engine CHRYSLER VOYAGER 2001 Service Manual

ENGINE OIL PRESSURE SENSOR (DIESEL) - BLACK 3 WAYCAV CIRCUIT FUNCTION
1 F855 20PK/YL SENSOR REFERENCE VOLTAGE A
2 G6 20VT/GY ENGINE OIL PRESSURE SENSOR SIGNAL
3 K936 20BR/YL ENGINE OIL PRESSURE SENSOR GROUND
ENGINE OIL TEMPERATURE SENSOR (DIESEL) - BLACK 2 WAYCAV CIRCUIT FUNCTION
1 K89 20DB/WT ENGINE OIL TEMPERATURE SENSOR SIGNAL
2 K900 20DB/OR SENSOR GROUND
FUEL HEATER (DIESEL) - BLACK 2 WAYCAV CIRCUIT FUNCTION
1 N1 16RD FUEL HEATER RELAY OUTPUT
2 Z201 18RD GROUND
FUEL INJECTOR NO. 1 (DIESEL) - BLACK 2 WAYCAV CIRCUIT FUNCTION
1 K111 14DB/LB COMMON INJECTOR DRIVER
2 K11 14WT/DB FUEL INJECTOR NO. 1 CONTROL
FUEL INJECTOR NO. 2 (DIESEL) - BLACK 2 WAYCAV CIRCUIT FUNCTION
1 K111 14DB/LB COMMON INJECTOR DRIVER
2 K12 14TN FUEL INJECTOR NO. 2 CONTROL
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CONNECTOR PINOUTS

GLOW PLUG RELAY (DIESEL) - BLACK 4 WAYCAV CIRCUIT FUNCTION
1 A202 10RD/WT FUSED B(+)
2 K152 20DB/WT GLOW PLUG RELAY CONTROL
3 K342 16BR/WT ECM/PCM RELAY OUTPUT
4 K154 10BR/OR GLOW PLUG RELAY OUTPUT
INTELLIGENT POWER MODULE C3 (DIESEL) - YELLOW/RED 20 WAYCAV CIRCUIT FUNCTION
1 N21 20DB/TN LIFT PUMP RELAY CONTROL
2- -
3 T751 20YL IGNITION SWITCH OUTPUT (START)
4 T2 18DG/WT TRS REVERSE SENSE
5 N2 18DB/YL LIFT PUMP RELAY OUTPUT
6 F202 18PK/GY IGNITION SWITCH OUTPUT (RUN-START)
7 C3 18DB/YL A/C COMPRESSOR CLUTCH RELAY OUTPUT
8 Z114 18BK/LG GROUND
9 C13 20LB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL
10 A119 16RD/OR FUSED B(+)
11 C41 20LB/DG CABIN HEATER ASSIST CONTROL
12 T753 20DG/YL IGNITION SWITCH OUTPUT (START)
13 - -
14 T752 20DG/OR ENGINE STARTER MOTOR RELAY CONTROL
15 Z116 18BK/VT GROUND
16 K51 20BR/WT ECM/PCM RELAY CONTROL
17 F202 18PK/GY IGNITION SWITCH OUTPUT (RUN-START)
18 - -
19 K342 16BR/WT ECM/PCM RELAY OUTPUT
20 - -
LEFT SPEED CONTROL SWITCH - WHITE 2 WAYCAV CIRCUIT FUNCTION
A V37 20VT/TN (BUILT-UP-
EXPORT)SPEED CONTROL SWITCH SIGNAL
A V37 20DG/VT (EXCEPT
BUILT-UP-EXPORT)SPEED CONTROL SWITCH SIGNAL
B Z23 20BK/VT LEFT SPEED CONTROL SWITCH GROUND
LIFT PUMP MOTOR (DIESEL) - BLACK 2 WAYCAV CIRCUIT FUNCTION
1 N2 18OR LIFT PUMP RELAY OUTPUT
2 Z201 18OR GROUND
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CONNECTOR PINOUTS

