belt CHRYSLER VOYAGER 2001 Service Manual

Component Page
Passenger Door Lock Switch........... 8W-80-91
Passenger Folding Mirror Relay
(Built-Up-Export)................. 8W-80-91
Passenger Heated Seat Back........... 8W-80-92
Passenger Heated Seat Cushion........ 8W-80-92
Passenger Heated Seat Module C1...... 8W-80-92
Passenger Heated Seat Module C2...... 8W-80-92
Passenger Heated Seat Module C3...... 8W-80-93
Passenger Power Seat Front Riser Motor . 8W-80-93
Passenger Power Seat Horizontal Motor . . 8W-80-93
Passenger Power Seat Rear Riser Motor . . 8W-80-93
Passenger Power Seat Recliner Motor.... 8W-80-93
Passenger Power Seat Switch.......... 8W-80-94
Passenger Power Window Motor........ 8W-80-94
Passenger Power Window Switch....... 8W-80-94
Passenger Seat Belt Switch........... 8W-80-94
Passenger Seat Belt Tensioner......... 8W-80-95
Power Folding Mirror Switch
(Built-Up-Export)................. 8W-80-95
Power Liftgate Module C1............ 8W-80-95
Power Liftgate Module C2............ 8W-80-96
Power Liftgate Motor................ 8W-80-96
Power Mirror Switch................. 8W-80-97
Power Outlet....................... 8W-80-97
Power Seat Circuit Breaker (30A)....... 8W-80-97
Powertrain Control Module C1
(2.4L/3.3L/3.8L)................... 8W-80-98
Powertrain Control Module C2
(2.4L/3.3L/3.8L)................... 8W-80-99
Power Window Circuit Breaker (25A) . . . 8W-80-100
Radiator Fan No. 1 (Diesel)........... 8W-80-100
Radiator Fan No. 1 (Gas)............ 8W-80-100
Radiator Fan No. 2 (Diesel)........... 8W-80-100
Radiator Fan No. 2 (Gas)............ 8W-80-100
Radiator Fan Relay (Gas)............ 8W-80-101
Radiator Fan Relay No. 1 (Diesel)...... 8W-80-101
Radiator Fan Relay No. 2 (Diesel)...... 8W-80-101
Radiator Fan Relay No. 3 (Diesel)...... 8W-80-102
Radio C1......................... 8W-80-102
Radio C2......................... 8W-80-102
Radio C3......................... 8W-80-102
Radio C4......................... 8W-80-103
Radio Choke...................... 8W-80-103
Rear A/C-Heater Unit (3 Zone HVAC) . . . 8W-80-103
Rear Auto Temp Control Switch (ATC) . . 8W-80-104
Rear Blower Front Control Switch
(3 Zone HVAC).................. 8W-80-104
Rear Blower Motor Power Module
C1(ATC) ....................... 8W-80-104
Rear Blower Motor Power Module
C2(ATC) ....................... 8W-80-104
Rear Blower Rear Control Switch
C1 (3 Zone HVAC)................ 8W-80-105
Rear Blower Rear Control Switch C2
(3 Zone HVAC).................. 8W-80-105Component Page
Rear Dome Lamp (Except Luxury)..... 8W-80-105
Rear Mode Motor (ATC)............. 8W-80-105
Rear Power Outlet................. 8W-80-105
Rear Temperature Motor (ATC)........ 8W-80-106
Rear Washer Pump Motor............ 8W-80-106
