torque CHRYSLER VOYAGER 2001 Service Manual

REMOVAL - BATTERY
WARNING: A SUITABLE PAIR OF HEAVY DUTY
RUBBER GLOVES SHOULD BE WORN WHEN
REMOVING OR SERVICING A BATTERY.
WARNING: SAFETY GLASSES SHOULD BE WORN
WHEN REMOVING OR SERVICING A BATTERY.
WARNING: REMOVE METALLIC JEWELRY TO
AVOID INJURY BY ACCIDENTAL ARCING OF BAT-
TERY CURRENT.
(1) Verify that the ignition switch and all accesso-
ries are OFF.
(2) Disconnect the battery cables from the battery
posts, negative first (Fig. 15).
(3) Remove the battery hold down retaining nut.
(4) Remove the battery hold down bracket.
(5) Remove the battery from the vehicle.
INSTALLATION
(1) Position the battery in the battery tray.
(2) Install the battery hold down bracket and
retaining nut. Torque the nut to 20 N´m (180 in. lbs.).(3) Connect the battery cables to the battery posts,
positive cable first. Torque terminal fasteners to 8.5
N´m (75 in. lbs.).
BATTERY HOLDDOWN
DESCRIPTION
The battery hold down hardware consists of a
molded plastic lip that is integral to the outboard
edge of the battery tray and support unit, a molded
steel hold down bracket and a single hex nut with a
coned washer.
When installing a battery into the battery tray, be
certain that the hold down hardware is properly
installed and that the fasteners are tightened to the
proper specifications. Improper hold down fastener
tightness, whether too loose or too tight, can result in
damage to the battery, the vehicle or both. Refer to
Battery Hold Downsin this section of this service
manual for the location of the proper battery hold
down installation procedures, including the proper
hold down fastener tightness specifications.
OPERATION
The battery holddown secures the battery in the
battery tray. This holddown is designed to prevent
battery movement during the most extreme vehicle
operation conditions. Periodic removal and lubrica-
tion of the battery holddown hardware is recom-
mended to prevent hardware seizure at a later date.
NOTE: Never operate a vehicle without a battery
holddown device properly installed. Damage to the
vehicle, components and battery could result.
REMOVAL
All of the battery hold down hardware can be ser-
viced without removal of the battery or the battery
tray and support unit.
(1) Turn the ignition switch to the Off position. Be
certain that all electrical accessories are turned off.
(2) Remove the nut with washer that secures the
battery hold down bracket to the battery tray and
support unit.
(3) Remove the battery hold down bracket from
the battery tray and support unit.
INSTALLATION
(1) Install the battery hold down bracket in the
battery tray and support unit.
(2) Install the nut with washer that secures the
battery hold down bracket to the battery tray and
support unit. Torque to 20 N´m (180 in. lbs.).
Fig. 15 BATTERY POSITION & ORIENTATION
1 - BATTERY THERMAL GUARD
2 - INTELLIGENT POWER MODULE
3 - FRONT CONTROL MODULE
8F - 16 BATTERY SYSTEMRS
BATTERY (Continued)

DIAGNOSIS AND TESTING - ON-BOARD
DIAGNOSTIC SYSTEM
The Powertrain Control Module (PCM) monitors
critical input and output circuits of the charging sys-
tem, making sure they are operational. A Diagnostic
Trouble Code (DTC) is assigned to each input and
output circuit monitored by the OBD system. Some
circuits are checked continuously and some are
checked only under certain conditions.
If the OBD system senses that a monitored circuit
is bad, it will put a DTC into electronic memory. The
DTC will stay in electronic memory as long as the
circuit continues to be bad. The PCM is programmed
to clear the memory after 50 engine starts if the
problem does not occur again.
DIAGNOSTIC TROUBLE CODES
A DTC description can be read using the DRBt
scan tool. Refer to the appropriate Powertrain Diag-
nostic Procedures manual for information.
A DTC does not identify which component in a cir-
cuit is bad. Thus, a DTC should be treated as a
symptom, not as the cause for the problem. In some
cases, because of the design of the diagnostic test
procedure, a DTC can be the reason for another DTC
to be set. Therefore, it is important that the test pro-cedures be followed in sequence, to understand what
caused a DTC to be set.
