diesel CHRYSLER VOYAGER 2001 Service Manual

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.
Power Liftgate Module C1 BK Left Quarter 35, 36
Power Liftgate Module C2 BK Left Quarter 35, 36
Power Liftgate Motor BK Left Quarter 36
Power Mirror Switch BK Rear of Switch 25
Power Outlet NAT Instrument Panel N/S
Power Seat Circuit Breaker GY Under Seat N/S
Powertrain Control Module C1 GY/BK LT Fender Side Shield N/S
Powertrain Control Module C2 GY LT Fender Side Shield N/S
Power Window Circuit Breaker GY Left Side Kick Panel 31, 32
Radiator Fan No.1 BK Left Side At Motor 1
Radiator Fan No.1 (Diesel) GY Left Side At Motor 3
Radiator Fan No.2 BK Right Side At Motor 1
Radiator Fan No.2 (Diesel) GY Right Side At Motor N/S
Radiator Fan Relay BK Top of Left Front Frame Rail 1
Radiator Fan Relay No. 1
(Diesel)BL Left Front Engine Compartment 3
Radiator Fan Relay No. 2
(Diesel)BL Left Front Engine Compartment 3
Radiator Fan Relay No. 3
(Diesel)BL Left Front Engine Compartment 3
Radio C1 GY Rear of Radio 16, 19, 21
Radio C2 BK Rear of Radio 16, 19, 21
Radio C3 WT/RD Rear of Radio 16, 21
Radio C4 Rear of Radio 16
Radio Choke LTGY Rear of Radio 31, 32
Rear A/C-Heater Unit LT/GN Right Quarter Panel N/S
Rear Automatic Temperature
Control Switch (ATC)BK Rear of Switch 30
Rear Blower Front Control Switch BK Rear of Switch
Rear Blower Rear Control Switch
C1BK At Switch In Headliner
Rear Blower Rear Control Switch
C2BK At Switch In Headliner
Rear Power Outlet RD Left Quarter Panel 36
Rear Washer Pump Motor BK Right Fender Well 4
Rear Wiper Motor BK At Motor 38
Recirculation Door Actuator NAT Right Side of HVAC
Remote Keyless Entry Antenna
(JAPAN)BK Right Upper Instrument Panel 23
Remote Keyless Entry Module BK/RD Top Left of I.P. 16, 17, 23
Right B-Pillar Switch GY Right B Pillar 29
Right Cinch/Release Motor BK Rear of Sliding Door 34
Right Combination Relay BK Left Quarter Panel N/S
Right Cylinder Lock Switch BK Right Front Door 33
RG8W-90 CONNECTOR/GROUND LOCATIONS BUX8Wa-90-9
CONNECTOR/GROUND LOCATIONS BUX (Continued)

Component/Ground Color Location Fig.
Sentry Key Immobilizer Module BK At Steering Column 16, 17, 18,
26
Siren (United Kingdom) BK Left Front Body N/S
Solenoid/Pressure Switch
Assembly (EATX)BK Side of Transmission N/S
Speed Control Servo BK Near Controller Antilock Brake 15
Thatcham Alarm Module C1 BK Top Right Side of Instrument Panel Near
SpeakerN/S
Thatcham Alarm Module C1 WT Top Right Side of Instrument Panel Near
SpeakerN/S
Throttle Position Sensor GY On Throttle Body 10, 14
Torque Converter Clutch Solenoid BK Front of Transmission 11
Traction Control Switch BK Rear of Swtich 17, 18, 26
Trailer Tow Connector BK LT Quarter Panel N/S
Transmission Control Module BK Top of Transmission 15
Transmission Range Sensor GY Top of Transmission 15
Vehicle Speed Sensor BK Rear of Transmission 10, 13
Washer Fluid Level Switch BK Bottom of Reservoir 4
Water in Fuel Sensor (Diesel) Left Rear Engine Compartment N/S
Wiper Module BK Left Side Cowl 7
RG8W-90 CONNECTOR/GROUND LOCATIONS BUX8Wa-90-11
CONNECTOR/GROUND LOCATIONS BUX (Continued)

Fig. 12 2.5 LITER DIESEL ENGINE FRONT
RG8W-90 CONNECTOR/GROUND LOCATIONS BUX8Wa-90-21
CONNECTOR/GROUND LOCATIONS BUX (Continued)

Fig. 13 2.5 LITER DIESEL ENGINE REAR
8Wa - 90 - 22 8W-90 CONNECTOR/GROUND LOCATIONS BUXRG
CONNECTOR/GROUND LOCATIONS BUX (Continued)

Fig. 3 2.5 LITER DIESEL ENGINE SPLICES REAR
RG8W-95 SPLICE LOCATIONS BUX8Wa-95-7
SPLICE LOCATIONS BUX (Continued)

Fig. 4 2.5 LITER DIESEL ENGINE SPLICES FRONT
8Wa - 95 - 8 8W-95 SPLICE LOCATIONS BUXRG
SPLICE LOCATIONS BUX (Continued)