Rear Wiper Motor.................. 8W-80-106
Recirculation Door Actuator (ATC)..... 8W-80-106
Recirculation Door Actuator (MTC)..... 8W-80-106
Remote Keyless Entry Antenna
(Japan)........................ 8W-80-107
Remote Keyless Entry Module........ 8W-80-107
Right B-Pillar Switch............... 8W-80-107
Right Cinch/Release Motor
(Power Sliding Door).............. 8W-80-107
Right Combination Relay
(Trailer Tow).................... 8W-80-107
Right Cylinder Lock Switch.......... 8W-80-108
Right Door Speaker................. 8W-80-108
Right Fog Lamp................... 8W-80-108
Right Front Door Ajar Switch (Base).... 8W-80-108
Right Front Door Lock Motor/Ajar Switch
(Except Base)................... 8W-80-108
Right Front Park/Turn Signal Lamp
(Except Built-Up-Export).......... 8W-80-109
Right Front Wheel Speed Sensor...... 8W-80-109
Right Full Open Switch
(Power Sliding Door).............. 8W-80-109
Right Headlamp (Except
Built-Up-Export)................. 8W-80-109
Right Headlamp Leveling Motor
(Built-Up-Export)................ 8W-80-110
Right High Beam Lamp
(Built-Up-Export)................ 8W-80-110
Right Instrument Panel Speaker....... 8W-80-110
Right Liftgate Flood Lamp........... 8W-80-110
Right Low Beam Lamp
(Built-Up-Export)................ 8W-80-110
Right Mid Reading Lamp
(Premium/Luxury)................ 8W-80-111
Right Park Lamp (Built-Up-Export).... 8W-80-111
Right Power Mirror................. 8W-80-111
Right Rear Lamp Assembly........... 8W-80-111
Right Rear Pillar Speaker............ 8W-80-112
Right Rear Reading Lamp (Luxury).... 8W-80-112
Right Rear Speaker................. 8W-80-112
Right Rear Vent Motor.............. 8W-80-112
Right Rear Wheel Speed Sensor....... 8W-80-112
Right Remote Radio Switch........... 8W-80-113
Right Repeater Lamp (Built-Up-Export) . 8W-80-113
Right Seat Airbag.................. 8W-80-113
Right Side Impact Airbag
Control Module.................. 8W-80-113
Right Sliding Door Control Module C1
(Power Sliding Door).............. 8W-80-113
8Wa - 80 - 4 8W-80 CONNECTOR PIN-OUTSRG

DRIVER SEAT BELT SWITCH - WHITE 2 WAY
CAV CIRCUIT FUNCTION
1 R59 18LG/TN DRIVER SEAT BELT SWITCH LINE 1
2 R57 18LG/GY DRIVER SEAT BELT SWITCH LINE 2
DRIVER SEAT BELT TENSIONER-2WAY
CAV CIRCUIT FUNCTION
1 R53 18LG/YL DRIVER SEAT BELT TENSIONER LINE 2
2 R55 18LG/DG DRIVER SEAT BELT TENSIONER LINE 1
EGR SOLENOID (DIESEL) - LT. GRAY 2 WAY
CAV CIRCUIT FUNCTION
1 K35 20GY/YL EGR SOLENOID CONTROL
2 K342 16BR/WT ECM/PCM RELAY OUTPUT
EGR SOLENOID (GAS) - GRAY 2 WAY
CAV CIRCUIT FUNCTION
1 K35 18DB/VT EGR SOLENOID CONTROL
2 F202 18PK/GY IGNITION SWITCH OUTPUT (RUN-START)
ELECTRIC WIPER DE-ICER C1 - WHITE 2 WAY
CAV CIRCUIT FUNCTION
1 F302 18GY/PK FUSED ACCESSORY RELAY OUTPUT
2- -
8Wa - 80 - 54 8W-80 CONNECTOR PIN-OUTSRG