A/C COMPRESSOR CLUTCH RELAYCAV CIRCUIT FUNCTION
30 INTERNAL FUSED B(+)
85 C13 18LB/OR (GAS) A/C COMPRESSOR CLUTCH RELAY CONTROL
85 C13 20LB/OR (DIESEL) A/C COMPRESSOR CLUTCH RELAY CONTROL
86 F202 18PK/GY (GAS) IGNITION SWITCH OUTPUT (RUN-START)
86 K342 16BR/WT (DIESEL) ECM/PCM RELAY OUTPUT
87 C3 18DB/YL A/C COMPRESSOR CLUTCH RELAY OUTPUT
87A --
ECM/PCM RELAY (DIESEL)CAV CIRCUIT FUNCTION
30 INTERNAL FUSED B(+)
85 K51 20BR/WT ECM/PCM RELAY CONTROL
86 INTERNAL FUSED B(+)
87 K342 16BR/WT ECM/PCM RELAY OUTPUT
87A --
FUEL HEATER RELAY (DIESEL)CAV CIRCUIT FUNCTION
30 INTERNAL FUSED B(+)
85 Z114 18BK/LG GROUND
86 INTERNAL IGNITION SWITCH OUTPUT (RUN-START)
87 N1 16DB/OR FUEL HEATER RELAY OUTPUT
87A --
LIFT PUMP RELAY (DIESEL)CAV CIRCUIT FUNCTION
30 INTERNAL FUSED B(+)
85 N21 20DB/TN LIFT PUMP RELAY CONTROL
86 F202 18PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START)
87 N2 18DB/YL LIFT PUMP RELAY OUTPUT
87A --
STARTER MOTOR RELAYCAV CIRCUIT FUNCTION
30 INTERNAL FUSED B(+)
85 T752 18DG/OR (GAS) ENGINE STARTER MOTOR RELAY CONTROL
85 T752 20DG/OR (DIESEL) ENGINE STARTER MOTOR RELAY CONTROL
86 INTERNAL IGNITION SWITCH OUTPUT (START)
87 T750 12YL/GY ENGINE STARTER MOTOR RELAY OUTPUT
87A --
RADIATOR FAN NO. 1 (DIESEL) - GRAY 2 WAYCAV CIRCUIT FUNCTION
1 N202 12DB/OR RADIATOR FAN NO. 1 CONTROL
2 N201 12DB/LG RADIATOR FAN RELAY NO. 1 OUTPUT
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CONNECTOR PINOUTS

GROUP TAB LOCATOR
INIntroduction
INaIntroduction
0Lubrication & Maintenance
0aLubrication & Maintenance
2Suspension
2aSuspension
3Differential & Driveline
5Brakes
5aBrakes
6aClutch
7Cooling
7aCooling
8AAudio
8AaAudio
8BChime/Buzzer
8BaChime/Buzzer
8EElectronic Control Modules
8FEngine Systems
8FaEngine Systems
8GHeated Systems
8HHorn
8IIgnition Control
8JInstrument Cluster
8JaInstrument Cluster
8LLamps
8LaLamps
8MMessage Systems
8NPower Systems
8NaPower Systems
8ORestraints
8PSpeed Control
8QVehicle Theft Security
8RWipers/Washers
8WaWiring
9Engine
9aEngine
11Exhaust System
11aExhaust System
13Frame & Bumpers
14Fuel System
14aFuel System
19Steering
19aSteering
21Transmission/Transaxle
21aTransmission/Transaxle
22Tires/Wheels
23Body
24Heating & Air Conditioning
24aHeating & Air Conditioning
25Emissions Control
25aEmissions Control
Service Manual Comment Forms