Fig. 6 LEFT FRONT ENGINE COMPARTMENT SPLICES
Fig. 7 LEFT FRONT ENGINE COMPARTMENT DIESEL
8Wa - 95 - 10 8W-95 SPLICE LOCATIONS BUXRG
SPLICE LOCATIONS BUX (Continued)

(3) Start engine and record oil pressure. Refer to
Specifications for correct oil pressure requirements.
(Refer to 9 - ENGINE - SPECIFICATIONS)
CAUTION: If oil pressure is 0 at idle, do not perform
the 3000 RPM test
(4) If oil pressure is 0 at idle. Shut off engine,
check for pressure relief valve stuck open, a clogged
oil pick-up screen or a damaged oil pick-up tube
O-ring.
(5) After test is complete, remove test gauge and
fitting.
(6) Install oil pressure switch and connector. (Refer
to 9 - ENGINE/LUBRICATION/OIL PRESSURE
SENSOR/SWITCH - INSTALLATION)
OIL
ENGINE OIL LEVEL CHECK
The best time to check engine oil level is after it
has sat overnight, or if the engine has been running,
allow the engine to be shut off for at least 5 minutes
before checking oil level.
Checking the oil while the vehicle is on level
ground will improve the accuracy of the oil level
reading. Remove dipstick and observe oil level. Add
oil only when the level is at or below the ADD mark
(Fig. 88).
STANDARD PROCEDURE - ENGINE OIL AND
FILTER CHANGE
Change engine oil at mileage and time intervals
described in the Maintenance Schedule. (Refer to
LUBRICATION & MAINTENANCE/MAINTE-
NANCE SCHEDULES - DESCRIPTION)
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DONOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY. CONTACT YOUR DEALER OR GOVERN-
MENT AGENCY FOR LOCATION OF COLLECTION
CENTER IN YOUR AREA.
Run engine until achieving normal operating tem-
perature.
(1) Position the vehicle on a level surface and turn
engine off.
(2) Hoist and support vehicle on safety stands.
Refer to Hoisting and Jacking Recommendations.
(Refer to LUBRICATION & MAINTENANCE/HOIST-
ING - STANDARD PROCEDURE)
(3) Remove oil fill cap.
(4) Place a suitable drain pan under crankcase
drain.
(5) Remove drain plug from crankcase and allow
oil to drain into pan. Inspect drain plug threads for
stretching or other damage. Replace drain plug and
gasket if damaged.
(6) Remove oil filter. (Refer to 9 - ENGINE/LUBRI-
CATION/OIL FILTER - REMOVAL)
(7) Install and tighten drain plug in crankcase.
(8) Install new oil filter. (Refer to 9 - ENGINE/LU-
BRICATION/OIL FILTER - INSTALLATION)
(9) Lower vehicle and fill crankcase with specified
type and amount of engine oil. (Refer to LUBRICA-
TION & MAINTENANCE/FLUID TYPES -
DESCRIPTION)
(10) Install oil fill cap.
(11) Start engine and inspect for leaks.
(12) Stop engine and inspect oil level.
NOTE: Care should be exercised when disposing
used engine oil after it has been drained from a
vehicle engine. Refer to the WARNING listed above.
OIL FILTER
DESCRIPTION
The engine oil filter (Fig. 89) is a high quality full-
flow, disposable type. Replace the oil filter with a
Mopartor the equivalent.
REMOVAL
(1) Raise vehicle on hoist.
(2) Position an oil collecting container under oil fil-
ter location.
CAUTION: When servicing the oil filter avoid
deforming the filter can by installing the remove/in-
stall tool band strap against the can to base lock
seam. The lock seam joining the can to the base is
reinforced by the base plate.
Fig. 88 Oil Level
1 - ENGINE OIL LEVEL DIPSTICK
RSENGINE 2.4L9-51
LUBRICATION (Continued)

OIL
STANDARD PROCEDURE - ENGINE OIL AND
FILTER CHANGE
Change engine oil at mileage and time intervals
described in the Maintenance Schedule. (Refer to
LUBRICATION & MAINTENANCE/MAINTE-
NANCE SCHEDULES - DESCRIPTION)
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY. CONTACT YOUR DEALER OR GOVERN-
MENT AGENCY FOR LOCATION OF COLLECTION
CENTER IN YOUR AREA.
Fig. 98 Engine Oiling System
1 - OIL SUPPLY FOR BALL SOCKET THROUGH PUSH ROD 7 - OUTER ROTOR
2 - OIL SUPPLY PASSAGE FROM SHAFT TO ROCKER ARM 8 - INNER ROTOR
3 - ROCKER SHAFT 9 - RELIEF VALVE
4 - OIL FLOWS TO ONLY ONE PEDASTAL ON EACH HEAD; THIRD
FROM REAR ON RIGHT HEAD, THIRD FROM FRONT ON LEFT
HEAD10 - OIL PAN
5 - ROCKER SHAFT TOWER 11 - OIL SCREEN
6 - CRANKSHAFT 12 - OIL PUMP CASE
Fig. 99 Checking Oil Pressure
1 - OIL FILTER
2 - OIL PRESSURE GAUGE
9 - 132 ENGINE 3.3/3.8LRS
LUBRICATION (Continued)