ERASING DIAGNOSTIC TROUBLE CODES
The DRBIIItScan Tool must be used to erase a
DTC.
SPECIFICATIONS
GENERATOR
Type Engine Minimun Test
Amperage
Denso 2.4 L 135 Amp
Denso 3.3/3.8L 135 Amp or 160
Amp
Test Specification:
1. Engine RPM : 2500 RPM620 RPM
2. Voltage Output : 14.0 V60.5 V
3. Field Current : 5 amps60.1 amps
Part number is located on the side of the generator.
TORQUE
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Battery Hold Down Clamp
Bolt20 14.7 180
Generator B+ Nut 12.4 9.2 110
Battery Terminal Nut 4 35
Generator Mounting Bolt
2.4L28.2 20.8 250
Starter Solenoid Battery
Nut 3.3/3.8L54.2 40
Generator Decoupler 109.8 81
8F - 22 CHARGINGRS
CHARGING (Continued)

INSTALLATION
(1) Install the Generator Decoupler to the genera-
tor shaft.
(2) Use Special Tool #8433 (Fig. 6) to tighten the
Generator Decoupler. Refer to the torque chart for
the proper torque.
(3) Install the Air Box, refer to the Engine section
for more information.
(4) Raise vehicle and support.
(5) Install accessory drive belt, refer to the Cooling
System section for proper procedures (Fig. 5).
(6) Install the right front lower splash shield.
(7) Lower vehicle.
(8) Connect battery negative cable.
VOLTAGE REGULATOR
DESCRIPTION
The Electronic Voltage Regulator (EVR) is not a
separate component. It is actually a voltage regulat-
ing circuit located within the Powertrain Control
Module (PCM). The EVR is not serviced separately. If
replacement is necessary, the PCM must be replaced.
OPERATION
The amount of DC current produced by the gener-
ator is controlled by EVR circuitry contained within
the PCM. This circuitry is connected in series with
the generators second rotor field terminal and its
ground.
Voltage is regulated by cycling the ground path to
control the strength of the rotor magnetic field. The
EVR circuitry monitors system line voltage (B+) and
battery temperature or inlet air temperature sensor
(refer to Battery Temperature Sensor or Inlet Air
Temperature Sensor for more information). It then
determines a target charging voltage. If sensed bat-
tery voltage is 325 mv or lower than the target volt-
age, the PCM grounds the field winding until sensed
battery volage is 325 mv above target voltage. A cir-
cuit in the PCM cycles the ground side of the gener-
ator field up to 250 times per second (250Hz), but
has the capability to ground the field control wire
100% of the time (full field) to achieve the target
voltage. If the charging rate cannot be monitored
(limp-in), a duty cycle of 25% is used by the PCM in
order to have some generator output. Also refer to
Charging System Operation for additional informa-
tion.
REMOVAL
The electronic voltage regulator is not a serviced
separately. If replacement is necessary, the PCM
must be replaced.
Fig. 6 SPECIAL TOOL 8433 AND DECOUPLER
8F - 26 CHARGINGRS
GENERATOR DECOUPLER PULLEY (Continued)

CONDITION POSSIBLE CAUSE CORRECTION
3. STARTER ASSEMBLY
FAULTY.3. IF ALL OTHER STARTING SYSTEM COMPONENTS AND
CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY.
4. ENGINE SEIZED. 4. REFER TO THE ENGINE SECTION, FOR DIAGNOSTIC AND
SERVICE PROCEDURES.
5. LOOSE
CONNECTION AT
BATTERY, PDC,
STARTER, OR ENGINE
GROUND.5. INSPECT FOR LOOSE CONNECTIONS.
6. FAULTY TEETH ON
RING GEAR.6. ROTATE FLYWHEEL 360É, AND INSPECT TEETHAND RING
GEAR REPLACED IF DAMAGED.
STARTER
ENGAGES,
SPINS OUT
BEFORE
ENGINE
STARTS.1. BROKEN TEETH ON
STARTER RING GEAR.1. REMOVE STARTER. INSPECT RING GEAR AND REPLACE
IF NECESSARY.
2. STARTER ASSEMBLY
FAULTY.2. IF ALL OTHER STARTING SYSTEM COMPONENTS AND
CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY.
