torque CHRYSLER VOYAGER 2002 Service Manual

(9) Install vibration damper (Refer to 9 - ENGINE/
ENGINE BLOCK/VIBRATION DAMPER - INSTAL-
LATION).
(10) Install accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(11) Install power steering belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(12) Install right engine mount assembly.
(13) Install air cleaner housing.
(14) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
(15) Connect negative battery cable.
TIMING BELT IDLER PULLEY
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(3) Remove air cleaner housing.
(4) Support engine and remove right engine
mount.
(5) Remove power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(6) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(7) Remove vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(8) Remove timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(9) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL).
NOTE: Idler pulley retaining bolts are LHD thread.
(10) Remove timing belt idler pulleys (Fig. 95).
INSTALLATION
(1) Install timing belt idler pulleys (Fig. 95).
Torque bolts to 47.1N´m.
(2) Install timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION) .
(3) Install timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(4) Install vibration damper (Refer to 9 - ENGINE/
ENGINE BLOCK/VIBRATION DAMPER - INSTAL-
LATION).(5) Install accessory drive belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(6) Install power steering belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(7) Install right engine mount.
(8) Install air cleaner housing.
(9) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
(10) Connect negative battery cable.
Fig. 95 TIMING BELT AND SPROCKETS
1 -CAMSHAFT SPROCKETS
2 - INJECTION PUMP SPROCKET
3 - INJECTION PUMP SPROCKET RETAINING NUT
4 - TIMING BELT
5 - TIMING BELT TENSIONER RETAINING BOLT
6 - TIMING BELT TENSIONER
7 - TENSIONER ALIGNMENT PIN
8 - IDLER PULLEY
9 - CAMSHAFT SPROCKET RETAINING BOLT
9a - 58 ENGINERG
TIMING BELT / CHAIN COVER(S) (Continued)
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ADJUSTMENTS
ADJUSTMENT - TIMING BELT TENSIONER
(1) With timing belt outer cover removed and tim-
ing belt installed.
(2) Loosen timing belt tensioner (Fig. 97).
(3) Align timing belt tensioner spring stop with
tensioner as shown (Fig. 98) and torque timing belt
tensioner retaining bolt to 34.7N´m.
(4) Rotate engine 2 complete revolution and then
recheck tensioner alignment. Readjust tensioner
alignment as necessary.
TIMING BELT/CHAIN AND
SPROCKETS
REMOVAL
CAUTION: Before removing the timing belt, the
engine must put at 90É after TDC. Failure to do so
could result in valve and/or piston damage during
reassembly. (Refer to 9 - ENGINE/VALVE TIMING -
STANDARD PROCEDURE)
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(3) Remove air cleaner housing assembly.
(4) Support engine and remove right engine
mount.
(5) Remove power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(6) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(7) Remove vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
Fig. 97 TIMING BELT TENSIONER ADJUSTMENT
1 - TIMING BELT IDLER PULLEY
2 - ENGINE FRONT COVER
3 - CRANKSHAFT HUB
4 - TIMING BELT TENSIONER
5 - TIMING BELT
Fig. 98 TIMING BELT TENSIONER ALIGNMENT
1 - TENSIONER SPRING STOP
2 - TIMING BELT TENSIONER
3 - TIMING BELT TENSIONER
4 - TIMING BELT
5 - TIMING BELT INNER COVER
9a - 60 ENGINERG
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EXHAUST SYSTEM
TABLE OF CONTENTS
page page
EXHAUST SYSTEM
DESCRIPTION..........................1
OPERATION............................2
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - EXCESSIVE
EXHAUST SYSTEM NOISE...............2
DIAGNOSIS AND TESTING - EXHAUST
SYSTEM RESTRICTION CHECK...........2
INSPECTION...........................3
ADJUSTMENTS.........................3
SPECIFICATIONS
TORQUE.............................3
SPECIAL TOOLS
EXHAUST SYSTEM.....................4
CATALYTIC CONVERTER
DESCRIPTION..........................4
OPERATION............................4REMOVAL.............................5
INSPECTION...........................6
INSTALLATION..........................6
CROSS-OVER PIPE - 3.3/3.8L
REMOVAL.............................6
INSTALLATION..........................6
HEAT SHIELDS
DESCRIPTION..........................6
OPERATION............................7
REMOVAL.............................7
INSTALLATION..........................7
MUFFLER
REMOVAL.............................7
INSTALLATION..........................8
RESONATOR
REMOVAL.............................9
INSTALLATION..........................9
EXHAUST SYSTEM
DESCRIPTION
The exhaust system consists of a catalytic converter,
muffler, and a resonator with connecting pipes in-be-
tween (Fig. 1). The system is serviced in two sections;
the catalytic converter and pipe, and the muffler and
resonator with connecting pipe. A band clamp is usedto connect the joint between the two components.
