wheel CHRYSLER VOYAGER 2001 Service Manual

CONTROLLER ANTILOCK BRAKE - BLACK 24 WAY
CAV CIRCUIT FUNCTION
1 Z107 12BK/DG (OTHER) GROUND
1 Z107 12BK/TN (EXCEPT BUILT-UP-
EXPORT/ 2.4L)GROUND
2 B1 18DG/OR RIGHT REAR WHEEL SPEED SENSOR SIGNAL
3 B2 18DG/LB RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUP-
PLY
4- -
5 D25 18WT/VT PCI BUS
6 B6 18DG/WT RIGHT FRONT WHEEL SPEED SENSOR SIGNAL
7 B7 18DG/VT RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT
SUPPLY
8- -
9 A111 12DG/RD FUSED B(+)
10 F500 18DG/PK FUSED IGNITION SWITCH OUTPUT (RUN)
11 - -
12 - -
13 - -
14 - -
15 - -
16 Z127 12BK/DG GROUND
17 - -
18 L50 18WT/TN PRIMARY BRAKE SWITCH SIGNAL
19 B3 18DG/YL LEFT REAR WHEEL SPEED SENSOR SIGNAL
20 B4 18DG/GY LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUP-
PLY
21 - -
22 B8 18DG/TN LEFT FRONT WHEEL SPEED SENSOR SIGNAL
23 B9 18DG/LG LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUP-
PLY
24 A107 12TN/RD FUSED B(+)
CRANK CASE VENTILATION HEATER (DIESEL) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 Z153 18BK/GY GROUND
2 N1 18DB/OR FUEL HEATER RELAY OUTPUT
RG8W-80 CONNECTOR PIN-OUTS8Wa-80-47

LEFT FRONT PARK/TURN SIGNAL LAMP (EXCEPT BUILT-UP-EXPORT) - BLACK 3 WAY
CAV CIRCUIT FUNCTION
1 L61 18WT/LG LEFT FRONT TURN SIGNAL DRIVER
2 L77 18WT/BR FUSED PARK LAMP RELAY OUTPUT (LEFT)
3 Z377 18BK/BR GROUND
LEFT FRONT WHEEL SPEED SENSOR - GRAY 2 WAY
CAV CIRCUIT FUNCTION
1 B9 18DG/LG LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUP-
PLY
2 B8 18DG/TN LEFT FRONT WHEEL SPEED SENSOR SIGNAL
LEFT FULL OPEN SWITCH (POWER SLIDING DOOR) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 Q53 20OR LEFT FULL OPEN SWITCH SENSE
2 Z77 20BK/GY GROUND
LEFT HEADLAMP (EXCEPT BUILT-UP-EXPORT) - BLACK 3 WAY
CAV CIRCUIT FUNCTION
1 L43 18WT/DB LEFT LOW BEAM DRIVER
2 Z343 18BK/LG GROUND
3 L33 18WT/LG LEFT HIGH BEAM DRIVER
LEFT HEADLAMP LEVELING MOTOR (BUILT-UP-EXPORT) - WHITE 3 WAY
CAV CIRCUIT FUNCTION
1 Z203 16BR GROUND
2 L77 16BK FUSED HEADLAMP SWITCH OUTPUT (LEFT)
3 L13 16RD HEADLAMP ADJUST SIGNAL
8Wa - 80 - 74 8W-80 CONNECTOR PIN-OUTSRG

LEFT REAR PILLAR SPEAKER - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 X157 20DG LEFT REAR PILLAR SPEAKER (+)
2 X151 20DG/WT LEFT REAR PILLAR SPEAKER (-)
LEFT REAR READING LAMP (LUXURY) - GRAY 3 WAY
CAV CIRCUIT FUNCTION
1 M22 20YL/OR COURTESY LAMPS DRIVER
2 Z327 20BK/OR GROUND
3 M27 20YL/LB READING LAMPS DRIVER
LEFT REAR SPEAKER - BLACK/RED 6 WAY
CAV CIRCUIT FUNCTION
1 X151 20DG/WT LEFT REAR PILLAR SPEAKER (-)
2 X15 16GY/DG AMPLIFIED SPEAKER GROUND
3 X157 20DG LEFT REAR PILLAR SPEAKER (+)
4 X51 20DG/DB LEFT REAR SPEAKER (+)
5 X13 16DG/GY RADIO CHOKE OUTPUT
6 X57 20DG/OR LEFT REAR SPEAKER (-)
LEFT REAR VENT MOTOR - NATURAL 3 WAY
CAV CIRCUIT FUNCTION
1 Q13 16OR/DB (LHD) DRIVER SIDE REAR WINDOW CLOSE
1 Q14 16OR/GY (RHD) PASSENGER SIDE REAR WINDOW CLOSE
2 Q23 16OR/LB (LHD) DRIVER SIDE REAR WINDOW OPEN
2 Q24 16OR/DG (RHD) PASSENGER SIDE REAR WINDOW OPEN
3- -
LEFT REAR WHEEL SPEED SENSOR - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 B4 18DG/GY LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUP-
PLY
2 B3 18DG/YL LEFT REAR WHEEL SPEED SENSOR SIGNAL
RG8W-80 CONNECTOR PIN-OUTS8Wa-80-77