OCCUPANT RESTRAINT CONTROLLER - YELLOW/RED 23 WAY
CAV CIRCUIT FUNCTION
1 R54 18LB/YL PASSENGER SEAT BELT TENSIONER LINE 2
2 R56 18LB/DG PASSENGER SEAT BELT TENSIONER LINE 1
3 R62 18LB/VT PASSENGER SQUIB 2 LINE 2
4 R64 18LB/WT PASSENGER SQUIB 2 LINE 1
5 R42 18LB/BR PASSENGER SQUIB 1 LINE 2
6 R44 18LB/OR PASSENGER SQUIB 1 LINE 1
7 R53 18LG/YL DRIVER SEAT BELT TENSIONER LINE 2
8 R55 18LG/DG DRIVER SEAT BELT TENSIONER LINE 1
9 R61 18LG/VT DRIVER SQUIB 2 LINE 1
10 R63 18LG/WT DRIVER SQUIB 2 LINE 2
11 R43 18LG/BR DRIVER SQUIB 1 LINE 1
12 R45 18LG/OR DRIVER SQUIB 1 LINE 2
13 - -
14 F201 18PK/OR FCM OUTPUT (RUN-START)
15 F100 18PK/VT FCM OUTPUT (RUN)
16 Z12 18BK/OR GROUND
17 R59 18LG/TN DRIVER SEAT BELT SWITCH LINE 1
18 R57 18LG/GY DRIVER SEAT BELT SWITCH LINE 2
19 R60 18LB/TN PASSENGER SEAT BELT SWITCH LINE 1
20 R58 18LB/GY PASSENGER SEAT BELT SWITCH LINE 2
21 D25 18WT/VT PCI BUS
22 - -
23 - -
OVERHEAD CONSOLE (EXCEPT BASE) - BLACK 12 WAY
CAV CIRCUIT FUNCTION
1 G23 20VT/DB SLIDING DOORS OVERHEAD SWITCH MUX
2 G25 20VT/TN LIFTGATE SWITCH MUX
3 D25 20WT/VT PCI BUS
4 Z113 20BK/DB GROUND
5 A114 20GY/RD FUSED B(+) (I.O.D.)
6 F503 20WT/PK IGNITION SWITCH OUTPUT (RUN)
7 Z13 20BK/WT GROUND
8 E15 20OR/DB ASH/RECEIVER LAMP FEED
9- -
10 - -
11 L24 20BK/GY (EXCEPT BUILT-UP-EX-
PORT) (PREMIUM/LUXURY)AUTOMATIC HEADLAMP SWITCH SENSOR
12 L1 20BK/WT (PREMIUM/LUXURY) BACK-UP LAMP FEED
RADIATOR FAN RELAY NO. 1 (DIESEL) - BLUE 9 WAY
CAV CIRCUIT FUNCTION
1- -
2 N201 12DB/LG RADIATOR FAN RELAY NO. 1 OUTPUT
3- -
4 K342 16BR/WT ECM/PCM RELAY OUTPUT
5- -
6 N210 18DB/DG LOW SPEED RADIATOR FAN RELAY CONTROL
7- -
8 A201 12RD/LG FUSED B(+)
9- -
RG8W-80 CONNECTOR PIN-OUTS8Wa-80-89

PASSENGER POWER SEAT SWITCH - GREEN 10 WAY
CAV CIRCUIT FUNCTION
1 Z848 14BK/OR GROUND
2 P44 14LG/VT PASSENGER RECLINER UP SWITCH SENSE
3 P16 14LG/WT PASSENGER HORIZONTAL REARWARD SWITCH
SENSE
4 P42 14LG/GY PASSENGER RECLINER DOWN SWITCH SENSE
5 A210 14OR/RD FUSED SEAT SWITCH DRIVER
6 P14 14LG/OR PASSENGER HORIZONTAL FORWARD SWITCH SENSE
7 P20 14LG/LB PASSENGER FRONT DOWN SWITCH SENSE
8 P12 14LG/YL PASSENGER REAR DOWN SWITCH SENSE
9 P10 14LG/TN PASSENGER REAR UP SWITCH SENSE
10 P18 14LG/OR PASSENGER FRONT UP SWITCH SENSE
PASSENGER POWER WINDOW MOTOR - RED 2 WAY
CAV CIRCUIT FUNCTION
1 Q12 14OR/BR PASSENGER WINDOW DRIVER UP
2 Q22 14OR/VT PASSENGER WINDOW DRIVER DOWN
PASSENGER POWER WINDOW SWITCH - BLACK 8 WAY
CAV CIRCUIT FUNCTION
1 F304 16WT/PK (BUILT-UP-EXPORT
LHD)FUSED WINDOW CIRCUIT BREAKER OUTPUT
1 F304 12WT/PK (EXCEPT BUILT-UP-
EXPORT RHD)FUSED WINDOW CIRCUIT BREAKER OUTPUT
2 Q26 12OR/GY MASTER WINDOW SWITCH PASSENGER DOWN
3 Q16 12OR/TN MASTER WINDOW SWITCH PASSENGER UP
4- -
5 Q22 14OR/VT PASSENGER WINDOW DRIVER DOWN
6 F304 16WT/PK FUSED WINDOW CIRCUIT BREAKER OUTPUT
7 Z422 20BK/BR GROUND
8 Q12 14OR/BR PASSENGER WINDOW DRIVER UP
