ABS CHRYSLER VOYAGER 2001 Service Manual

WIPER BLADES
REMOVAL
(1) Lift the wiper arm away from the glass.
(2) Disengage the release tab holding the wiper
blade to the wiper arm and remove the wiper blade
from the wiper arm (Fig. 14) and (Fig. 15).
CLEANING
Wiper blades exposed to the weather for a long
period of time tend to lose their wiping effectiveness.
Periodic cleaning of the wiper blade is recommended
to remove the accumulation of salt and road grime.
The wiper blades, arms and windshield should be
cleaned with a sponge or cloth and a mild detergent
or nonabrasive cleaner. If the wiper blades continue
to streak or smear, they should be replaced. Thewiper blade should run smoothly across the wind-
shield in both directions. The wiper blade should
slightly roll over center when the blade reverses
direction. A wiper blade insert that has lost flexibility
or a wiper arm that has lost spring tension, will
cause the blade to skip or chatter across the wind-
shield. If the wiper blades are new and the wiper
arm spring tension is OK and a chattering sound is
emitted from the wiper(s), the wiper blade is not roll-
ing over center. If this condition exists, (refer to 8 -
ELECTRICAL/WIPERS/WASHERS/WIPER ARMS -
ADJUSTMENTS).
INSTALLATION
(1) Position the blade onto the arm.
(2) Engage the blade to the retainer by pulling up
on the blade until the tabs snap into position (Fig.
14).
WIPER BLADE ELEMENTS
REMOVAL
(1) Disengage the release tab holding the wiper
blade to the wiper arm and remove the wiper blade
from the wiper arm (Fig. 14).
(2) Disengage clip holding the wiper element to
wiper blade (Fig. 16).
(3) Pull the element from the claws on the wiper
blade.
Fig. 14 WINDSHIELD WIPER BLADE
1 - RELEASE TAB
Fig. 15 REAR WIPER
1 - WIPER ARM
2 - BLADE LATCH
Fig. 16 WIPER BLADE ELEMENT
1 - CLAW
2 - TO GRASP AND PULL
3 - CHANNEL
4 - RUBBER ELEMENT
5 - VERTABRA
RSWIPERS/WASHERS8R-9

(2) Insert the removed wire in the same cavity on
the repair connector.
(3) Repeat steps for each wire in the connector,
being sure that all wires are inserted into the proper
cavities. For additional connector pin-out identifica-
tion, refer to the wiring diagrams.
(4) When the connector is re-assembled, the lock-
ing tab must be placed in the locked position to pre-
vent terminal push out.
(5) Connect connector to its mating half/compo-
nent.
(6) Connect battery and test all affected systems.
CONNECTOR - MOLEX
REMOVAL
(1) Disconnect battery.
(2) Disconnect the connector from its mating half/
component.
(3) Insert special tool 6742 into the terminal end of
the connector (Fig. 10).
(4) Using special tool 6742, release the locking fin-
gers on the terminal (Fig. 11).
(5) Pull on the wire to remove it from the connec-
tor.
(6) Repair or replace the terminal as necessary.
INSTALLATION
(1) Reset the terminal locking tang.
(2) Insert the removed wire in the same cavity on
the repair connector.
(3) Repeat steps for each wire in the connector,
being sure that all wires are inserted into the proper
cavities. For additional connector pin-out identifica-
tion, refer to the wiring diagrams.(4) Connect connector to its mating half/compo-
nent.
(5) Connect battery and test all affected systems.
CONNECTOR - THOMAS AND
BETTS
REMOVAL
(1) Disconnect battery.
(2) Disconnect the connector from its mating half/
component.
(3) Push in the two lock tabs on the side of the
connector (Fig. 12).