RIGHT FRONT PARK/TURN SIGNAL LAMP (EXCEPT BUILT-UP-EXPORT) - BLACK 3 WAY
CAV CIRCUIT FUNCTION
1 L60 18WT/TN RIGHT FRONT TURN SIGNAL DRIVER
2 L78 18WT/OR FUSED PARK LAMP RELAY OUTPUT (RIGHT)
3 Z378 18BK/TN GROUND
RIGHT FRONT WHEEL SPEED SENSOR - GRAY 2 WAY
CAV CIRCUIT FUNCTION
1 B7 18DG/VT RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT
SUPPLY
2 B6 18DG/WT RIGHT FRONT WHEEL SPEED SENSOR SIGNAL
RIGHT FULL OPEN SWITCH (POWER SLIDING DOOR) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 Q52 20OR RIGHT FULL OPEN SWITCH SENSE
2 Z76 20BK/YL GROUND
RIGHT HEADLAMP (EXCEPT BUILT-UP-EXPORT) - BLACK 3 WAY
CAV CIRCUIT FUNCTION
1 L44 16WT/TN RIGHT LOW BEAM DRIVER
2 Z344 16BK/TN GROUND
3 L34 16WT/GY RIGHT HIGH BEAM DRIVER
RG8W-80 CONNECTOR PIN-OUTS8Wa - 80 - 109

RIGHT REAR PILLAR SPEAKER - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 X158 20GY/YL RIGHT REAR PILLAR SPEAKER (+)
2 X152 20GY/WT RIGHT REAR PILLAR SPEAKER (-)
RIGHT REAR READING LAMP (LUXURY) - GRAY 3 WAY
CAV CIRCUIT FUNCTION
1 M22 20YL/OR COURTESY LAMPS DRIVER
2 Z327 20BK/OR GROUND
3 M27 20YL/LB READING LAMPS DRIVER
RIGHT REAR SPEAKER - BLACK/RED 6 WAY
CAV CIRCUIT FUNCTION
1 X152 20GY/WT RIGHT REAR PILLAR SPEAKER (-)
2 X15 16GY/DG AMPLIFIED SPEAKER GROUND
3 X158 20GY/YL RIGHT REAR PILLAR SPEAKER (+)
4 X52 20GY/DB RIGHT REAR SPEAKER (+)
5 X13 16DG/GY RADIO CHOKE OUTPUT
6 X58 20GY/OR RIGHT REAR SPEAKER (-)
RIGHT REAR VENT MOTOR - NATURAL 3 WAY
CAV CIRCUIT FUNCTION
1- -
2 Q14 16OR/GY (LHD) PASSENGER SIDE REAR WINDOW CLOSE
2 Q13 16OR/DB (RHD) DRIVER SIDE REAR WINDOW CLOSE
3 Q24 16OR/DG (LHD) PASSENGER SIDE REAR WINDOW OPEN
3 Q23 16OR/LB (RHD) DRIVER SIDE REAR WINDOW OPEN
RIGHT REAR WHEEL SPEED SENSOR - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 B2 18DG/LB RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUP-
PLY
2 B1 18DG/OR RIGHT REAR WHEEL SPEED SENSOR SIGNAL
8Wa - 80 - 112 8W-80 CONNECTOR PIN-OUTSRG