PASSENGER SEAT BELT SWITCH-2WAY
CAV CIRCUIT FUNCTION
1 R60 18LB/TN PASSENGER SEAT BELT SWITCH LINE 1
2 R58 18LB/GY PASSENGER SEAT BELT SWITCH LINE 2
8Wa - 80 - 94 8W-80 CONNECTOR PIN-OUTSRG

PASSENGER SEAT BELT TENSIONER-2WAY
CAV CIRCUIT FUNCTION
1 R54 18LB/YL PASSENGER SEAT BELT TENSIONER LINE 2
2 R56 18LB/DG PASSENGER SEAT BELT TENSIONER LINE 1
POWER FOLDING MIRROR SWITCH (BUILT-UP-EXPORT) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 Z888 20BK/YL GROUND
2 P136 20TN/YL FOLDING MIRROR SWITCH SENSE
POWER LIFTGATE MODULE C1 - BLACK 8 WAY
CAV CIRCUIT FUNCTION
1 Q83 18OR/GY LIFTGATE LATCH CLUTCH DRIVER
2 Q88 14TN/BR (BUILT-UP-EXPORT) LIFTGATE OPEN DRIVER
2 Q88 16TN/BR (EXCEPT BUILT-UP-EX-
PORT)LIFTGATE OPEN DRIVER
3 Q89 16TN/OR (EXCEPT BUILT-UP-EX-
PORT)LIFTGATE CLOSE DRIVER
3 Q89 14TN/OR (BUILT-UP-EXPORT) LIFTGATE CLOSE DRIVER
4- -
5 A115 12YL/RD FUSED B(+)
6- -
7- -
8 Z125 14BK/WT GROUND
RG8W-80 CONNECTOR PIN-OUTS8Wa-80-95

Component/Ground Color Location Fig.
Driver Heated Seat Module C3 GN At Seat N/S
Driver Power Seat Front Riser
MotorRD At Seat N/S
Driver Power Seat Horizontal
MotorBK At Seat N/S
Driver Power Seat Rear Riser
MotorRD At Seat N/S
Driver Power Seat Recliner Motor GN At Seat N/S
Driver Power Seat Switch GN At Switch N/S
Driver Power Window Motor RD At Motor N/S
Driver Power Window Switch GN At Switch N/S
Driver Power Window Switch
(RHD)NAT At Switch N/S
Driver Seatbelt Switch WT At Switch on Seat Harness N/S
Driver Seatbelt Tensioner On Seat Harness N/S
EGR Solenoid (Diesel) BK Above Transmission
Right Side of EngineN/S
EGR Solenoid GY Above Transmission
Right Side of Engine10, 11, 12,
14
Electric Wiper De-Icer-C1 WT Right Side Instrument Panel 16, 20, 23
Electric Wiper De-Icer-C2 WT Left Side Instrument Panel 16, 17 22
Engine Control Module C1
(Diesel)BK Right Side of Engine 12
Engine Control Module C2
(Diesel)BK Right Side of Engine 12
Engine Coolant Temperature
Sensor (Gas)BK On Cylinder Block N/S
Engine Coolant Temperature
Sensor (Diesel)BL On Cylinder Block 12
Engine Oil Pressure Sensor
(Diesel)BK Rear of Engine 13
Engine Oil Pressure Switch LTGN On Cylinder Block 10
Engine Oil Temperature Sensor
(Diesel)BK Rear of Engine 13
EVAP/Purge Solenoid BK Right Motor Mount 10, 14
Evaporator Temperature Sensor BK Right Side of HVAC N/S
Floor Console Lamp BK At Lamp N/S
Floor Console Power Outlet RD At Front Console N/S
Front Blower Module C1 (ATC) BK On HVAC N/S
Front Blower Module C2 (ATC) BK On HVAC N/S
Front Cigar Lighter RD/NAT Rear of Lighter 16, 19, 21
Front Reading Lamps/Switch BK At Switch N/S
Front Washer Pump Motor BK Right Fender Well 4
Fuel Heater (Diesel) BK Left Rear Engine Compartment N/S
Fuel Injector No.1 BK At Fuel Injector N/S
8Wa - 90 - 4 8W-90 CONNECTOR/GROUND LOCATIONS BUXRG
CONNECTOR/GROUND LOCATIONS BUX (Continued)

Component/Ground Color Location Fig.