STARTER DOES
NOT
DISENGAGE.1. STARTER
IMPROPERLY
INSTALLED.1. INSTALL STARTER. TIGHTEN STARTER MOUNTING
HARDWARE TO CORRECT TORQUE SPECIFICATIONS.
2. STARTER RELAY
FAULTY.2. REFER TO RELAY TEST, IN THIS SECTION. REPLACE
RELAY, IF NECESSARY.
3. IGNITION SWITCH
FAULTY.3. REFER TO IGNITION SWITCH TEST, IN THE STEERING
SECTION.. REPLACE SWITCH, IF NECESSARY.
4. STARTER ASSEMBLY
FAULTY.4. IF ALL OTHER STARTING SYSTEM COMPONENTS AND
CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY.
5. FAULTY TEETH ON
RING GEAR.5. ROTATE FLYWHEEL 360É, AND INSPECT TEETH AND RING
GEAR REPLACED IF DAMAGED.
CONTROL CIRCUIT TEST
The starter control circuit has:
²Starter motor with integral solenoid
²Starter relay
²Transmission range sensor, or Park/Neutral
Position switch with automatic transmissions
²Ignition switch
²Battery
²All related wiring and connections
²Powertrain Control Module (PCM)
CAUTION: Before performing any starter tests, the
ignition and fuel systems must be disabled.
²To disable ignition and fuel systems, disconnect
the Automatic Shutdown Relay (ASD). The ASD relay
is located in the Power Distribution Center (PDC).
Refer to the PDC cover for the proper relay location.
STARTER SOLENOID
WARNING: CHECK TO ENSURE THAT THE TRANS-
MISSION IS IN THE PARK POSITION WITH THE
PARKING BRAKE APPLIED.
(1) Verify battery condition. Battery must be in
good condition with a full charge before performing
any starter tests. Refer to Battery Tests.
(2) Perform Starter Solenoid test BEFORE per-
forming the starter relay test.
(3) Perform a visual inspection of the starter/
starter solenoid for corrosion, loose connections or
faulty wiring.
(4) Locate and remove the starter relay from the
Power Distribution Center (PDC). Refer to the PDC
label for relay identification and location.
RSSTARTING8F-29
STARTING (Continued)

(1) Check battery before performing this test. Bat-
tery must be fully charged.
(2) Connect a volt-ampere tester to the battery ter-
minals. Refer to the operating instructions provided
with the tester being used.
(3) To disable the ignition and fuel systems, dis-
connect the Automatic Shutdown Relay (ASD). The
ASD relay is located in the Power Distribution Cen-
ter (PDC). Refer to the PDC cover for proper relay
location.
(4) Verify that all lights and accessories are OFF,
and the transmission shift selector is in the PARK
and SET parking brake.
CAUTION: Do not overheat the starter motor or
draw the battery voltage below 9.6 volts during
cranking operations.
(5) Rotate and hold the ignition switch in the
START position. Observe the volt-ampere tester (Fig.
2).
²If voltage reads above 9.6 volts, and amperage
draw reads above 280 amps, check for engine seizing
or faulty starter.
²If voltage reads 12.4 volts or greater and amper-
age reads 0 to 10 amps, check for corroded cables
and/or bad connections.
²Voltage below 9.6 volts and amperage draw
above 300 amps, the problem is the starter. Replace
the starter refer to starter removal.
(6) After the starting system problems have been
corrected, verify the battery state-of-charge and
charge battery if necessary. Disconnect all testingequipment and connect ASD relay. Start the vehicle
several times to assure the problem has been cor-
rected.
SPECIFICATIONS
STARTER
MANUFACTURER NIPPONDENSO
Engine Application 2.4L /3.3/3.8L
Power rating 1.2 Kw
Voltage 12 VOLTS
No. of Fields 4
No. of Poles 4
Brushes 4
Drive Conventional Gear Train
Free running Test
Voltage 11
Amperage Draw 73 Amp
Minimum Speed 3401 RPM
SolenoidClosing Voltage 7.5 Volts
Cranking Amperage Draw
test150 - 200 Amps.
Engine should be up to operating temperature.
Extremely heavy oil or tight engine will increase
starter amperage draw.
