diesel CHRYSLER VOYAGER 2001 Service Manual

(9) Tighten the hose and tube assembly to the toe-
board cross member at two locations.
(10) Install the second hose to the underbody hose
and tube assembly.
(11) Connect the rubber fuel hose between the
body tube assembly and the fuel pump nipple at the
body tube joint. Close the fuel fill cap.
(12) Remove the heater unit support device from
under the vehicle.
(13) Lower vehicle from lift.
(14) Refill cooling system(Refer to 7 - COOLING -
STANDARD PROCEDURE).
(15) Verify function of the cabin heater.
SUPPLEMENTAL DIESEL
HEATER WIRING
REMOVAL
(1) Elevate vehicle on a lift taking note of the
exhaust tube flexible section.
(2) Unplug connector from vehicle wiring harness
to cabin heater harness.
(3) Unplug connector from cabin heater harness to
dosing pump connector.
(4) Unplug two connectors from cabin heater har-
ness to cabin heater controller connectors.
(5) Remove two wiring harness connectors from
underbody.
(6) Remove two wiring harness connectors from
cabin heater shield.
(7) Carefully route the cabin heater harness to the
left side between the cabin heater unit and the cabin
heater shield.
INSTALLATION
(1) Carefully route the cabin heater harness from
the left side of the cabin heater between the cabin
heater unit and the cabin heater shield.
(2) Install the two wiring harness retaining con-
nectors to the cabin heater shield.
(3) Route the wiring harness along the underside
of the vehicle and install the two wiring harness
retaining connectors.
(4) Plug the two connectors from the cabin heater
harness to the cabin heater controller.
(5) Plug the connector to the cabin heater harness
to the dosing pump connector.
(6) Plug the connector from the vehicle wiring har-
ness to the cabin heater harness.
(7) Lower the vehicle.
(8) Verify function of the cabin heater.
AIR INTAKE PIPE
REMOVAL
NOTE: Heater air intake tube is part of an assembly
that includes the heater cooling intake and return
pipes. If heater air intake tube requires removal or
replacement the entire assembly will require remov-
al/replacement.
(1) Drain cooling system(Refer to 7 - COOLING -
STANDARD PROCEDURE).
(2) Remove clamps from the heater tubes at the
lower heater port and the lower EGR connector
which are located under the hood.
(3) Remove the retaining clamp at the heater air
intake muffler connection(Refer to 24 - HEATING &
AIR CONDITIONING/CABIN HEATER/INLET
MUFFLER - REMOVAL).
(4) Remove the clamp at the flexible tube to steel
tube connection (Fig. 7).
(5) Remove the two retaining screws and remove
pipe assembly (Fig. 8).
Fig. 7 FLEXIBLE AIR INTAKE LINE
1 - HEATER UNIT AND SPLASH SHIELD
2 - DOSING PUMP
3 - DOSING PUMP FUEL LINE
4 - FLEXIBLE INTAKE LINE
5 - CLAMP
6 - STEEL INTAKE PIPE
RGHEATING & AIR CONDITIONING24a-11
HEATER UNIT (Continued)