Component/Ground Color Location Fig.
Instrument Panel Power Outlet NAT Center of Instrument Panel 16, 19, 21
Intelligent Power Module C1 LTGN Left Fender Shield 8
Intelligent Power Module C2 GN/BL Left Fender Shield 8
Intelligent Power Module C3
(Diesel)YL/RD Left Fender Shield 8
Intelligent Power Module C3
(Gas)NAT/RD Left Fender Shield 8
Intelligent Power Module C4 BL Left Fender Shield 8
Intelligent Power Module C5 BK Left Fender Shield 8
Intelligent Power Module C6 NAT Left Fender Shield 8
Intelligent Power Module C7 BK/RD Left Fender Shield 8
Intelligent Power Module C8 OR Left Fender Shield 8
Intelligent Power Module C9 BK Left Fender Shield 8
Knock Sensor GY Front of Cylinder Block
Leak Detection Pump LTGY At Pump 10, 11, 15
Left B Pillar Switch GY Left B Pillar 30
Left Cinch/Release Motor GY Left Sliding Door N/S
Left Combination Relay BK Left Rear Quarter Panel N/S
Left Cylinder Lock Switch BK At Switch N/S
Left Door Speaker BK At Speaker N/S
Left Fog Lamp WT At Lamp N/S
Left Front Door Ajar Switch BK At Switch N/S
Left Front Door Lock Motor/Ajar
SwitchBK Left Door N/S
Left Front Park/Turn Signal Lamp BK At Lamp 1, 6
Left Front Wheel Speed Sensor BK Left Fender Side Shield N/S
Left Full Open Switch BK Left Sliding Door N/S
Left Headlamp BK At Lamp 1, 6
Left Headlamp Leveling Motor WT At Motor N/S
Left High Beam Lamp BK At Lamp N/S
Left Instrument Panel Speaker BK At Speaker 16, 17, 22
Left Lavalier Module BK At Module N/S
Left Liftgate Flood Lamp GY At Lamp 38
Left Low Beam Lamp BK At Lamp N/S
Left Mid Reading Lamp GY At Lamp N/S
Left Park Lamp BK At Lamp N/S
Left Power Mirror BK At Mirror 22
Left Rear Door Ajar Switch GY Left C Pillar N/S
Left Rear Lamp Assembly BK At Lamp 36
Left Rear Reading Lamp BK At Lamp N/S
Left Rear Speaker BK At Speaker 36
Left Rear Vent Motor NAT At Motor 35, 36
Left Rear Wheel Speed Sensor BK Center Rear of Floor Pan 36
8Wa - 90 - 6 8W-90 CONNECTOR/GROUND LOCATIONS BUXRG
CONNECTOR/GROUND LOCATIONS BUX (Continued)

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)

Component/Ground Color Location Fig.
Right Door Speaker BK/RD At Speaker N/S
Right Fog Lamp WT At Lamp 4
Right Front Door Ajar Switch BK At B Pillar N/S
Right Front Door Lock Motor/Ajar
SwitchRight Front Door 33
Right Front Park/Turn Signal
LampBK At Lamp 1, 4
Right Front Wheel Speed Sensor BK Right Fender Side Shield 10, 13, 14
Right Full Open Switch BK Right Sliding Door 34
Right Headlamp BK At Lamp 1, 4
Right Headlamp Leveling Motor WT At Right Headlamp N/S
Right High Beam Lamp BK At Right Headlamp N/S
Right Instrument Panel Speaker BK At Speaker 16, 19, 20
Right Lavalier Module BK At Module 2
Right Liftgate Flood Lamp BK At Lamp 38
Right Low Beam Lamp BK At Right Headlamp N/S
Right Mid Reading Lamp GY At Lamp N/S
Right Park Lamp BK AT Lamp N/S
Right Power Mirror BK At Mirror 16, 20, 23
Right Rear Lamp Assembly BK At Lamp 37
Right Rear Pillar Speaker BK At Speaker 37
Right Rear Reading Lamp GY At Lamp N/S
Right Rear Speaker BK At Speaker 37
Right Rear Vent Motor NAT At Motor 37
Right Rear Wheel Speed Sensor BK Center Rear of Floor Pan 37
Right Remote Radio Switch BK At Steering Wheel N/S
Right Repeater GY Right Front Fender 29
Right Seat Airbag YL At Passenger Seat N/S
Right Side Impact Airbag Control
ModuleYL Right B Pillar 29
Right Sliding Door Control
Module C1BK Rear of Door 34, 35
Right Sliding Door Control
Module C2BK/RD Rear of Door 34, 35
Right Sliding Door Latch Sensing
SwitchBK At Sliding Door 34
Right Sliding Door Lock Motor BK Rear of Door 34
Right Sliding Door Lock
Motor/Ajar SwitchBK At Latch N/S
Right Sliding Door Motor BK At Sliding Door 34
Right Speed Control Switch BK At Steering Wheel N/S
Right Stop/Turn Signal Relay BK LT Quarter Panel N/S
Right Turn Signal Lamp OR At Lamp N/S
Right Visor/Vanity Lamp BK At Lamp N/S
8Wa - 90 - 10 8W-90 CONNECTOR/GROUND LOCATIONS BUXRG
CONNECTOR/GROUND LOCATIONS BUX (Continued)