Memory Seat Rear Vertical Motor RD Under Seat N/S
Memory Seat Rear Vertical
Position SensorBK Under Seat N/S
Memory Seat Recliner Motor GN Under Seat N/S
Memory Seat Recliner Position
SensorBK Under Seat N/S
Memory Seat Switch BK At Switch Driver Door N/S
Message Center WT Rear of Message Center 16, 17, 23
Mode Door Actuator BK Left Side of HVAC N/S
Multi Function Switch BK At Steering Column 16, 17, 18,
19, 26
Occupant Restraint Controller YL/RD Right Side of Instrument Panel 16, 20, 21
Output Speed Sensor GY Front of Transmission 15
Overhead Console BK Front of Console N/S
Oxygen Sensor 1/1 Upstream GY Rear of Engine 10, 11, 15
Oxygen Sensor 1/2 Downstream BK Rear of Engine 10, 11, 15
Park/Neutral Positon Switch BK Front of Transmission 11
Passenger Airbag YL Passenger Side of Instrument Panel 16, 19, 20,
25
Passenger Blend Door Actuator On HVAC N/S
Passenger Door Courtesy Lamp BK At Lamp 33
Passenger Door Lock Switch BK At Switch 33
Passenger Folding Mirror Relay BL Right Kick Panel N/S
Passenger Heated Seat Back GN At Seat N/S
Passenger Heated Seat Cushion BK At Seat N/S
Passenger Heated Seat Module
C1GY At Heated Seat N/S
Passenger Heated Seat Module
C2GY At Heated Seat Back N/S
Passenger Heated Seat Module
C3GN At Heated Seat N/S
Passenger Power Seat Front
Riser MotorRD Under Seat N/S
Passenger Power Seat Horizontal
MotorBK Under Seat N/S
Passenger Power Seat Rear
Riser MotorRD Under Seat N/S
Passenger Power Seat Recliner
MotorGN Under Seat N/S
Passenger Power Seat Switch GN At Switch N/S
Passenger Power Window Motor RD At Motor 33
Passenger Power Window Switch BK At Switch 33
Passenger Seatbelt Switch On Seat Harness N/S
Passenger Seatbelt Tensioner On Seat Harness N/S
Power Folding Mirror Switch BK Near Steering Column 26
8Wa - 90 - 8 8W-90 CONNECTOR/GROUND LOCATIONS BUXRG
CONNECTOR/GROUND LOCATIONS BUX (Continued)

CLEANING..............................35
INSPECTION............................35
CONNECTING ROD BEARINGS
STANDARD PROCEDURE..................35
CONNECTING ROD - FITTING.............35
CRANKSHAFT
DESCRIPTION...........................36
OPERATION.............................36
STANDARD PROCEDURE..................36
CRANKSHAFT END-PLAY................36
REMOVAL..............................36
INSPECTION............................37
INSTALLATION...........................37
CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDURE..................38
MAIN BEARING - FITTING................38
CRANKSHAFT OIL SEAL - FRONT
REMOVAL..............................40
INSTALLATION...........................40
CRANKSHAFT OIL SEAL - REAR
REMOVAL..............................41
INSTALLATION...........................41
PISTON & CONNECTING ROD
DESCRIPTION...........................42
OPERATION.............................42
REMOVAL..............................42
INSTALLATION...........................43
PISTON RINGS
STANDARD PROCEDURE..................44
PISTON RING - FITTING.................44
VIBRATION DAMPER
REMOVAL..............................46
INSTALLATION...........................46
STRUCTURAL COLLAR
REMOVAL..............................46
INSTALLATION...........................46
ENGINE MOUNTING
DESCRIPTION...........................47
FRONT MOUNT
REMOVAL..............................47
INSTALLATION...........................47
LEFT MOUNT
REMOVAL..............................47
INSTALLATION...........................48
REAR MOUNT
REMOVAL..............................48
INSTALLATION...........................48
RIGHT MOUNT
REMOVAL..............................50
INSTALLATION...........................50
LUBRICATION
DESCRIPTION...........................50
OPERATION.............................50
DIAGNOSIS AND TESTING.................50
ENGINE OIL PRESSURE CHECKING........50
OIL
STANDARD PROCEDURE..................51ENGINE OIL LEVEL CHECK...............51
ENGINE OIL CHANGE...................51
OIL FILTER
DESCRIPTION...........................51
REMOVAL..............................51
INSTALLATION...........................52
OIL PAN
REMOVAL..............................52