Fig. 10 MOLEX CONNECTOR REPAIR
1 - CONNECTOR
2 - SPECIAL TOOL 6742
Fig. 11 USING SPECIAL TOOL 6742
1 - CONNECTOR
2 - SPECIAL TOOL 6742
Fig. 12 THOMAS AND BETTS CONNECTOR LOCK
RELEASE TABS
1 - LOCK TABS
RG8W-01 WIRING DIAGRAM INFORMATION8Wa-01-9
CONNECTOR - AUGAT (Continued)

Component Page
Ignition Switch....................... 8Wa-10
Inlet Air Temperature Sensor............ 8Wa-30
Instrument Cluster................... 8Wa-40
Instrument Panel Switch Bank . . 8Wa-44, 52, 53, 63
Intelligent Power Module............... 8Wa-10
Knock Sensor........................ 8Wa-30
Leak Detection Pump.................. 8Wa-30
License Lamp........................ 8Wa-51
Lift Pump Motor..................... 8Wa-30
Lift Pump Relay...................... 8Wa-30
Liftgate Ajar Switch................... 8Wa-61
Liftgate Cinch/Release Motor............ 8Wa-61
Liftgate Cylinder Lock Switch........... 8Wa-39
Liftgate Flood Lamps.................. 8Wa-44
Liftgate Left Pinch Sensor.............. 8Wa-61
Low Beam Lamps.................... 8Wa-50
Manifold Absolute Pressure Sensor....... 8Wa-30
Mass Air Flow Sensor................. 8Wa-30
Memory Power Seat Switch............. 8Wa-63
Memory Seat Front Vertical Motor........ 8Wa-63
Memory Seat Front Vertical Position
Sensor........................... 8Wa-63
Memory Seat Horizontal Motor.......... 8Wa-63
Memory Seat Horizontal Position Sensor . . . 8Wa-63
Memory Seat Rear Vertical Motor........ 8Wa-63
Memory Seat Rear Vertical Position
Sensor........................... 8Wa-63
Memory Seat Recliner Motor............ 8Wa-63
Memory Seat Recliner Position Sensor..... 8Wa-63
Memory Seat Switch.................. 8Wa-63
Memory Seat/Mirror Module............ 8Wa-62
Message Center...................... 8Wa-46
Mode Door Actuator................... 8Wa-42
Multi- Function Switch................ 8Wa-50
Name Brand Speaker Relay............. 8Wa-47
Occupant Restraint Controller........... 8Wa-43
Overhead Console.................... 8Wa-49
Oxygen Sensors...................... 8Wa-30
Park Lamp Relay..................... 8Wa-10
Park Lamps......................... 8Wa-50
Park/Neutral Position Switch............ 8Wa-31
Park/Turn Signal Lamps............... 8Wa-50
Parking Brake Switch................. 8Wa-40
Passenger Folding Mirror Relay.......... 8Wa-62
Power Folding Mirror Switch............ 8Wa-62
Power Liftgate Motor.................. 8Wa-61
Power Mirror Switch.................. 8Wa-62
Power Mirrors....................... 8Wa-62
Power Outlets....................... 8Wa-41
Power Seat Circuit Breaker............. 8Wa-10
Power Seat Front Riser Motors.......... 8Wa-63
Power Seat Horizontal Motors........... 8Wa-63
Power Seat Rear Riser Motors........... 8Wa-63
Power Seat Recliner Motors............. 8Wa-63Component Page
Power Seat Switches.................. 8Wa-63
Power Window Circuit Breaker.......... 8Wa-10
Power Window Motors................. 8Wa-60
Power Window Switches................ 8Wa-60
Powertrain Control Module............. 8Wa-30
PTC ............................... 8Wa-10
Radiator Fan Relays.................. 8Wa-42
Radiator Fans....................... 8Wa-42
Radio Choke......................... 8Wa-47
Radio.............................. 8Wa-47
Reading Lamps...................... 8Wa-44
Rear A/C-Heater Unit................. 8Wa-42
Rear Auto Temp Control Switch.......... 8Wa-42
Rear Blower Front Control Switch........ 8Wa-42
Rear Blower Motor Power Module........ 8Wa-42
Rear Blower Motor Relay............... 8Wa-42
Rear Blower Motor.................... 8Wa-42
Rear Blower Rear Control Switch........ 8Wa-42
Rear Intrusion Sensor................. 8Wa-39
Rear Lamp Assemblies................. 8Wa-51
Rear Mode Motor..................... 8Wa-42
Rear Temperature Motor............... 8Wa-42
Rear Washer Pump Motor.............. 8Wa-53
Rear Window Defogger Grid............. 8Wa-48
Rear Wiper Motor.................... 8Wa-53