EMISSIONS CONTROL 2.5L TURBO DIESEL
TABLE OF CONTENTS
page page
EMISSIONS CONTROL 2.5L TURBO DIESEL
DESCRIPTION............................1
SPECIFICATIONS.........................2EXHAUST GAS RECIRCULATION.............3
ON-BOARD DIAGNOSTICS..................6
EMISSIONS CONTROL 2.5L
TURBO DIESEL
DESCRIPTION
The 2.5L diesel Engine Control Module (ECM) con-
trols many different circuits in the fuel injection
pump and engine systems. If the ECM senses a prob-
lem with a monitored circuit that indicates an actual
problem, a Diagnostic Trouble Code (DTC) will be
stored in the ECM's memory, and eventually may
illuminate the MIL (Malfunction Indicator Lamp)
constantly while the key is on. If the problem is
repaired, or is intermittent, the ECM will erase the
DTC after 40 warm-up cycles without the the fault
detected. A warm-up cycle consists of starting the
vehicle when the engine is cold, then the engine is
warmed up to a certain temperature, and finally, the
engine temperature falls to a normal operating tem-
perature, then the key is turned off.
Certain criteria must be met for a DTC to be
entered into ECM memory. The criteria may be a
specific range of engine rpm, engine or fuel tempera-
ture and/or input voltage to the ECM. A DTC indi-
cates that the ECM has identified an abnormal
signal in a circuit or the system.
There are several operating conditions that the
ECM does not monitor and set a DTC for. Refer to
the following Monitored Circuits and Non±Monitored
Circuits in this section.
ECM MONITORED SYSTEMS
The ECM can detect certain problems in the elec-
trical system.
Open or Shorted Circuit± The ECM will not
distinguish between an open or a short to ground,
however the ECM can determine if there is excessive
current on a circuit, such as a short to voltage or a
decrease in component resistance.
Output Device Current Flow± The ECM senses
whether the output devices are electrically connected.
If there is a problem with the circuit, the ECM
senses whether the circuit is open, shorted to ground
(±), or shorted to (+) voltage.Fuel Pressure:Fuel pressure is controlled by the
fuel injection pump and fuel pressure solenoid. The
ECM uses a fuel pressure sensor to determine if a
fuel pressure problem exists.
Fuel Injector Malfunctions:The ECM can deter-
mine if a fuel injector has an electrical problem. The
fuel injectors on the diesel engine arecontrolledby
the ECM.
ECM NON±MONITORED SYSTEMS
The ECM does not monitor the following circuits,
systems or conditions that could have malfunctions
that result in driveability problems. A DTC will not
be displayed for these conditions.
Cylinder Compression:The ECM cannot detect
uneven, low, or high engine cylinder compression.
Exhaust System:The ECM cannot detect a
plugged, restricted or leaking exhaust system.
Vacuum Assist:Leaks or restrictions in the vac-
uum circuits of the Exhaust Gas Recirculation Sys-
tem (EGR) are not monitored by the ECM.
ECM System Ground:The ECM cannot deter-
mine a poor system ground. However, a DTC may be
generated as a result of this condition.
ECM/PCM Connector Engagement:The ECM
cannot determine spread or damaged connector pins.
However, a DTC may be generated as a result of this
condition.
HIGH AND LOW LIMITS
The ECM compares input signals from each input
device. It has high and low limits that are pro-
grammed into it for that device. If the inputs are not
within specifications and other DTC criteria are met,
a DTC will be stored in memory. Other DTC criteria
might include engine rpm limits or input voltages
from other sensors or switches. The other inputs
might have to be sensed by the ECM when it senses
a high or low input voltage from the control system
device in question.
RGEMISSIONS CONTROL 2.5L TURBO DIESEL25a-1

SPECIFICATIONS
SPECIFICATIONS - TORQUE
2.5L DIESEL - TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
EGR Valve Nuts 32.4 24 Ð
EGR Cooler to EGR Bolts 32.4 24 Ð
25a - 2 EMISSIONS CONTROL 2.5L TURBO DIESELRG
EMISSIONS CONTROL 2.5L TURBO DIESEL (Continued)

ON-BOARD DIAGNOSTICS
TABLE OF CONTENTS
page
ON-BOARD DIAGNOSTICS
DESCRIPTION............................6
ON-BOARD DIAGNOSTICS
DESCRIPTION - DIAGNOSTIC TROUBLE CODES
On the following pages, a list of DTC's is provided
for the 2.5L diesel engine. A DTC indicates that the
ECM has recognized an abnormal signal in a circuit
or the system. A DTC may indicate the result of a
failure, but most likely will not identify the failed
component directly. Refer to the appropriate diagnos-
tic manual for more information on diagnosis of trou-
ble codes.
ACCESSING DIAGNOSTIC TROUBLE CODES
A stored DTC can be displayed through the use of
the DRB IIItscan tool. The DRB IIItconnects to the
data link connector. The data link connector is
located under the instrument panel near bottom of
the steering column (Fig. 1).
ERASING TROUBLE CODES
After the problem has been repaired, use the DRB
IIItscan tool to erase a DTC.
ENGINE CONTROL MODULE (ECM) - DRBIIITCODES
Generic Scan Tool Code DRB IIITScan Tool Display
P0070 Ambient Air Temperature Circuit Signal Voltage Too High
Ambient Air Temperature Circuit Signal Voltage Too Low
P0100 Mass Air Flow Sensor Plausibility
Mass Air Flow Sensor Plausibility Positive Area
Mass Air Flow Sensor Signal Voltage Too High
Mass Air Flow Sensor Signal Voltage Too Low
Mass Air Flow Sensor Supply Voltage Too High Or Low
P0105 Barometric Pressure Circuit Signal Voltage To High
Barometric Pressure Circuit Signal Voltage To Low
P0110 Intake Air Temperature Sensor Circuit Signal Too High
Intake Air Temperature Sensor Circuit Signal Too Low
Fig. 1 DATA LINK CONNECTOR
25a - 6 ON-BOARD DIAGNOSTICSRG