Three support hanger rods with rubber isolators are
used to support and isolate the exhaust system. A flex-
ible joint, integral to the catalytic converter, allows for
engine movement. On vehicles equipped with AWD, an
additional heat shield is mounted to the catalytic con-
verter. The exhaust system is tuned for each vehicle/
powertrain combination.
Fig. 1 Exhaust System - Typical (All Vehicles)
1 - CATALYTIC CONVERTER 4 - SUPPORT - RESONATOR
2 - BAND CLAMP 5 - RESONATOR
3 - SUPPORTS - MUFFLER 6 - MUFFLER
RSEXHAUST SYSTEM11-1
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(1) Disconnect and remove the upstream (before
catalytic converter) oxygen sensor. (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/O2 SENSOR -
REMOVAL)
(2) Install the Exhaust Back Pressure Fitting
Adaptor CH8519.
(3) Connect the Low Pressure Sensor (15 psi)
CH7063 to the back pressure fitting.
(4) Following the PEP module instruction manual,
connect all required cables to the DRB IIItand PEP
module. Select the available menu options on the
DRBIIItdisplay screen for using the digital pressure
gauge function.
(5) Apply the park brake and start the engine.
(6) With transmission in Park or Neutral, raise
engine speed to 2000 RPM. Monitor the pressure
readings on the DRBIIIt. Back pressure should not
exceed specified limit. Refer to specification in table
below EXHAUST BACK PRESSURE LIMITS .
NOTE: For applications with dual catalytic convert-
ers, repeat test on opposite converter using the
previous steps.
(7) If pressure exceeds maximum limits, inspect
exhaust system for restricted component. For further
catalytic converter inspection procedures, (Refer to 11
- EXHAUST SYSTEM/CATALYTIC CONVERTER -
INSPECTION). Replace component(s) as necessary.
EXHAUST BACK PRESSURE LIMITS
Exhaust Back Pressure Limit (Max)
Vehicle in Park/Neutral
(no load) RPM3.45 Kpa (0.5 psi)
INSPECTION
Inspect the exhaust pipes, catalytic converters,
muffler, and resonators for cracked joints, broken
welds and corrosion damage that would result in a
leaking exhaust system. Inspect the clamps, support
brackets, and insulators for cracks and corrosion
damage.
NOTE: Slip joint band clamps are spot welded to
exhaust system. If a band clamp must be replaced,
the spot weld must be ground off.
ADJUSTMENTS
A misaligned exhaust system is usually indicated
by a vibration, rattling noise, or binding of exhaust
system components. These noises are sometimes hard
to distinguish from other chassis noises. Inspect
exhaust system for broken, damaged or loose compo-
nents such as; clamps, heat shields, isolators, andhanger brackets. Replace or tighten as necessary. It
is important that exhaust system clearances and
alignment be maintained.
Perform the following procedures to align the
exhaust system:
(1) Loosen band clamp at catalytic converter pipe
to muffler/resonator assembly.
(2) Align the exhaust system by inserting pipe
inward or outward until specification is achieved as
shown in (Fig. 2).
(3) Tighten band clamp to 54 N´m (40 ft. lbs.).
SPECIFICATIONS
TORQUE
DESCRIPTION N´mFt.
Lbs.In.
Lbs.
Band Clamp 54 40 Ð
Cross-over PipeÐFastener 41 30 Ð
Exhaust Manifold FlangeÐFastener 37 Ð 325
Heat Shield (Muffler)ÐFastener 2.6 Ð 23
Heat Shield (Toe Board)ÐFastener 2.6 Ð 23
Heat Shield (Resonator Pipe)Ð
Fastener2.6 Ð 23
Insulator Mounting BracketÐBolts 28 Ð 250
Fig. 2 Exhaust System Alignment
1 - HANGER BRACKET TO BODY
2 - ISOLATOR
3 - HANGER - MUFFLER/RESONATOR SUPPORT
4-6mm(0.25 in.)
RSEXHAUST SYSTEM11-3
EXHAUST SYSTEM (Continued)
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CAUTION: Band clamps should never be tightened
such that the two sides of the clamps are bottomed
out against the center hourglass shaped center
block. Once this occurs, the clamp band has been
stretched and has lost its clamping force and must
be replaced.
To replace the band clamp; remove the nut and peel
back the ends of the clamp until spot weld breaks.