Recirculation Door Actuator............. 8Wa-42
Remote Keyless Entry Antenna.......... 8Wa-61
Remote Keyless Entry Module........... 8Wa-61
Remote Radio Switches................ 8Wa-47
Repeater Lamps...................... 8Wa-52
Seat Airbags......................... 8Wa-43
Seat Belt Switches.................... 8Wa-43
Seat Belt Tensioners.................. 8Wa-43
Sentry Key Immobilizer Module.......... 8Wa-39
Side Impact Airbag Control Module....... 8Wa-43
Siren.............................. 8Wa-39
Sliding Door Control Modules........... 8Wa-61
Sliding Door Latch Sensing Switches...... 8Wa-61
Sliding Door Lock Motor/Ajar Switches.... 8Wa-61
Sliding Door Lock Motors............... 8Wa-61
Sliding Door Motors................... 8Wa-61
Solenoid/Pressure Switch Assy........... 8Wa-31
Speakers........................... 8Wa-47
Speed Control Servo................... 8Wa-33
Speed Control Switches................ 8Wa-33
Speed Sensor- Input................... 8Wa-31
Speed Sensor- Output................. 8Wa-31
Splice Information.................... 8Wa-70
Starter Motor Relay................... 8Wa-21
Starter Motor........................ 8Wa-21
Stop/Turn Signal Relays................ 8Wa-54
Thatcham Alarm Indicator.............. 8Wa-39
Thatcham Alarm Module............... 8Wa-39
Throttle Position Sensor................ 8Wa-30
8Wa - 02 - 2 8W-02 COMPONENT INDEXRG

8W-30 FUEL/IGNITION SYSTEM
Component Page
A/C Compressor Clutch.............. 8Wa-30-17
A/C Compressor Clutch Relay....... 8Wa-30-3, 17
A/C Pressure Sensor........... 8Wa-30-9, 15, 24
Accelerator Pedal Position Sensor...... 8Wa-30-31
Auto Shut Down Relay.... 8Wa-30-2, 5, 7, 8, 12, 13
Battery..................... 8Wa-30-2, 17, 25
Battery Temperature Sensor.......... 8Wa-30-24
Body Control Module.............. 8Wa-30-4, 18
Boost Pressure Sensor............... 8Wa-30-24
Brake Lamp Switch............ 8Wa-30-6, 20, 30
Cabin Heater Assist................ 8Wa-30-21
Camshaft Position Sensor....... 8Wa-30-7, 13, 23
Clockspring..................... 8Wa-30-3, 22
Clutch Departure Switch............. 8Wa-30-29
Crank Case Ventilation Heater........ 8Wa-30-18
Crankshaft Position Sensor...... 8Wa-30-7, 13, 23
Data Link Connector.............. 8Wa-30-4, 21
Diagnostic Junction Port........... 8Wa-30-4, 22
Dosing Pump...................... 8Wa-30-21
ECM/PCM Relay....... 8Wa-30-17, 19, 23, 25, 27
EGR Solenoid................... 8Wa-30-5, 27
Engine Control Module..... 8Wa-30-17, 18, 19, 20,
21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31
Engine Coolant Temp Sensor..... 8Wa-30-9, 15, 24
Engine Oil Pressure Sensor........... 8Wa-30-20
Engine Oil Pressure Switch........... 8Wa-30-6
Engine Oil Temperature Sensor....... 8Wa-30-23
EVAP/Purge Solenoid................ 8Wa-30-3
Front Control Module........ 8Wa-30-3, 4, 21, 29
Fuel Heater....................... 8Wa-30-28
Fuel Heater Relay............... 8Wa-30-18, 28
Fuel Injector No. 1............. 8Wa-30-8, 12, 26
Fuel Injector No. 2............. 8Wa-30-8, 12, 26
Fuel Injector No. 3............. 8Wa-30-8, 12, 26
Fuel Injector No. 4............. 8Wa-30-8, 12, 26
Fuel Injector No. 5................. 8Wa-30-12
Fuel Injector No. 6................. 8Wa-30-12
Fuel Pressure Sensor............... 8Wa-30-30
Fuel Pressure Solenoid.............. 8Wa-30-19
Fuel Pump Module............... 8Wa-30-4, 18
Fuel Pump Relay................... 8Wa-30-4
Fuse 15 (IPM) (Diesel)............ 8Wa-30-21, 28
Fuse 16 (IPM (Diesel).... 8Wa-30-17, 19, 23, 25, 27
Fuse 16 (IPM) (Gas)...... 8Wa-30-2, 5, 7, 8, 12, 13
Fuse 17 (IPM) (Diesel)............ 8Wa-30-18, 28
Fuse 17 (IPM) (Gas)............... 8Wa-30-2, 4
Fuse 18 (IPM)..................... 8Wa-30-17Component Page
Fuse 26 (IPM)..................... 8Wa-30-30
Fuselink......................... 8Wa-30-25
G100.......................... 8Wa-30-2, 17
G101.......................... 8Wa-30-2, 17
