disconnect reverse lamp connector.
(38) Disconnect shifter cables at the tranmission
(Refer to 21 - TRANSMISSION/TRANSAXLE/MAN-
UAL/GEAR SHIFT CABLE - REMOVAL).
(39) Disconnect exhaust pipe from the turbo-
charger downpipe and reposition to right side of vehi-
cle.
(40) Disconnect cabin heater coolant line (Refer to
24 - HEATING & AIR CONDITIONING/CABIN
HEATER/HEATER UNIT - REMOVAL).
(41) Remove front engine mount bracket retaining
bolts from lower radiator support
(42) Lower vehicle. Evacuate the A/C system
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/REFRIGERANT - STANDARD PROCE-
DURE).
(43) Disconnect the A/C lines at the A/C compres-
sor.
(44) Disconnect the fuel supply and return lines.
(45) Position engine cradle under engine and lower
vehicle over cradle.
(46) Remove right engine mount bolts.
Fig. 7 CHARGE AIR COOLER HOSES
1 - COOLING MODULE
2 - BYPASS HOSE
3 - UPPER RADIATOR HOSE
4 - CHARGE AIR COOLER OULET HOSE
5 - CHARGE AIR COOLER INLET HOSE
6 - LOWER RADIATOR HOSE
7 - CHARGE AIR COOLER
Fig. 8 UPPER AND LOWER RADIATOR HOSES
1 - COOLANT BYPASS HOSE
2 - RADIATOR ASSEMBLY
3 - UPPER RADIATOR HOSE
4 - COOLING FAN
5 - LOWER RADIATOR HOSE
6 - CHARGE AIR COOLER
7 - RADIATOR BRACKET
RGENGINE 2.5L TURBO DIESEL9a-5
ENGINE 2.5L TURBO DIESEL (Continued)

(7) Attach front engine mount bracket to lower
radiator support. Torque to 54N´m (40 ft. lbs.)
(8) Connect cabin heater coolant hose.
(9) Connect exhaust pipe to the turbocharger
downpipe flange. Torque to 28 N´m (250 in. lbs.)
(10) Connect reverse lamp electrical connector at
transmission.
(11) Connect both shifter cables (Refer to 21 -
TRANSMISSION/TRANSAXLE/MANUAL/GEAR
SHIFT CABLE - INSTALLATION).
(12) Connect the clutch slave cylinder quick dis-
connect connector (RHD only)(Refer to 6 - CLUTCH/
SLAVE CYLINDER - INSTALLATION).
(13) Install engine harness into bracket on trans-
mission.
(14) Lower vehicle.
(15) Connect fuel supply and return lines.
(16) Connect A/C lines to A/C compressor. Torque
to 23N´m (17 ft. lbs.)
(17) Route engine wiring harnes to proper location.
(18) Connect engine harness ground cables to
engine block
(19) Connect starter solenoid electrical connector
and battery feed wire to starter. Torque to 10N´m (90
in. lbs.)
(20) Connect A/C compressor, injection pump, glow
plugs, and coolant temperature sensor electrical con-
nectors.
(21) Connect generator electrical connector. Torque
to 9N´m (75 in. lbs.)
(22) Connect the fuel injector, fuel pressure sensor,
boost pressure/intake air temp sensor, cam sensor,
and egr solenoid electrical connectors (Fig. 9).
(23) Connect egr solenoid vacuum supply line to
brake boost vacuum supply line.
(24) Connect brake booster vacuum supply line.
(25) Connect heater core return hose to coolant
pipe.
(26) Connect lower radiator hose to engine (Fig. 8).
(27) Install charger air cooler inlet hose (Fig. 7).
(28) Install charge air cooler outlet hose (Fig. 7).
(29) Connect upper radiator hose to engine (Fig.
8).
(30) Install battery shield.
(31) Install coolant reserve pressure container
(Refer to 7 - COOLING/ENGINE/COOLANT RECOV-
ERY PRESS CONTAINER - INSTALLATION).
(32) Install power steering reservoir and bracket
(Fig. 5).
(33) Raise vehicle
(34) Connect oil pressure sensor, oil temperature
sensor, engine speed sensor, and vehicle speed sensor
electrical connector (Fig. 10).(35) Install suspension cradle in vehicle (Refer to
13 - FRAME & BUMPERS/FRAME/ENGINE CRA-
DLE CROSSMEMBER - INSTALLATION).
(36) Install both axle shaft assemblies (Refer to 3 -
DIFFERENTIAL & DRIVELINE/HALF SHAFT -
INSTALLATION).
(37) Connect the power steering supply, pressure,
and return lines to power steering pump (Fig. 5).
(38) Install the power steering line brackets on oil
pan (Fig. 5).
(39) Install lower splash shield and side panels.
(40) Install both front wheel and tire assemblies.
(41) Lower vehicle.
(42) Install air cleaner housing, MAF sensor, and
air intake tube assembly (Fig. 4).
(43) Refill transmission to proper level (Refer to 21
- TRANSMISSION/TRANSAXLE/MANUAL/FLUID -
STANDARD PROCEDURE).