Clean remaining spot weld from the pipe using a
file or grinder until surface is smooth.
NOTE: Maintain proper clamp orientation when
replacing with new clamp.
(5) Tighten the band clamp to 55 N´m (40 ft. lbs.)
(Fig. 12).
(6) Connect the right side half shaft to the rear
differential module (AWD equipped only).
RESONATOR
REMOVAL
(1) (Refer to 11 - EXHAUST SYSTEM/MUFFLER -
REMOVAL)
INSTALLATION
(1) (Refer to 11 - EXHAUST SYSTEM/MUFFLER -
INSTALLATION)
Fig. 12 Band Clamp
1 - BAND CLAMP
2 - TORQUE SPECIFICATION
RSEXHAUST SYSTEM11-9
MUFFLER (Continued)
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EXHAUST SYSTEM AND TURBOCHARGER
TABLE OF CONTENTS
page page
EXHAUST SYSTEM AND TURBOCHARGER
DESCRIPTION..........................1
SPECIFICATIONS - TORQUE...............1
TURBOCHARGER SYSTEM
DESCRIPTION..........................2
OPERATION............................2
TURBOCHARGER
REMOVAL.............................4CLEANING.............................5
INSTALLATION..........................5
HEAT SHIELDS
REMOVAL.............................5
INSTALLATION..........................6
EXHAUST SYSTEM AND
TURBOCHARGER
DESCRIPTION
The basic exhaust system consists of an engine
exhaust manifold, turbocharger, exhaust down pipe,
exhaust pipe, exhaust heat shield(s), muffler and
exhaust tailpipe
The exhaust system uses a single muffler.
The exhaust system must be properly aligned to
prevent stress, leakage and body contact. If the sys-
tem contacts any body panel, it will transfer objec-
tionable noises originating from the engine to the
body.When inspecting an exhaust system, critically
inspect for cracked or loose joints, stripped screw or
bolt threads, corrosion damage and worn, cracked or
broken hangers. Replace all components that are
badly corroded or damaged. DO NOT attempt to
repair.
When replacement is required, use original equip-
ment parts (or equivalent). This will assure proper
alignment and provide acceptable exhaust noise lev-
els.
CAUTION: Avoid application of rust prevention com-
pounds or undercoating materials to exhaust sys-
tem floor pan exhaust heat shields. Light overspray
near the edges is permitted. Application of coating
will result in excessive floor pan temperatures and
objectionable fumes.
SPECIFICATIONS - TORQUE
2.5L DIESEL - TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Exhaust Manifold Nuts 32.4 24 Ð
Exhaust Manifold Heat
shield Bolts27.5 21 Ð
Turbocharger Bracket
Bolts47.1 35 Ð
Turbocharger Downpipe
Nuts32.4 24 Ð
Turbocharger Oil Feed
Line Fitting24.5 18 215
Turbocharger to Exhaust
Manifold Nuts32.4 24 Ð
RGEXHAUST SYSTEM AND TURBOCHARGER11a-1
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(8) With exhaust manifold and turbocharger
assembly on work bench, remove turbocharger to
exhaust manifold retaining bolts. Separate exhaust
manifold and turbocharger.
CLEANING
All old gaskets should be inspected for any tears or
signs of prior leakage. If any gaskets show such indi-
cations, they should be replaced with new gaskets.
All gasket mating surfaces must be cleaned of old
gasket material to produce a smooth and dirt free
sealing surface for the new gasket.
INSTALLATION
(1) Connect exhaust manifold and turbocharger.
Torque nuts to 32.4N´m.
(2) Position new exhaust manifol gasket on
exhaust manifol studs (Fig. 6).
(3) Install exhaust manifold and turbocharger on
engine (Fig. 6). Torque nuts to 32.4N´m.
(4) Connect turbocharger oil supply and return
lines at turbocharger (Fig. 6). Torque oil supply line
to 24.5N´m.
(5) Install exhaust manifold shield (Fig. 6). Torque
bolts to 27.5N´m.
(6) Install engine lift hook (Fig. 6). Torque bolts to
32.4N´m.
(7) Install thermostat to upper radiator hose tube
and turbocharger outlet tube (Fig. 5).
(8) Install engine in vehicle (Refer to 9 - ENGINE
- INSTALLATION).
HEAT SHIELDS
REMOVAL
(1) Remove front wiper unit (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
REMOVAL).
(2) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(3) Partially drain cooling system (Refer to 7 -
COOLING/ENGINE/COOLANT - STANDARD PRO-
CEDURE).
(4) Remove thermostat housing to upper radiator
hose tube (Fig. 7).