G103.................. 8Wa-30-5, 6, 17, 18, 21
G200............................ 8Wa-30-22
G300....................... 8Wa-30-6, 20, 29
G302....................... 8Wa-30-4, 18, 28
Generator...................... 8Wa-30-2, 18
Glow Plug No. 1................... 8Wa-30-25
Glow Plug No. 2................... 8Wa-30-25
Glow Plug No. 3................... 8Wa-30-25
Glow Plug No. 4................... 8Wa-30-25
Glow Plug Relay................... 8Wa-30-25
Idle Air Control Motor............ 8Wa-30-11, 14
Ignition Coil.................... 8Wa-30-7, 13
Ignition Switch.................... 8Wa-30-16
Inlet Air Temperature Sensor...... 8Wa-30-10, 14
Intelligent Power Module . . . 8Wa-30-2, 3, 4, 5, 7, 8,
12, 13, 16, 17, 18, 19, 21, 23, 25, 27, 28, 29, 30
Knock Sensor................... 8Wa-30-9, 15
Leak Detection Pump............... 8Wa-30-16
Left Speed Control Switch.......... 8Wa-30-3, 22
Lift Pump Motor................... 8Wa-30-28
Lift Pump Relay................... 8Wa-30-28
Manifold Absolute Pressure Sensor . . . 8Wa-30-9, 15
Mass Air Flow Sensor............... 8Wa-30-19
Oxygen Sensor 1/1 Upstream.......... 8Wa-30-5
Oxygen Sensor 1/2 Downstream........ 8Wa-30-5
Park/Neutral Position Switch......... 8Wa-30-11
Powertrain Control Module . . . 8Wa-30-2, 3, 4, 5, 6,
7, 8, 9, 10, 11, 12, 13, 14, 15, 16
Radiator Fan Relay.................. 8Wa-30-3
Radiator Fan Relay No. 1............ 8Wa-30-30
Radiator Fan Relay No. 2............ 8Wa-30-30
Radiator Fan Relay No. 3............ 8Wa-30-30
Right Speed Control Switch......... 8Wa-30-3, 22
Speed Control Servo................. 8Wa-30-6
Starter Motor Relay.............. 8Wa-30-4, 18
Throttle Position Sensor.......... 8Wa-30-10, 14
Torque Converter Clutch Solenoid...... 8Wa-30-16
Transmission Control
Module................. 8Wa-30-7, 10, 11, 14
Transmission Range Sensor........ 8Wa-30-11, 14
Vehicle Speed Sensor........... 8Wa-30-7, 11, 27
Water In Fuel Sensor............... 8Wa-30-29
RG8W-30 FUEL/IGNITION SYSTEM8Wa-30-1

Component Page
Intelligent Power Module C4.......... 8W-80-69
Intelligent Power Module C5.......... 8W-80-69
Intelligent Power Module C6.......... 8W-80-70
Intelligent Power Module C7.......... 8W-80-70
Intelligent Power Module C8.......... 8W-80-71
Intelligent Power Module C9.......... 8W-80-71
Knock Sensor (2.4L)................. 8W-80-71
Knock Sensor (3.3L/3.8L)............. 8W-80-71
Leak Detection Pump
(Except Built-Up-Export)........... 8W-80-72
Left B-Pillar Switch................. 8W-80-72
Left Cinch/Release Motor
(Power Sliding Door)............... 8W-80-72
Left Combination Relay (Trailer Tow).... 8W-80-72
Left Cylinder Lock Switch............. 8W-80-72
Left Door Speaker................... 8W-80-73
Left Fog Lamp..................... 8W-80-73
Left Front Door Ajar Switch (Base)...... 8W-80-73
Left Front Door Lock Motor/Ajar Switch
(Except Base).................... 8W-80-73
Left Front Park/Turn Signal Lamp (Except
Built-Up-Export).................. 8W-80-74
Left Front Wheel Speed Sensor......... 8W-80-74
Left Full Open Switch (Power Sliding Door). 8W-80-74
Left Headlamp (Except Built-Up-Export) . 8W-80-74
Left Headlamp Leveling Motor
(Built-Up-Export)................. 8W-80-74
Left High Beam Lamp (Built-Up-Export) . 8W-80-75
Left Instrument Panel Speaker......... 8W-80-75
Left Liftgate Flood Lamp............. 8W-80-75
Left Low Beam Lamp (Built-Up-Export) . . 8W-80-75
Left Mid Reading Lamp
(Premium/Luxury)................. 8W-80-75
Left Park Lamp (Built-Up-Export)...... 8W-80-76
Left Power Mirror................... 8W-80-76
Left Rear Lamp Assembly............. 8W-80-76
Left Rear Pillar Speaker.............. 8W-80-77
Left Rear Reading Lamp (Luxury)...... 8W-80-77
Left Rear Speaker................... 8W-80-77
Left Rear Vent Motor................ 8W-80-77
Left Rear Wheel Speed Sensor......... 8W-80-77
Left Remote Radio Switch............. 8W-80-78