Torques
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Starter Mounting Bolts 47.4 35
Starter Solenoid Battery
Nut11.3 8.3 100
8F - 32 STARTINGRS
STARTING (Continued)

IGNITION CONTROL
TABLE OF CONTENTS
page page
IGNITION CONTROL
DESCRIPTION............................1
OPERATION.............................1
SPECIFICATIONS.........................1
AUTO SHUT DOWN RELAY
DESCRIPTION............................3
OPERATION.............................3
CAMSHAFT POSITION SENSOR
DESCRIPTION............................3
OPERATION.............................3
REMOVAL...............................3
INSTALLATION............................5
IGNITION COIL
DESCRIPTION............................6
OPERATION.............................6REMOVAL...............................6
INSTALLATION............................6
KNOCK SENSOR
DESCRIPTION............................7
OPERATION.............................7
REMOVAL...............................7
INSTALLATION............................8
SPARK PLUG
DESCRIPTION............................8
REMOVAL...............................9
INSTALLATION............................9
SPARK PLUG CABLE
DESCRIPTION............................9
REMOVAL...............................9
INSTALLATION............................9
IGNITION CONTROL
DESCRIPTION - IGNITION SYSTEM
NOTE: All engines use a fixed ignition timing sys-
tem. Basic ignition timing is not adjustable. All
spark advance is determined by the Powertrain
Control Module (PCM).
The distributorless ignition system used on these
engines is referred to as the Direct Ignition System
(DIS). The system's three main components are the
coils, crankshaft position sensor, and camshaft posi-
tion sensor. The coil on plug ignition system utilizesan ignition coil for every cylinder, it is mounted
directly over the each spark plug.
OPERATION - IGNITION SYSTEM
The crankshaft position sensor and camshaft posi-
tion sensor are hall effect devices. The camshaft posi-
tion sensor and crankshaft position sensor generate
pulses that are inputs to the PCM. The PCM deter-
mines engine position from these sensors. The PCM
calculates injector sequence and ignition timing from
crankshaft & camshaft position. For a description of
both sensors, refer to Camshaft Position Sensor and
Crankshaft Position Sensor in this section.
SPECIFICATIONS
TORQUE
DESCRIPTION N´m Ft. Lbs. In. Lbs.
2.4L Target Magnet Screw 3 30
2.4L Camshaft Sensor Screw 12.9 115
3.3/3.8L Camshaft Sensor Screw 14.1 125
2.4L Ignition coil bolts 11.8 105
3.3/3.8L Ignition coil bolts 11.8 105
Spark Plugs 17.5 13
Knock Sensor 10 7
RSIGNITION CONTROL8I-1

(4) Remove bolt holding sensor.
(5) Rotate sensor away from block.
(6) Pull sensor up out of the chain case cover.Do
not pull on the sensor lead.There is an O-ring on
the sensor case. The O-ring may make removal diffi-
cult. A light tap to top of sensor prior to removal may
reduce force needed for removal.
INSTALLATION - 2.4L
The target magnet has locating dowels that fit into
machined locating holes in the end of the camshaft
(Fig. 8).(1) Install target magnet in end of camshaft.
Tighten mounting screw to 3 N´m (30 in. lbs.) torque.
Over torqueing could cause cracks in magnet. If mag-
net cracks replace it.
(2) Install camshaft position sensor. Tighten sensor
mounting screws to 12.9 N´m (115 in. lbs.) torque.
(3) Carefully attach electrical connector to cam-
shaft position sensor. Installation at an angle may
damage the sensor pins.
(4) Connect the negative battery cable.
INSTALLATION - 3.3/3.8L
If the removed sensor is reinstalled, clean off
the old spacer on the sensor face. A NEW
SPACER must be attached to the face before
installation.Inspect O-ring for damage, replace if
necessary. If the sensor is being replaced, confirm
that the paper spacer is attached to the face and
O-ring is positioned in groove of the new sensor (Fig.
9).
(1) Apply a couple drops of clean engine oil to the
O-ring prior to installation.
(2) Install sensor in the chain case cover and
rotate into position.
(3) Push sensor down until contact is made with
the camshaft gear. While holding the sensor in this
position, install and tighten the retaining bolt 14
N´m (125 in. lbs.) torque.