(44) Refill engine coolant (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(45) Recharge A/C system (Refer to 24 - HEATING
& AIR CONDITIONING/PLUMBING/REFRIGER-
ANT - STANDARD PROCEDURE) .
(46) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION) (Fig. 3).
(47) Connect negative battery cable.
INSTALLATION - ENGINE COVER
(1) Install engine cover on engine.
(2) Install the engine cover mounting bolts (Fig.
11).
SPECIFICATIONS
SPECIFICATIONS - 2.5L COMMON RAIL
DIESEL ENGINE
ENGINE SPECIFICATIONS
DESCRIPTION SPECIFICATION
Type R2516C
Number of Cylinders 4
Bore 92 mm
Stroke 94 mm
Displacement 2499.5cc
Injection Order 1-3-4-2
Compression Ratio 17.5:1 (  0.5)
Maximum Power 103kW (140 HP) @ 4000
RPM
Peak Torque 340Nm (34.6 kgm) @
1800 RPM
RGENGINE 2.5L TURBO DIESEL9a-7
ENGINE 2.5L TURBO DIESEL (Continued)

momentarily turn off the injectors. This helps
improve fuel economy, emissions and engine braking.
WIDE-OPEN-THROTTLE MODE
This is an OPEN LOOP mode. During wide-open-
throttle operation, the following inputs are used by
the PCM:
²Inlet/Intake air temperature
²Engine coolant temperature
²Engine speed
²Knock sensor
²Manifold absolute pressure
²Throttle position
When the PCM senses a wide-open-throttle condi-
tion through the Throttle Position Sensor (TPS) it de-
energizes the A/C compressor clutch relay. This
disables the air conditioning system.
The PCM does not monitor the heated oxygen sen-
sor inputs during wide-open-throttle operation except
for downstream heated oxygen sensor and both
shorted diagnostics. The PCM adjusts injector pulse
width to supply a predetermined amount of addi-
tional fuel.
IGNITION SWITCH OFF MODE
When the operator turns the ignition switch to the
OFF position, the following occurs:
²All outputs are turned off, unless 02 Heater
Monitor test is being run. Refer to the Emission sec-
tion for On-Board Diagnostics.
²No inputs are monitored except for the heated
oxygen sensors. The PCM monitors the heating ele-
ments in the oxygen sensors and then shuts down.
FUEL CORRECTION or ADAPTIVE MEMORIES
DESCRIPTION
In Open Loop, the PCM changes pulse width with-
out feedback from the O2 Sensors. Once the engine
warms up to approximately 30 to 35É F, the PCM
goes into closed loopShort Term Correctionand
utilizes feedback from the O2 Sensors. Closed loop
Long Term Adaptive Memoryis maintained above
170É to 190É F unless the PCM senses wide open
throttle. At that time the PCM returns to Open Loop
operation.
OPERATION
Short Term
The first fuel correction program that begins func-
tioning is the short term fuel correction. This system
corrects fuel delivery in direct proportion to the read-
ings from the Upstream O2 Sensor.The PCM monitors the air/fuel ratio by using the
input voltage from the O2 Sensor. When the voltage
reaches its preset high or low limit, the PCM begins
to add or remove fuel until the sensor reaches its
switch point. The short term corrections then begin.
The PCM makes a series of quick changes in the
injector pulse-width until the O2 Sensor reaches its
opposite preset limit or switch point. The process
then repeats itself in the opposite direction.
Short term fuel correction will keep increasing or
decreasing injector pulse-width based upon the
upstream O2 Sensor input. The maximum range of
authority for short term memory is 25% (+/-) of base
pulse-width.
Long Term
The second fuel correction program is the long
term adaptive memory. In order to maintain correct
emission throughout all operating ranges of the
engine, a cell structure based on engine rpm and load
(MAP) is used.
Ther number of cells varies upon the driving con-
ditions. Two cells are used only during idle, based
upon TPS and Park/Neutral switch inputs. There
may be two other cells used for deceleration, based
on TPS, engine rpm, and vehicle speed. The other
twelve cells represent a manifold pressure and an
rpm range. Six of the cells are high rpm and the
other six are low rpm. Each of these cells is a specific
MAP voltage range .
As the engine enters one of these cells the PCM
looks at the amount of short term correction being
used. Because the goal is to keep short term at 0 (O2
Sensor switching at 0.5 volt), long term will update
in the same direction as short term correction was
moving to bring the short term back to 0. Once short
term is back at 0, this long term correction factor is
stored in memory.
The values stored in long term adaptive memory
are used for all operating conditions, including open
loop. However, the updating of the long term memory
occurs after the engine has exceeded approximately
17É F, with fuel control in closed loop and two min-
utes of engine run time. This is done to prevent any
transitional temperature or start-up compensations
from corrupting long term fuel correction.
Long term adaptive memory can change the pulse-
width by as much as 25%, which means it can correct
for all of short term. It is possible to have a problem
that would drive long term to 25% and short term to
another 25% for a total change of 50% away from
base pulse-width calculation.
RSFUEL INJECTION14-19
FUEL INJECTION (Continued)