Left Repeater Lamp (Built-Up-Export) . . . 8W-80-78
Left Seat Airbag.................... 8W-80-78
Left Side Impact Airbag Control Module . . 8W-80-78
Left Sliding Door Control Module C1
(Power Sliding Door)............... 8W-80-78
Left Sliding Door Control Module C2
(Power Sliding Door)............... 8W-80-79
Left Sliding Door Latch Sensing Switch
(Power Sliding Door)............... 8W-80-79
Left Sliding Door Lock Motor
(Power Sliding Door)............... 8W-80-79
Left Sliding Door Lock Motor/Ajar Switch
(Manual Sliding Door).............. 8W-80-80Component Page
Left Sliding Door Motor
(Power Sliding Door)............... 8W-80-80
Left Speed Control Switch............ 8W-80-80
Left Stop/Turn Signal Relay (Trailer Tow) . 8W-80-80
Left Turn Signal Lamp
(Built-Up-Export)................. 8W-80-81
Left Visor/Vanity Lamp
(Premium/Luxury)................. 8W-80-81
License Lamp (Manual Release)........ 8W-80-81
License Lamp (Power Liftgate)......... 8W-80-81
License Lamp (Power Release)......... 8W-80-82
Liftgate Ajar Switch (Manual Release) . . . 8W-80-82
Liftgate Ajar Switch (Power Release).... 8W-80-82
Liftgate Cinch/Release Motor
(Power Liftgate).................. 8W-80-82
Liftgate Cylinder Lock Switch.......... 8W-80-82
Liftgate Left Pinch Sensor
(Power Liftgate).................. 8W-80-83
Liftgate Right Pinch Sensor
(Power Liftgate).................. 8W-80-83
Lift Pump Motor (Diesel)............. 8W-80-83
Low Note Horn..................... 8W-80-83
Manifold Absolute Pressure
Sensor (Gas)..................... 8W-80-83
Mass Air Flow Sensor (Diesel)......... 8W-80-84
Memory Power Seat Switch........... 8W-80-84
Memory Seat/Mirror Module C1........ 8W-80-84
Memory Seat/Mirror Module C2........ 8W-80-85
Memory Seat/Mirror Module C3........ 8W-80-85
Memory Seat/Mirror Module C4........ 8W-80-86
Memory Seat Front Vertical Motor...... 8W-80-86
Memory Seat Front Vertical
Position Sensor................... 8W-80-86
Memory Seat Horizontal Motor......... 8W-80-86
Memory Seat Horizontal
Position Sensor................... 8W-80-86
Memory Seat Rear Vertical Motor....... 8W-80-87
Memory Seat Rear Vertical
Position Sensor................... 8W-80-87
Memory Seat Recliner Motor.......... 8W-80-87
Memory Seat Recliner Position Sensor . . . 8W-80-87
Memory Seat Switch................. 8W-80-87
Message Center (High Line)........... 8W-80-88
Mode Door Actuator (ATC)............ 8W-80-88
Mode Door Actuator (MTC)............ 8W-80-88
Multi-Function Switch............... 8W-80-88
Occupant Restraint Controller......... 8W-80-89
Overhead Console (Except Base)........ 8W-80-89
Oxygen Sensor 1/1 Upstream (Gas)...... 8W-80-90
Oxygen Sensor 1/2 Downstream (Gas) . . . 8W-80-90
Park/Neutral Position Switch (ATX)..... 8W-80-90
Passenger Airbag................... 8W-80-90
Passenger Blend Door Actuator (ATC) . . . 8W-80-90
Passenger Blend Door Actuator (MTC) . . . 8W-80-91
Passenger Door Courtesy Lamp........ 8W-80-91
RG8W-80 CONNECTOR PIN-OUTS8Wa-80-3

LIFTGATE LEFT PINCH SENSOR (POWER LIFTGATE) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 Q77 20OR/DB RIGHT PINCH SENSOR SIGNAL
2 Q76 20OR/LB PINCH SENSOR SIGNAL
LIFTGATE RIGHT PINCH SENSOR (POWER LIFTGATE) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 Q77 20OR/DB RIGHT PINCH SENSOR SIGNAL
2 Z78 20BK/OR GROUND
LIFT PUMP MOTOR (DIESEL) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 N2 18OR LIFT PUMP RELAY OUTPUT
2 Z201 18OR GROUND
LOW NOTE HORN - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 Z298 18BK/DB GROUND
2 X2 18DG/OR HORN RELAY OUTPUT
MANIFOLD ABSOLUTE PRESSURE SENSOR (GAS) - BLACK 3 WAY
CAV CIRCUIT FUNCTION
1 K1 18VT/BR MANIFOLD ABSOLUTE PRESSURE SENSOR SIGNAL
2 K900 18DB/DG SENSOR GROUND
3 F855 18OR/PK (EXCEPT BUILT-UP-
EXPORT)5 VOLT SUPPLY
3 F855 18PK/YL (BUILT-UP-EXPORT) 5 VOLT SUPPLY
RG8W-80 CONNECTOR PIN-OUTS8Wa-80-83

Component/Ground Color Location Fig.