(4) Connect camshaft position sensor electrical
connector to harness connector.
(5) Install the air box cover and inlet hose (Fig. 6).
(6) Connect the negative battery cable.
Fig. 7 CAMSHAFT POSITION SENSOR
Fig. 8 Target Magnet Installation
1 - LOCATING DOWELS
2 - LOCATING HOLES (2)
Fig. 9 Camshaft Position Sensor and Spacer
1 - ELECTRICAL CONNECTOR
2 - O-RING
3 - PAPER SPACER
RSIGNITION CONTROL8I-5
CAMSHAFT POSITION SENSOR (Continued)

INSTALLATION - 2.4L
The knock sensor threads into the side of the cyl-
inder block in front of the starter (Fig. 13).
(1) Install knock sensor. Tighten knock sensor to
10 N´m (7 ft. lbs.) torque.Over or under tighten-
ing effects knock sensor performance, possibly
causing improper spark control.
(2) Attach electrical connector to knock sensor.
INSTALLATION - 3.8L
The knock sensor threads into the side of the cyl-
inder block in the rear.
(1) Install knock sensor. Tighten knock sensor to
10 N´m (7 ft. lbs.) torque.Over or under tighten-
ing effects knock sensor performance, possibly
causing improper spark control.
(2) Attach electrical connector to knock sensor.
(3) On All Wheel Drive vehicles install the PTU
(Power Transfer Unit) for the rear wheels, refer to
the Transmission section for more information.
(4) Lower vehicle.
(5) Connect the negative cable.
SPARK PLUG
DESCRIPTION - STANDARD 2.4L
All engines use resistor spark plugs. They have
resistance values ranging from 6,000 to 20,000 ohms
when checked with at least a 1000 volt spark plug
tester.
Do not use an ohm meter to check the resis-
tance of the spark plugs. This will give an inac-
curate reading.
Refer to the Specifications section for gap and type
of spark plug.
DESCRIPTION - PLATINUM 3.3/3.8L
These engines utilize platinum spark plugs. Refer
to the maintenance schedule.
All engines use resistor spark plugs. They have
resistance values ranging from 6,000 to 20,000 ohms
when checked with at least a 1000 volt spark plug
tester.
Do not use an ohm meter to check the resis-
tance of the spark plugs. This will give an inac-
curate reading.
The spark plugs are double platinum and have a
recommended service life of 100,000 miles for normal
driving conditions per schedule A in this manual. The
spark plugs have a recommended service life of
75,000 miles for severe driving conditions per sched-
ule B in this manual. A thin platinum pad is welded
to both electrode ends as show in (Fig. 14). Extreme
care must be used to prevent spark plug cross
threading, mis-gaping and ceramic insulator damage
during plug removal and installation.
Fig. 13 Knock Sensor
1 - GENERATOR
2 - INTAKE MANIFOLD
3 - KNOCK SENSOR
4-STARTER
Fig. 14 Platinum Pads
1 - APPLY ANTI-SEIZE COMPOUND HERE ONLY
2 - PLATINUM SPARK SURFACE
8I - 8 IGNITION CONTROLRS
KNOCK SENSOR (Continued)

CAUTION: Cleaning of the platinum plug may dam-
age the platinum tip.
REMOVAL
When replacing the spark plugs and spark plug
cables, route the cables correctly and secure them in
the appropriate retainers. Failure to route the cables
properly can cause the radio to reproduce ignition
noise, cross ignition of the spark plugs orshort cir-
cuit the cables to ground.
Always remove cables by grasping at the boot,
rotating the boot 1/2 turn, and pulling straight back
in a steady motion.
(1) Prior to removing the spark plug, spray com-
pressed air around the spark plug hole and the area
around the spark plug.
(2) Remove the spark plug using a quality socket
with a foam insert.
(3) Inspect the spark plug condition.
INSTALLATION
When replacing the spark plugs and spark plug
cables, route the cables correctly and secure them in
the appropriate retainers. Failure to route the cables
properly can cause the radio to reproduce ignition
noise, cross ignition of the spark plugs orshort cir-
cuit the cables to ground.(1) To avoid cross threading, start the spark plug
into the cylinder head by hand.
(2) Tighten spark plugs to 17.5 N´m (13 ft. lbs.)
torque.