Fig. 9 RIGHT FRONT WHEEL HOUSING
8Wa - 90 - 18 8W-90 CONNECTOR/GROUND LOCATIONS BUXRG
CONNECTOR/GROUND LOCATIONS BUX (Continued)

ENGINE 2.4L
DESCRIPTION
The 2.4 Liter (148 cu. in.) in-line four cylinder
engine is a double over head camshaft with hydraulic
lifters and four valve per cylinder design. The engine
is free-wheeling; meaning it has provisions for piston-
to-valve clearance. However valve-to-valve interfer-
ence can occur, if camshafts are rotated
independently.
The cylinders are numbered from front of the
engine to the rear. The firing order is 1±3±4±2.
The engine identification number is located on the
rear of the cylinder block (Fig. 1).
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE
The combustion pressure leakage test provides an
accurate means for determining engine condition.
Combustion pressure leakage testing will detect:
²Exhaust and intake valve leaks (improper seat-
ing).
²Leaks between adjacent cylinders or into water
jacket.
²Any causes for combustion/compression pressure
loss.
WARNING: DO NOT REMOVE THE RADIATOR CAP
WITH THE SYSTEM HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM COOLANT CAN
OCCUR.
Check the coolant level and fill as required. DO
NOT install the radiator cap.
Start and operate the engine until it attains nor-
mal operating temperature, then turn the engine
OFF.
Clean spark plug recesses with compressed air.
Remove the spark plugs.
Remove the oil filler cap.Remove the air cleaner.
Calibrate the tester according to the manufactur-
er's instructions. The shop air source for testing
should maintain 483 kPa (70 psi) minimum, 1,379
kPa (200 psi) maximum, with 552 kPa (80 psi) rec-
ommended.
Perform the test procedures on each cylinder
according to the tester manufacturer's instructions.
While testing, listen for pressurized air escaping
through the throttle body, tailpipe and oil filler cap
opening. Check for bubbles in the radiator coolant.
All gauge pressure indications should be equal,
with no more than 25% leakage per cylinder.
FOR EXAMPLE:At 552 kPa (80 psi) input pres-
sure, a minimum of 414 kPa (60 psi) should be main-
tained in the cylinder.
DIAGNOSIS AND TESTING - CYLINDER
COMPRESSION PRESSURE
The results of a cylinder compression pressure test
can be utilized to diagnose several engine malfunc-
tions.
Ensure the battery is completely charged and the
engine starter motor is in good operating condition.
Otherwise the indicated compression pressures may
not be valid for diagnosis purposes.
(1) Check engine oil level and add oil if necessary.
(2) Drive the vehicle until engine reaches normal
operating temperature. Select a route free from traf-
fic and other forms of congestion, observe all traffic
laws, and accelerate through the gears several times
briskly.
(3) Remove all spark plugs from engine. As spark
plugs are being removed, check electrodes for abnor-
mal firing indicators fouled, hot, oily, etc. Record cyl-
inder number of spark plug for future reference.
(4) Disconnect the ignition coil electrical connector.
(5) Be sure throttle blade is fully open during the
compression check.
(6) Insert compression gage adaptor Special Tool
8116 or the equivalent, into the #1 spark plug hole in
cylinder head. Connect the 0±500 psi (Blue) pressure
transducer with cable adaptors to the DRBIIIt.
(7) Crank engine until maximum pressure is
reached on gage. Record this pressure as #1 cylinder
pressure.
(8) Repeat the previous step for all remaining cyl-
inders.
(9) Compression should not be less than 689 kPa
(100 psi) and not vary more than 25 percent from cyl-
inder to cylinder.
(10) If one or more cylinders have abnormally low
compression pressures, repeat the compression test.
(11) If the same cylinder or cylinders repeat an
abnormally low reading on the second compression
test, it could indicate the existence of a problem in
Fig. 1 Engine Identification
1 - ENGINE IDENTIFICATION LOCATION
RSENGINE 2.4L9-3