Left Remote Radio Switch Steering Wheel N/S
Left Repeater Lamp GY Left Front Fender 5
Left Seat Airbag YL Left Seat N/S
Left Side Impact Airbag Control
ModuleYL Left B Pillar 30
Left Sliding Door Control Module
C1BK Left Sliding Door N/S
Left Sliding Door Control Module
C2BK/RD Left Sliding Door N/S
Left Sliding Door Latch Sensing
SwitchBK Left Sliding Door N/S
Left Sliding Door Lock Motor BK Left Sliding Door N/S
Left Sliding Door Lock Motor/Ajar
SwitchBK Left Sliding Door N/S
Left Sliding Door Motor BK Left Sliding Door N/S
Left Speed Control Switch BK Steering Wheel N/S
Left Stop/Turn Signal Relay BK Left Quarter Panel N/S
Left Turn Signal Lamp BK AT Lamp N/S
Left Visor/Vanity Lamp BK At Lamp N/S
License Lamp DKGY At Lamp 38
Lift Pump Motor BK Left Rear Engine Compartment N/S
Liftgate Ajar Switch (Manual
Release)BK At Latch 38
Liftgate Ajar Switch (Power
Release)BK Lower Liftgate 38
Liftgate Cinch/Release Motor BL Liftgate N/S
Liftgate Cylinder Lock Switch BK At Switch 38
Liftgate Left Pinch Sensor BK Left Side of Liftgate N/S
Liftgate Right Pinch Sensor BK Right Side of Liftgate N/S
Low Note Horn BK Left Frame Rail 6
Manifold Absolute Pressure
SensorBK On Intake 11
Mass Air Flow Sensor (Diesel) OR Top of Engine 12, 13
Memory Power Seat Switch GN On Seat N/S
Memory Seat/Mirror Module C1 GY Under Driver Seat N/S
Memory Seat/Mirror Module C2 GY Under Driver Seat N/S
Memory Seat/Mirror Module C3 GY Under Driver Seat N/S
Memory Seat/Mirror Module C4 WT Under Driver Seat N/S
Memory Seat Front Vertical Motor RD Under Seat N/S
Memory Seat Front Vertical
Position SensorBK Under Seat N/S
Memory Seat Horizontal Motor BK Under Seat N/S
Memory Seat Horizontal Position
SensorBK Under Seat N/S
RG8W-90 CONNECTOR/GROUND LOCATIONS BUX8Wa-90-7
CONNECTOR/GROUND LOCATIONS BUX (Continued)

Splice Number Location Fig.