INSTALLATION...........................52
OIL PUMP
REMOVAL..............................52
DISASSEMBLY...........................53
CLEANING..............................53
INSPECTION............................53
ASSEMBLY.............................55
INSTALLATION...........................55
INTAKE MANIFOLD
DESCRIPTION...........................56
OPERATION.............................56
DIAGNOSIS AND TESTING.................56
INTAKE MANIFOLD LEAKS...............56
INTAKE MANIFOLD - UPPER
REMOVAL..............................56
INSPECTION............................57
INSTALLATION...........................57
INTAKE MANIFOLD - LOWER
REMOVAL..............................58
INSPECTION............................58
INSTALLATION...........................58
EXHAUST MANIFOLD
DESCRIPTION...........................59
OPERATION.............................59
REMOVAL..............................59
CLEANING..............................59
INSPECTION............................59
INSTALLATION...........................59
TIMING BELT COVER(S)
REMOVAL..............................60
INSTALLATION...........................61
TIMING BELT AND SPROCKET(S)
REMOVAL..............................61
CLEANING..............................62
INSTALLATION...........................62
TIMING BELT TENSIONER & PULLEY
REMOVAL..............................64
INSTALLATION...........................65
BALANCE SHAFT
DESCRIPTION...........................66
OPERATION.............................66
REMOVAL..............................66
INSTALLATION...........................67
BALANCE SHAFT CARRIER
REMOVAL..............................70
INSTALLATION...........................70
BALANCE SHAFT CHAIN
REMOVAL..............................70
INSTALLATION...........................70
9 - 2 ENGINE 2.4LRS

(7) After the oil leak root cause and appropriate
corrective action have been identified, replace compo-
nent(s) as necessary.
DIAGNOSIS AND TESTING - ENGINE
Engine diagnosis is helpful in determining the
causes of malfunctions not detected and remedied by
routine maintenance.
These malfunctions may be classified as either
mechanical (e.g., a strange noise), or performance
(e.g., engine idles rough and stalls).
Refer to the Engine Mechanical and the Engine
Performance diagnostic charts, for possible causes
and corrections of malfunctions (Refer to 9 - ENGINE
- DIAGNOSIS AND TESTING - MECHANICAL)
(Refer to 9 - ENGINE - DIAGNOSIS AND TESTING
- PERFORMANCE).For fuel system diagnosis, (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY - DIAGNOSIS AND
TESTING).
Additional tests and diagnostic procedures may be
necessary for specific engine malfunctions that can-
not be isolated with the Service Diagnosis charts.
Information concerning additional tests and diagno-
sis is provided within the following:
²Cylinder Compression Pressure Test
²Cylinder Combustion Pressure Leakage Test
²Engine Cylinder Head Gasket Failure Diagnosis
²Intake Manifold Leakage Diagnosis
²Lash Adjuster (Tappet) Noise Diagnosis
²Engine Oil Leak Inspection
DIAGNOSIS AND TESTING - ENGINE PERFORMANCE
CONDITION POSSIBLE CAUSE CORRECTION
ENGINE WILL NOT START 1. Weak battery. 1. Test battery. Charge or replace
as necessary. (Refer to 8 -
ELECTRICAL/BATTERY SYSTEM -
DIAGNOSIS AND TESTING)
2. Corroded or loose battery
connections.2. Clean and tighten battery
connections. Apply a coat of light
mineral grease to terminals.
3. Faulty starter. 3. Test starting system. (Refer to 8 -
ELECTRICAL/STARTING -
DIAGNOSIS AND TESTING)
4. Faulty coil(s) or control unit. 4. Test and replace as needed.
(Refer to Appropriate Diagnostic
Information)
5. Incorrect spark plug gap. 5. Set gap. (Refer to 8 -
ELECTRICAL/IGNITION CONTROL
- SPECIFICATIONS)
6. Contamination in fuel system. 6. Clean system and replace fuel
filter.
7. Faulty fuel pump. 7. Test fuel pump and replace as
needed. (Refer to Appropriate
Diagnostic Information)
8. Incorrect engine timing. 8. Check for a skipped timing
belt/chain.
RSENGINE 2.4L9-5
ENGINE 2.4L (Continued)

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)