wheel CHRYSLER VOYAGER 2001 Workshop Manual

4.0 DISCLAIMERS, SAFETY,
WARNINGS
4.1 DISCLAIMERS
All information, illustrations, and specifications
contained in this manual are based on the latest
information available at the time of publication.
The right is reserved to make changes at any time
without notice.
4.2 SAFETY
4.2.1 TECHNICIAN SAFETY INFORMATION
WARNING: ENGINES PRODUCE CARBON
MONOXIDE THAT IS ODORLESS, CAUSES
SLOWER REACTION TIME, AND CAN LEAD
TO SERIOUS INJURY. WHEN THE ENGINE IS
OPERATING, KEEP SERVICE AREAS WELL
VENTILATED OR ATTACH THE VEHICLE
EXHAUST SYSTEM TO THE SHOP EXHAUST
REMOVAL SYSTEM.
Set the parking brake and block the wheels before
testing or repairing the vehicle. It is especially
important to block the wheels on front wheel drive
vehicles; the parking brake does not hold the drive
wheels.
When servicing a vehicle, always wear eye pro-
tection, and remove any metal jewelry such as
watchbands or bracelets that might make electrical
contact.
When diagnosing a powertrain system problem,
it is important to follow approved procedures where
applicable. These procedures can be found in the
service manual. Following these procedures is very
important to the safety of individuals performing
diagnostic tests.
4.2.2 VEHICLE PREPARATION FOR
TESTING
Make sure the vehicle being tested has a fully
charged battery. If it does not, false diagnostic codes
or error messages may occur.
4.2.3 SERVICING SUB-ASSEMBLIES
Some components of the powertrain system are
intended to be serviced as an assembly only. At-
tempting to remove or repair certain system sub-
components may result in personal injury and/or
improper system operation. Only those components
with approved repair and installation procedures in
the service manual should be serviced.
4.2.4 DRBIIITSAFETY INFORMATION
WARNING: EXCEEDING THE LIMITS OF THE
DRBIIITMULTIMETER IS DANGEROUS. IT
CAN EXPOSE YOU TO SERIOUS OR
POSSIBLY FATAL INJURY. CAREFULLY
READ AND UNDERSTAND THE CAUTIONS
AND SPECIFICATION LIMITS.
Follow the vehicle manufacturer 's service specifi-
cations at all times.
²Do not use the DRBIIItif it has been damaged.
²Do not use the test leads if the insulation is
damaged or if metal is exposed.
²To avoid electrical shock, do not touch the test
leads, tip or the circuit being tested.
²Choose the proper range and function for the
measurement. Do not try voltage or current mea-
surements that may exceed the rated capacity.
²Do not exceed the limits shown in the table below:
FUNCTION INPUT LIMIT
Volts 0-500 peak volts AC
0-500 volts DC
Ohms (Resistance)* 0-1.12 megohms
Frequency Measure
Frequency Generated0-10 kHz
Temperature -58 - +1100ÉF
-50 - +600ÉC
* Ohms cannot be measured if voltage is present.
Ohms can be measured only in a non-powered
circuit.
²Voltage between any terminal and ground must
not exceed 500v DC or 500v peak AC.
²Use caution when measuring voltage above 25v
DC or 25v AC.
²The circuit being tested must be protected by a 10
amp fuse or circuit breaker.
²Use the low current shunt to measure circuits up
to 10 amps. Use the high current shunt to mea-
sure circuits exceeding 10 amps.
²When testing for the presence of voltage or cur-
rent, make sure the meter is functioning cor-
rectly. Take a reading of a known voltage or
current before accepting a zero reading.
²When measuring current, connect the meter in
series with the load.
²Disconnect the live test lead before disconnecting
the common test lead.
7
GENERAL INFORMATION