S119 (2.5L) Near T/O for Engine Starter Motor 4
S120 (2.4L) Near T/O for Oxygen Sensors 2
S120 (3.3L/3.8L) Near T/O for Oxygen Sensors 5
S121 (3.3L/3.8L) Near T/O for Output Speed Sensor 5
S122 (2.4L) In T/O to Engine Starter Motor 1
S122 (3.3L/3.8L) In T/O to Engine Starter Motor 5
S123 In T/O to Low Note Horn 8
S124 (2.4L) Near T/O for Fuel Injector No.2 N/S
S124 (3.3L/3.8L) Near T/O for Fuel Injector No.5 and No.6 N/S
S125 (2.4L) In T/O for Manifold Absolute Pressure Sensor N/S
S127 (2.5L) Near T/O for Engine Starter Motor N/S
S128 (2.5L) Near T/O for Engine Starter Motor 4
S129 (2.5L) Near T/O for Battery (+) N/S
S130 (2.5L) Near T/O for Battery (+) N/S
S131 (3.3L/3.8L) Near T/O for Transmission Control Module N/S
S132 (2.5L) Near T/O for Battery (+) N/S
S133 (2.5L) Near T/O for Intelligent Power Module C3 N/S
S135 (2.5L) Near T/O for Glow Plug No.2 4
S136 (2.5L) Between T/O for Radiator Fan No.2 and T/O for G102 N/S
S137 (2.5L) Near T/O for A/C Compressor Clutch 4
S138 (2.5L) Between T/O for Radiator Fan No.2 and T/O for G102 N/S
S139 (2.5L) Between T/O for Engine Starter Motor and T/O for
Engine Control Module C13
S141 (2.4L) Near T/O for Powertrain Control Module N/S
S141 (2.5L) Near /t/O for G100 N/S
S141 (3.3L/3.8L) Near T/O for Powertrain Control Module N/S
S142 (3.3L/3.8L) Near T/O for A/C Compressor Clutch 5
S143 (2.5L) Near T/O for Engine Control Module C1 4
S143 (3.3L/3.8L) Near T/O for Intelligent Power Module - C3 N/S
S144 (2.5L) Between T/O for Battery Temperature Sensor and T/O for
C1034
S145 (2.5L) Near T/O for Battery (+) N/S
S148 (2.5L) Near T/O for Engine Starter Motor 4
S150 (2.5L) Between T/O for Battery Temperature Sensor and T/O for
C103N/S
S151 (2.5L) Near T/O for Radiator Fan Relay No.1 7
S152 (2.5L) Near T/O for Left Fog Lamp N/S
S157 (2.5L) Near T/O for Glow Plug No.1 4
S187 (2.5L) Near T/O for Engine Control Module C1 4
S188 (2.5L) Near T/O for Radiator Fan Relay No.1 7
S201 In T/O to Instrument Panel Speaker 9
S202 Near T/O for Instrument Panel Switch Bank 9, 10
S203 Near T/O for Instrument Panel Switch Bank 9, 10
8Wa - 95 - 2 8W-95 SPLICE LOCATIONS BUXRG
SPLICE LOCATIONS BUX (Continued)

(1) Inspect air cleaner, induction system and
intake manifold to insure system is dry and clear of
foreign material.
(2) Remove negative battery cable.
(3) Place a shop towel around the spark plugs
when removing them from the engine. This will catch
any fluid that may possibly be in the cylinder under
pressure.
(4) With all spark plugs removed, rotate engine
crankshaft using a breaker bar and socket.
(5) Identify the fluid in the cylinder(s) (i.e., cool-
ant, fuel, oil or other).
(6) Make sure all fluid has been removed from the
cylinders. Inspect engine for damage (i.e., connecting
rods, pistons, valves, etc.)
(7) Repair engine or components as necessary to
prevent this problem from re-occurring.
CAUTION: Squirt approximately one teaspoon of oil
into the cylinders, rotate engine to lubricate the cyl-
inder walls to prevent damage on restart.
(8) Install new spark plugs.
(9) Drain engine oil and remove oil filter.
(10) Install a new oil filter.
(11) Fill engine with specified amount of approved
oil.
(12) Connect negative battery cable.
(13) Start engine and check for any leaks.
STANDARD PROCEDURE - FORM-IN-PLACE
GASKETS AND SEALERS
There are numerous places where form-in-place
gaskets are used on the engine. Care must be taken
when applying form-in-place gaskets to assure
obtaining the desired results.Do not use form-in-
place gasket material unless specified.Bead size,
continuity, and location are of great importance. Too
thin a bead can result in leakage while too much can
result in spill-over which can break off and obstruct
fluid feed lines. A continuous bead of the proper
width is essential to obtain a leak-free gasket.
There are numerous types of form-in-place gasket
materials that are used in the engine area. Mopart
Engine RTV GEN II, MopartATF-RTV, and Mopart
Gasket Maker gasket materials, each have different
properties and can not be used in place of the other.