VIN CODE BREAKDOWN CHART
POSITION INTERPRETATION CODE = DESCRIPTION
1 Country of Origin 1 = Built in the United States by DaimlerChrysler
2 = Built in Canada by DaimlerChrysler Canada
Inc.
2 Make B = Dodge
C = Chrysler
3 Vehicle Type 4 = Multipurpose Pass. Vehicle Less Side Air
Bags
8 = Multipurpose Pass. Vehicle With Side Air
Bags
4 Gross Vehicle Weight Rating G = 2268 - 2721 kg. (5001 - 6000 lbs.)
5 Car Line P = Chrysler, Town & Country - FWD
P = Dodge, Caravan/Grand Caravan - FWD
T = Chrysler, Town & Country - AWD
T = Dodge, Grand Caravan - AWD
J = Chrysler, Voyager/Grand Voyager - FWD
6 Series 2 = Low Line
4 = High Line
5 = Premium
6 = Sport
7 = Special
7 Body Style 4 = Long Wheel Base
5 = Short Wheel Base
8 Engine B = 2.4 L 4 cyl. MPI 16-VALVE DOHC
G = 3.3 L 6 cyl. Ethanol Flexible Fuel MPI
R = 3.3 L 6 cyl. Gas MPI
L = 3.8 L 6 cyl. Gas MPI
9 Check Digit See explanation in this section.
10 Model Year 1= 2001
11 Assembly Plant B = St. Louis South
R = Windsor
12 through 17 Sequence Number A six digit number assigned by assembly plant.
2 INTRODUCTIONRS
VEHICLE IDENTIFICATION NUMBER (Continued)

VECI LABEL
DESCRIPTION
All models have a Vehicle Emission Control Infor-
mation (VECI) Label. Chrysler permanently attaches
the label in the engine compartment. It cannot be
removed without defacing information and destroying
the label.
The label contains the vehicle's emission specifica-
tions and vacuum hose routings. All hoses must be
connected and routed according to the label.
BODY CODE PLATE
DESCRIPTION
The Body Code Plate (Fig. 3) is located in the
engine compartment on the radiator closure panel
crossmember. There are seven lines of information on
the body code plate. Lines 4, 5, 6, and 7 are not used
to define service information. Information reads from
left to right, starting with line 3 in the center of the
plate to line 1 at the bottom of the plate.
BODY CODE PLATE ± LINE 3
DIGITS 1 THROUGH 12
Vehicle Order Number
DIGITS 13 THROUGH 17
Open space
DIGITS 18 AND 19
Vehicle Shell Line
²NS
DIGIT 20
Carline
FWD
²H = Plymouth
²K = Dodge
²Y = Chrysler
AW D
²C = Chrysler
²D = Dodge
²P = Plymouth
DIGIT 21
Price Class
²H = Highline
²L = Lowline
²P = Premium
²S = Luxury
²X = Premium
DIGITS 22 AND 23
Body Type
²52 = Short Wheel Base
²53 = Long Wheel Base
BODY CODE PLATE LINE 2
DIGITS 1, 2 AND 3
Paint procedure
DIGIT 4
Open Space
DIGITS 5 THROUGH 7
Primary paint
Refer to Group 23, Body for color codes.
DIGIT 8 AND 9
Open Space
DIGITS 10 THROUGH 12
Secondary Paint
Fig. 3 Body Code Plate
1 - PRIMARY PAINT
2 - SECONDARY PAINT
3 - VINYL ROOF
4 - VEHICLE ORDER NUMBER
5 - CAR LINE SHELL
6 - PAINT PROCEDURE
7 - ENGINE
8 - TRIM
9 - TRANSMISSION
10 - MARKET
11 - VIN
RSINTRODUCTION3