Symptom:
*CHECKING THE ENGINE MECHANICAL SYSTEMS
POSSIBLE CAUSES
CHECKING ENGINE MECHANICAL SYSTEMS
TEST ACTION APPLICABILITY
1NOTE: The following items should be checked as a possible cause of a
Driveability or No-Start problem.
WARNING: Do not attempt to remove or separate high pressure fuel line.
Attempting to do so could result in severe bodily injury or death.
Engine Valve Timing - must be within specification
Engine Compression - must be within specifications
Camshaft Lobes - check for abnormal wear
Camshaft Position Sensor - check the camshaft position sensor tooth for debris and
deterioration
Crankshaft Position Sensor - check the crankshaft tone wheel for debris and
deterioration
Engine Exhaust System - must be free of any restriction
Engine Drive Sprocket - must be properly positioned
Power Brake Booster - must be free of any vacuum leaks
Fuel - must have adequate supply and must be free of contamination and gasoline
Fuel Injectors - must not be plugged or restricted
Fuel Injection Pump - must be producing the correct output volume and pressure
Inspect the Fuel Lines, Fuel Filter and Fuel Pressure Relief Valve for signs of
restriction and leaks
NOTE: Check for any Technical Service Bulletins that may relate to the
problem.
Are there any problems evident?All
Ye s®Repair as necessary.
Perform ROAD TEST VERIFICATION - VER-2.
No®Test Complete.
194
DRIVEABILITY - DIESEL

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 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)

VEHICLE IDENTIFICATION
NUMBER
DESCRIPTION
The Vehicle Identification Number (VIN) can be
viewed through the windshield at the upper left cor-
ner of the instrument panel, near the left windshield
pillar (Fig. 5). The VIN consists of 17 characters in a
combination of letters and numbers that provide spe-
cific information about the vehicle. Refer to VIN
Code Breakdown Chart for decoding information.
To protect the consumer from theft and possible
fraud the manufacturer is required to include a
Check Digit at the ninth position of the Vehicle Iden-
tification Number. The check digit is used by the
manufacturer and government agencies to verify the
authenticity of the vehicle and official documenta-
tion. The formula to use the check digit is not
released to the general public.
VIN CODE BREAKDOWN CHART
POSITION INTERPRETATION CODE = DESCRIPTION
1 Country of Origin 1 = Built in the Graz Austria by DaimlerChrysler
2 Make 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
RatingG = 2268 - 2721 kg. (5001 - 6000 lbs.)
5 Car Line Y = Voyager/Grand Voyager - FWD Left Hand Drive
C = Voyager/Grand Voyager - AWD Left Hand Drive
H = Voyager/Grand Voyager - FWD Right Hand Drive
K = Voyager/Grand Voyager - AWD Right Hand Drive
I = Caravan 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
R = 3.3 L 6 cyl. Gasoline MPI
M = 2.5 L 4 cyl. Turbo Diesel
9 Check Digit See explanation in this section.
10 Model Year 1= 2001
11 Assembly Plant U = Graz Austria
12 through 17 Sequence Number A six digit number assigned by assembly plant.
Fig. 5 Vehicle Identification Number (VIN Plate)
1 - DEFROSTER OUTLET
2 - VIN #
3 - HEATED WINDSHIELD GRID
RGINTRODUCTION9a

PARTS & LUBRICANT
RECOMMENDATION
STANDARD PROCEDURE - Classification of
Lubricants
Only lubricants that bear designations defined by
the following organization should be used to service a
DaimlerChrysler vehicle.
²Society of Automotive Engineers (SAE)
²American Petroleum Institute (API) (Fig. 2)
²National Lubricating Grease Institute (NLGI)
(Fig. 3)
ENGINE OIL
SAE VISCOSITY RATING INDICATES ENGINE OIL VISCOSITY
An SAE viscosity grade is used to specify the vis-
cosity of engine oil. Engine oils also have multiple
viscosities. These are specified with a dual SAE vis-
cosity grade which indicates the cold-to-hot tempera-
ture viscosity range.
²SAE 30 = single grade engine oil.
²SAE 10W-30 = multiple grade engine oil.Daim-
lerChrysler only recommends multiple grade engine
oils.
API QUALITY CLASSIFICATION
This symbol (Fig. 2) on the front of an oil container
means that the oil has been certified by the Ameri-
can Petroleum Institute (API) to meet all the lubri-
cation requirements specified by DaimlerChrysler.
Refer to Group 9, Engine for gasoline engine oil
specification.
FLEXIBLE FUEL ENGINE OIL ± 3.3L ENGINE
Engine Oil Selection for Operating on E-85
FuelIf vehicle operates on E-85 fuel either full or
part-time, use only MopartFlexible Fuel SAE 5W-30
engine oil or an equivalent that meets
DaimlerChrysler Standard MS-9214. Equivalent com-
mercial Flexible Fuel engine oils may be labeled asMulti-Fuel, Variable Fuel, Flexible Fuel, etc. These
engine oils are preferred for use in Flexible Fuel
engines.
CAUTION: If Flexible Fuel engine oil is not used
when using E-85 fuel, engine wear or damage may
result.
GEAR LUBRICANTS
SAE ratings also apply to multiple grade gear
lubricants. In addition, API classification defines the
lubricants usage.
LUBRICANTS AND GREASES
Lubricating grease is rated for quality and usage
by the NLGI. All approved products have the NLGI
symbol (Fig. 3)on the label. At the bottom NLGI sym-
bol is the usage and quality identification letters.
Wheel bearing lubricant is identified by the letter
ªGº. Chassis lubricant is identified by the latter ªLº.
The letter following the usage letter indicates the
quality of the lubricant. The following symbols indi-
cate the highest quality.
STANDARD PROCEDURE - PARTS AND
LUBRICANT RECOMMENDATIONS
When service is required, DaimlerChrysler Motor
Corporation recommends that only Mopartbrand
parts, lubricants and chemicals be used. Mopar pro-
vides the best engineered products for servicing
DaimlerChrysler Corporation vehicles.
ENGINE COOLANT
The green coolantMUST NOT BE MIXEDwith
the orange or magenta coolants. When replacing cool-
ant the complete system flush must be performed
before using the replacement coolant. (Refer to
LUBRICATION & MAINTENANCE/FLUID TYPES -
DESCRIPTION)
Fig. 2 API Symbol
Fig. 3 NLGI Symbol
1 - WHEEL BEARINGS
2 - CHASSIS LUBRICATION
3 - CHASSIS AND WHEEL BEARINGS
0 - 2 LUBRICATION & MAINTENANCERS