MOPARtENGINE RTV GEN IIis used to seal
components exposed to engine oil. This material is a
specially designed black silicone rubber RTV that
retains adhesion and sealing properties when
exposed to engine oil. Moisture in the air causes the
material to cure. This material is available in three
ounce tubes and has a shelf life of one year. After one
year this material will not properly cure. Alwaysinspect the package for the expiration date before
use.
MOPARtATF RTVis a specifically designed
black silicone rubber RTV that retains adhesion and
sealing properties to seal components exposed to
automatic transmission fluid, engine coolants, and
moisture. This material is available in three ounce
tubes and has a shelf life of one year. After one year
this material will not properly cure. Always inspect
the package for the expiration date before use.
MOPARtGASKET MAKERis an anaerobic type
gasket material. The material cures in the absence of
air when squeezed between two metallic surfaces. It
will not cure if left in the uncovered tube. The
anaerobic material is for use between two machined
surfaces. Do not use on flexible metal flanges.
MOPARtBED PLATE SEALANTis a unique
(green-in-color) anaerobic type gasket material that
is specially made to seal the area between the bed-
plate and cylinder block without disturbing the bear-
ing clearance or alignment of these components. The
material cures slowly in the absence of air when
torqued between two metallic surfaces, and will rap-
idly cure when heat is applied.
MOPARtGASKET SEALANTis a slow drying,
permanently soft sealer. This material is recom-
mended for sealing threaded fittings and gaskets
against leakage of oil and coolant. Can be used on
threaded and machined parts under all tempera-
tures. This material is used on engines with multi-
layer steel (MLS) cylinder head gaskets. This
material also will prevent corrosion. MopartGasket
Sealant is available in a 13 oz. aerosol can or 4oz./16
oz. can w/applicator.
SEALER APPLICATION
MopartGasket Maker material should be applied
sparingly 1 mm (0.040 in.) diameter or less of sealant
to one gasket surface. Be certain the material sur-
rounds each mounting hole. Excess material can eas-
ily be wiped off. Components should be torqued in
place within 15 minutes. The use of a locating dowel
is recommended during assembly to prevent smear-
ing material off the location.
MopartEngine RTV GEN II or ATF RTV gasket
material should be applied in a continuous bead
approximately 3 mm (0.120 in.) in diameter. All
mounting holes must be circled. For corner sealing, a
3.17 or 6.35 mm (1/8 or 1/4 in.) drop is placed in the
center of the gasket contact area. Uncured sealant
may be removed with a shop towel. Components
should be torqued in place while the sealant is still
wet to the touch (within 10 minutes). The usage of a
locating dowel is recommended during assembly to
prevent smearing material off the location.
9 - 10 ENGINE 2.4LRS
ENGINE 2.4L (Continued)

AIR CLEANER ELEMENT
REMOVAL
(1) Unsnap 2 clips.
(2) Lift cover and pull toward the engine and
remove cover tabs from air box.
(3) Lift cover and remove the element (Fig. 11).
INSTALLATION
(1) Install the air filter element into air box (Fig.
11).
(2) Move cover so that the tabs insert into the air
box.
(3) Push cover down and snap the 2 clips.
AIR CLEANER HOUSING
REMOVAL
(1) Disconnect the negative battery cable.(2) Disconnect the inlet air temperature sensor
(Fig. 12).
(3) Remove the inlet hose to throttle body (Fig. 11).
(4) Remove the bolt for air box at upper radiator
cross member.
(5) Pull air box up and off over the single locating
pin.
(6) Remove air box from vehicle
INSTALLATION
(1) Install air box into vehicle and onto the locat-
ing pin.
(2) Install bolt to hold air box to the upper radia-
tor cross member.
(3) Install the inlet hose to the throttle body.
(4) Connect the inlet air temperature sensor (Fig.
12).
(5) Connect the negative battery cable.
CYLINDER HEAD
DESCRIPTION
The cross flow designed, aluminum cylinder head
contains dual over-head camshafts with four valves
per cylinder (Fig. 13). The valves are arrange in two
in-line banks. The intake valves face toward the
front of the vehicle. The exhaust valves face the dash
panel. The cylinder head incorporates powdered
metal valve guides and seats. The cylinder head is
sealed to the block using a multi-layer steel head
gasket and retaining bolts.
Integral oil galleries providing lubrication passages
to the hydraulic lash adjusters, camshafts, and valve
mechanisms.
Cylinder Compression Pressure Adaptor 8116
Fig. 11 AIR BOX COVER
Fig. 12 IAT SENSOR 2.4L
9 - 22 ENGINE 2.4LRS
SPECIAL TOOLS (Continued)