DIGIT 13 AND 14
Open Space
DIGITS 15 THROUGH 18
Interior Trim Code
DIGIT 19
Open Space
DIGITS 20, 21, AND 22
Engine Code
²EDZ = 2.4 L 4 cyl. DOHC Gasoline
²EFA = 3.0 L 6 cyl. Gasoline
²EGA = 3.3 L 6 cyl. Gasoline
²EGH = 3.8 L 6 cyl. Gasoline
²EGM = 3.3 L 6 cyl. Ethanol Flexible Fuel
DIGIT 23
Open Space
BODY CODE PLATE LINE 1
DIGITS 1, 2, AND 3
Transaxle Codes
²DGB = 41TH 4-speed Automatic Transaxle
²DGL = 41TE 4-speed Electronic Automatic Tran-
saxle
²DGM = 31TH 3-speed Automatic Transaxle
DIGIT 4
Open SpaceDIGIT 5
Market Code
²C = Canada
²B = International
²M = Mexico
²U = United States
DIGIT 6
Open Space
DIGITS 7 THROUGH 23
Vehicle Identification Number
²Refer to Vehicle Identification Number (VIN)
paragraph for proper breakdown of VIN code.
IF TWO BODY CODE PLATES ARE REQUIRED
The last code shown on either plate will be fol-
lowed by END. When two plates are required, the
last code space on the first plate will indicate (CTD)
When a second plate is required, the first four
spaces of each line will not be used due to overlap of
the plates.
INTERNATIONAL SYMBOLS
DESCRIPTION
The graphic symbols illustrated in the following
International Control and Display Symbols Chart are
used to identify various instrument controls. The
symbols correspond to the controls and displays that
are located on the instrument panel.
4 INTRODUCTIONRS
BODY CODE PLATE (Continued)

FASTENER IDENTIFICATION
DESCRIPTION
The SAE bolt strength grades range from grade 2
to grade 8. The higher the grade number, the greater
the bolt strength. Identification is determined by the
line marks on the top of each bolt head. The actual
bolt strength grade corresponds to the number of line
marks plus 2. The most commonly used metric bolt
strength classes are 9.8 and 10.9. The metric
strength class identification number is imprinted on
the head of the bolt. The higher the class number,
the greater the bolt strength. Some metric nuts are
imprinted with a single-digit strength class on the
nut face. Refer to the Fastener Identification and
Fastener Strength Charts.
FASTENER USAGE
DESCRIPTION - FASTENER USAGE
WARNING: USE OF AN INCORRECT FASTENER
MAY RESULT IN COMPONENT DAMAGE OR PER-
SONAL INJURY.
Figure art, specifications and torque references in
this Service Manual are identified in metric and SAE
format.
During any maintenance or repair procedures, it is
important to salvage all fasteners (nuts, bolts, etc.)
for reassembly. If the fastener is not salvageable, a
fastener of equivalent specification must be used.
International Symbols
1 High Beam 13 Rear Window Washer
2 Fog Lamps 14 Fuel
3 Headlamp, Parking Lamps, Panel Lamps 15 Engine Coolant Temperature
4 Turn Warning 16 Battery Charging Condition
5 Hazard Warning 17 Engine Oil
6 Windshield Washer 18 Seat Belt
7 Windshield Wiper 19 Brake Failure
8 Windshield Wiper and Washer 20 Parking Brake
9 Windscreen Demisting and Defrosting 21 Front Hood
10 Ventilating Fan 22 Rear hood (Decklid)
11 Rear Window Defogger 23 Horn
12 Rear Window Wiper 24 Lighter
RSINTRODUCTION5
INTERNATIONAL SYMBOLS (Continued)