LUBRICANTS AND GREASES
Lubricating grease is rated for quality and usage
by the NLGI. All approved products have the NLGI
symbol (Fig. 7) on the label. At the bottom NLGI
symbol is the usage and quality identification letters.
Wheel bearing lubricant is identified by the letter
ªGº. Chassis lubricant is identified by the latter ªLº.
The letter following the usage letter indicates the
quality of the lubricant. The following symbols indi-
cate the highest quality.
OPERATION
The cooling system is designed around the coolant.
The coolant must accept heat from engine metal, in
the cylinder head area near the exhaust valves and
engine block. Then coolant carries the heat to the
radiator where the tube/fin radiator can transfer the
heat to the air.
WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL
BASE COOLANT AND IS HARMFUL IF SWAL-
LOWED OR INHALED. IF SWALLOWED, DRINK
TWO GLASSES OF WATER AND INDUCE VOMIT-
ING. IF INHALED, MOVE TO FRESH AIR AREA.
SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT
STORE IN OPEN OR UNMARKED CONTAINERS.
WASH SKIN AND CLOTHING THOROUGHLY AFTER
COMING IN CONTACT WITH ETHYLENE GLYCOL.
KEEP OUT OF REACH OF CHILDREN. DISPOSE OF
GLYCOL BASE COOLANT PROPERLY, CONTACT
YOUR DEALER OR GOVERNMENT AGENCY FOR
LOCATION OF COLLECTION CENTER IN YOUR
AREA. DO NOT OPEN A COOLING SYSTEM WHEN
THE ENGINE IS AT OPERATING TEMPERATURE OR
HOT UNDER PRESSURE, PERSONAL INJURY CAN
RESULT. AVOID RADIATOR COOLING FAN WHEN
ENGINE COMPARTMENT RELATED SERVICE IS
PERFORMED, PERSONAL INJURY CAN RESULT.
FLUID FILL/CHECK
LOCATIONS
DESCRIPTION
The fluid check/fill points and lubrication locations
are located in each applicable Sections.
MAINTENANCE SCHEDULES
DESCRIPTION
There are two maintenance schedules that show
proper service for your vehicle.
First is Schedule ±A. It lists all the scheduled
maintenance to be performed under ªnormalº operat-
ing conditions.
Second is Schedule ±B. It is a schedule for vehi-
cles that are operated under the following conditions:
²Frequent short trip driving less than 10 miles
(16.2 km)
²Frequent driving in dusty conditions
²Frequent off-road or desert operation
²Frequent trailer towing
²Day and night temperatures are below freezing
²Frequent long periods of engine idling
²Frequent stop and go driving
²More than 50% of your driving is at sustained
high speeds during hot weather, above 90ÉF (32ÉC)*
²Taxi, police or delivery service
²If equipped for and operation with E-85
(ethanol) fuel.
DESCRIPTION
At Each Stop For Fuel
²Check engine oil level and add as required.
²Check windshield washer solvent and add as
required.
Once A Month
²Check tire pressure and look for unusual wear
or damage.
²Check fluid levels of coolant reservoir, brake
master cylinder, power steering and transmission.
Add fluid as required.
²Check all lights and all other electrical items for
correct operation.
At Each Oil Change
²Change oil filter
²Inspect the exhaust system.
²Inspect brake hoses.
²Inspect the CV joints and front suspension com-
ponent boots and seals.
²Rotate the tires at each oil change interval
shown on Schedule ± A (7,500 miles - 12 000 km) or
Fig. 7 NLGI Symbol
1 - WHEEL BEARINGS
2 - CHASSIS LUBRICATION
3 - CHASSIS AND WHEEL BEARINGS
RSLUBRICATION & MAINTENANCE0-7
FLUID TYPES (Continued)