(3) Install spark plug cables over spark plugs. A
click will be heard and felt when the cable properly
attaches to the spark plug.
SPARK PLUG CABLE
DESCRIPTION
Spark Plug cables are sometimes referred to as
secondary ignition wires. The wires transfer electri-
cal current from the ignition coil pack to individual
spark plugs at each cylinder. The resistive spark plug
cables are of nonmetallic construction. The cables
provide suppression of radio frequency emissions
from the ignition system.
Check the spark plug cable connections for good
contact at the coil, and spark plugs. Terminals should
be fully seated. The insulators should be in good con-
dition and should fit tightly on the coil, and spark
plugs. Spark plug cables with insulators that are
cracked or torn must be replaced.
Clean Spark Plug cables with a cloth moistened
with a non-flammable solvent. Wipe the cables dry.
Check for brittle or cracked insulation. The spark
plug cables and spark plug boots are made from high
temperature silicone materials. All spark plug cable
leads are properly identified with cylinder numbers.
The inside of most the spark plug boot is coated with
a special high temperature silicone grease for greater
sealing and to minimize boot bonding to the spark
plug insulator.
REMOVAL
Failure to route the cables properly could cause the
radio to reproduce ignition noise, cross ignition of the
spark plugs or short circuit the cables to ground.
Remove spark plug cable from coil first.
Always remove the spark plug cable by grasping
the top of the spark plug insulator, turning the boot
1/2 turn and pulling straight up in a steady motion.
INSTALLATION
Failure to route the cables properly could cause the
radio to reproduce ignition noise, cross ignition of the
spark plugs or short circuit the cables to ground.
Install spark plug insulators over spark plugs.
Ensure the top of the spark plug insulator covers the
upper end of the spark plug tube.Then connect the
other end to coil pack.
Fig. 15 Setting Spark Plug Electrode Gap
1 - TAPER GAUGE
RSIGNITION CONTROL8I-9
SPARK PLUG (Continued)

ature Module (CT) equipped vehicles depress the
US/M push buttonto step through the zone num-
bers, until the zone number for your geographic loca-
tion appears in the display.
(6) On Electronic Vehicle Information Center
(EVIC) and Compass Mini-Trip Computer (CMTC)
equipped vehicles momentarily depress and release
theReset push buttonto enter the displayed zone
number into the EVIC/CMTC module memory. On
Compass Temperature Module (CT) equipped vehicles
depress theC/T push buttonto enter the displayed
zone number into the electronic module memory.
(7) Confirm that the correct directions are now
indicated by the compass.
REMOVAL - OVERHEAD CONSOLE
(1) Disconnect and isolate the remote negative bat-
tery cable.
(2) Remove the overhead console retaining screw,
located in the front of console.
(3) Using your fingertips, grasp the sides of the
overhead console and pull straight down evenly to
disengage the two snap clips at the rear of the unit.
(4) Lower the overhead console far enough to
access the wire harness connectors.
(5) Disconnect the EVIC, CMTC or CT electronic
module and the reading/courtesy lamps electrical
connector.
(6) Remove the overhead console from the vehicle.
INSTALLATION
(1) Position the overhead console in the vehicle.
(2) Connect the EVIC, CMTC or CT electronic
module and the reading/courtesy lamps electrical
connector.
(3) Using your fingertips, grasp the sides of the
overhead console and push straight up evenly to
engage the two snap clips at the rear of the unit.
CAUTION: DO NOT PRESS ON THE SUNGLASS
STORAGE BIN DOOR. DAMAGE TO THE DOOR MAY
RESULT.
(4) Install the overhead console retaining screw,
located in the front of console. Torque the screw to
1.2 N´m (10 in. lbs.).
(5) Connect the remote negative battery cable.
ELECTRONIC VEHICLE INFO
CENTER
DESCRIPTION
The Electronic Vehicle Information Center (EVIC)
is a module located in the overhead console on some
models. The EVIC module features a large Vacuum
Fluorescent Display (VFD) screen for displaying
information, and back-lit push button switches
labeled C/T (compass/thermometer), RESET, STEP,
and MENU.
Fig. 2 Variance Settings
8M - 6 OVERHEAD CONSOLERS
OVERHEAD CONSOLE (Continued)