INTRODUCTION
TABLE OF CONTENTS
page page
BODY CODE PLATE
DESCRIPTION............................1
FASTENER IDENTIFICATION
DESCRIPTION............................2
FASTENER USAGE
DESCRIPTION............................5
THREADED HOLE REPAIR
DESCRIPTION............................5
INTERNATIONAL VEHICLE CONTROL &
DISPLAY SYMBOLS
DESCRIPTION............................5
METRIC SYSTEM
DESCRIPTION............................6TORQUE REFERENCES
DESCRIPTION............................8
VEHICLE IDENTIFICATION NUMBER
DESCRIPTION............................9
VEHICLE SAFETY CERTIFICATION LABEL
DESCRIPTION...........................10
E-MARK LABEL
DESCRIPTION...........................10
VECI LABEL
DESCRIPTION...........................10
MANUFACTURE PLATE
DESCRIPTION...........................10
BODY CODE PLATE
DESCRIPTION
The Body Code Plate (Fig. 1) is located in the
engine compartment on the radiator closure panel
crossmember. There are seven lines of information on
the body code plate. Lines 4, 5, 6, and 7 are not used
to define service information. Information reads from
left to right, starting with line 3 in the center of the
plate to line 1 at the bottom of the plate.
BODY CODE PLATE ± LINE 3
DIGITS 1 THROUGH 12
Vehicle Order Number
DIGITS 13 THROUGH 17
Open space
DIGITS 18 AND 19
Vehicle Shell Line
²RG
DIGIT 20
Carline
FWD
²Y = Chrysler
AW D
²C = Chrysler
Fig. 1 BODY CODE PLATE
1 - PRIMARY PAINT
2 - SECONDARY PAINT
3 - VINYL ROOF
4 - VEHICLE ORDER NUMBER
5 - CAR LINE SHELL
6 - PAINT PROCEDURE
7 - ENGINE
8 - TRIM
9 - TRANSMISSION
10 - MARKET
11 - VIN
RGINTRODUCTION1a

DIGIT 21
Price Class
²H = Highline
²L = Lowline
²P = Premium
²S = Luxury
²X = Premium
DIGITS 22 AND 23
Body Type
²52 = Short Wheel Base
²53 = Long Wheel Base
BODY CODE PLATE LINE 2
DIGITS 1, 2 AND 3
Paint procedure
DIGIT 4
Open Space
DIGITS 5 THROUGH 7
Primary paint(Refer to 23 - BODY/PAINT - SPEC-
IFICATIONS).
DIGIT 8 AND 9
Open Space
DIGITS 10 THROUGH 12
Secondary Paint
DIGIT 13 AND 14
Open Space
DIGITS 15 THROUGH 18
Interior Trim Code
DIGIT 19
Open Space
DIGITS 20, 21, AND 22
Engine Code
²ENC = 2.5 L 4 cyl. Turbo Diesel
DIGIT 23
Open Space
BODY CODE PLATE LINE 1
DIGITS 1, 2, AND 3
Transaxle Codes
²DGB = 41TH 4-speed Automatic Transaxle
²DGL = 41TE 4-speed Electronic Automatic
Transaxle
²DGM = 31TH 3-speed Automatic Transaxle
DIGIT 4
Open Space
DIGIT 5
Market Code
²C = Canada
²B = International
²M = Mexico
²U = United States
DIGIT 6
Open Space
DIGITS 7 THROUGH 23
Vehicle Identification Number
²Refer to Vehicle Identification Number (VIN)
paragraph for proper breakdown of VIN code.
IF TWO BODY CODE PLATES ARE REQUIRED
The last code shown on either plate will be fol-
lowed by END. When two plates are required, the
last code space on the first plate will indicate (CTD)
When a second plate is required, the first four
spaces of each line will not be used due to overlap of
the plates.
FASTENER IDENTIFICATION
DESCRIPTION
The SAE bolt strength grades range from grade 2
to grade 8. The higher the grade number, the greater
the bolt strength. Identification is determined by the
line marks on the top of each bolt head. The actual
bolt strength grade corresponds to the number of line
marks plus 2. The most commonly used metric bolt
strength classes are 9.8 and 10.9. The metric
strength class identification number is imprinted on
the head of the bolt. The higher the class number,
the greater the bolt strength. Some metric nuts are
imprinted with a single-digit strength class on the
nut face. Refer to the Fastener Identification and
Fastener Strength Charts (Fig. 2) and (Fig. 3).
2a INTRODUCTIONRG
BODY CODE PLATE (Continued)