112,500 Miles (180 000 km) or at 90 months
²Change the engine oil.
²Replace the engine oil filter.
²Inspect the brake linings.
120,000 Miles (192 000 km) or at 96 months
²Change the engine oil.
²Replace the engine oil filter.
²Replace the engine air cleaner element (fil-
ter).
²Check and replace the PCV valve, if neces-
sary.*
²Inspect the serpentine drive belt. Not required if
replaced at 75,000, 90,000 or 105,000 miles.
²Inspect the tie rod ends and boot seals.
*This maintenance is recommended by Daimler-
Chrysler Corporation to the owner but is not
required to maintain the emissions warranty.
NOTE: Inspection and service should also be per-
formed anytime a malfunction is observed or sus-
pected. Retain all receipts.
SCHEDULE±B±CHRYSLER TOWN AND
COUNTRY VEHICLES
Follow this schedule if the vehicle is usually oper-
ates under one or more of the following conditions.
²Frequent short trip driving less than 5 miles (8
km)
²Frequent driving in dusty conditions
²Frequent trailer towing
²Day and night temperatures are below freezing
²Frequent long periods of engine idling
²Frequent stop and go driving
²More than 50% of your driving is at sustained
high speeds during hot weather, above 90ÉF (32ÉC)*
²Taxi, police or delivery service
²If equipped for and operation with E-85
(ethanol) fuel.
3,000 Miles (5 000 km)
²Change the engine oil.
²Replace the engine oil filter.
6,000 Miles (10 000 km)
²Change the engine oil.
²Replace the engine oil filter.
9,000 Miles (14 000 km)
²Change the engine oil.
²Replace the engine oil filter.
²Inspect the brake linings.
12,000 Miles (19 000 km)
²Change the engine oil.
²Replace the engine oil filter.
15,000 Miles (24 000 km)
²Change the engine oil.
²Replace the engine oil filter.
²Inspect the engine air cleaner element (fil-
ter). Replace as necessary.*
²Change the All Wheel Drive (AWD) power trans-
fer unit fluid. (See the note at the end of Schedule ±
B.)
18,000 Miles (29 000 km)
²Change the engine oil.
²Replace the engine oil filter.
²Inspect the brake linings.
21,000 Miles (34 000 km)
²Change the engine oil.
²Replace the engine oil filter.
²Change the All Wheel Drive (AWD) overrunning
clutch and rear carrier fluid. (See the note at the end
of Schedule ± B.)
24,000 Miles (38 000 km)
²Change the engine oil.
²Replace the engine oil filter.
27,000 Miles (43 000 km)
²Change the engine oil.
²Replace the engine oil filter.
²Inspect the brake linings.
30,000 Miles (48 000 km)
²Change the engine oil.
²Replace the engine oil filter.
²Replace the engine air cleaner element (fil-
ter).
²Inspect the PCV valve, replace as neces-
sary.*
²Change the All Wheel Drive (AWD) power trans-
fer unit fluid. (See the note at the end of Schedule ±
B.)
²Inspect the tie rod ends and boot seals.
33,000 Miles (53 000 km)
²Change the engine oil.
²Replace the engine oil filter.
36,000 Miles (58 000 km)
²Change the engine oil.
²Replace the engine oil filter.
²Inspect the brake linings.
39,000 Miles (62 000 km)
²Change the engine oil.
²Replace the engine oil filter.
RSLUBRICATION & MAINTENANCE0-9
MAINTENANCE SCHEDULES (Continued)