(5) Remove exhaust manifold heat shield retaining
bolts and remove shield (Fig. 8).
Fig. 7 TURBOCHARGER AND COOLANT PIPES
1 - TURBOCHARGER OUTLET PIPE RETAINING BOLT
2 - TURBOCHARGER OUTLET PIPE
3 - ADAPTER HOSE
4 - HEAT SHIELD
5 - HOSE CLAMPS
6 - TURBOCHARGER INLET PIPE RETAINING BOLT
7 - TURBOCHARGER INLET PIPE
8 - ADAPTER HOSE
9 - HOSE CLAMPS
10 - CLAMP
11 - EGR VALVE TO INTAKE AIR INLET PIPE
12 - CLAMP
13 - THERMOSTAT HOUSING TO UPPER RADIATOR HOSE
PIPE
RGEXHAUST SYSTEM AND TURBOCHARGER11a-5
TURBOCHARGER (Continued)
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INSTALLATION
(1) Reposition exhaust heat shield (Fig. 8).
(2) Install exhaust heat shield retaining bolts (Fig.
8). Torque bolts to 27.5N´m.
(3) Install thermostat housing to upper radiator
hose tube (Fig. 7).
(4) Refill cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(5) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
(6) Install front wiper unit (Refer to 8 - ELECTRI-
CAL/WIPERS/WASHERS/WIPER MODULE -
INSTALLATION).
Fig. 8 EXHAUST MANIFOLD AND TURBOCHARGER
1 - TURBOCHARGER OIL SUPPLY BANJO BOLT
2 - COPPER WASHER
3 - EXHAUST MANIFOLD GASKET
4 - COPPER WASHER
5 - EXHAUST MANIFOL HEAT SHIEL RETAINING BOLT
6 - TURBOCHARGER
7 - ENGINE LIFT HOOK
8 - ENGINE LIFT HOOK RETAINING BOLT
9 - SPACER
10 - EXHAUST MANIFOLD RETAINING NUT
11 - TURBOCHARGER OIL RETURN HOSE
12 - HOSE CLAMPS
13 - EXHAUST MANIFOLD STUDS
11a - 6 EXHAUST SYSTEM AND TURBOCHARGERRG
HEAT SHIELDS (Continued)
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FRAME & BUMPERS
TABLE OF CONTENTS
page page
BUMPERS
SPECIFICATIONS - TORQUE...............1
FRONT FASCIA
REMOVAL.............................1
INSTALLATION..........................1
FRONT BUMPER REINFORCEMENT
REMOVAL.............................2
INSTALLATION..........................2
REAR FASCIA
REMOVAL.............................3
INSTALLATION..........................3
REAR BUMPER REINFORCEMENT
REMOVAL.............................3
INSTALLATION..........................3
REAR FASCIA - SCUFF PAD
REMOVAL.............................4INSTALLATION..........................4
FRAME
SPECIFICATIONS
FRAME DIMENSIONS...................4
SPECIFICATIONS - TORQUE.............9
FRONT CRADLE CROSSMEMBER
DESCRIPTION
DESCRIPTION - FRONT CRADLE
CROSSMEMBER.......................9
DESCRIPTION - FRONT CRADLE
CROSSMEMBER THREAD REPAIR.........9
REMOVAL.............................10
INSTALLATION.........................12
FRONT CROSSMEMBER MOUNT BUSHINGS
REMOVAL.............................12
INSTALLATION.........................12
BUMPERS
SPECIFICATIONS - TORQUE
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Front bumper reinforcement attaching nut 54 40 Ð
Rear bumper reinforcement attaching nut 27 20 Ð
FRONT FASCIA
REMOVAL
(1) Release hood latch and open hood.
(2) Remove the headlamp assemblies (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
HEADLAMP - REMOVAL).
(3) Hoist vehicle and support with safety stands.
(4) Remove the five bolts attaching bottom of fas-
cia/air dam to radiator closure panel.
(5) Remove front wheels.
(6) Remove front wheelhouse splash shields fasten-
ers as necessary to gain access to bolts attaching
front fascia to fender. (Refer to 23 - BODY/EXTERI-
OR/ WHEELHOUSE SPLASH SHIELD - REMOV-
AL).
(7) Remove the two bolts and two nuts attaching
fascia to the front fenders (Fig. 1).
(8) Disconnect fog lamp wire connectors, if neces-
sary.
(9) Lower vehicle.(10) Remove two bolts attaching the upper grille
support to the headlamp mounting panel at each side
of the grille.
(11) Remove bumper fascia from vehicle.
INSTALLATION
(1) Position front bumper fascia on vehicle.
(2) Install the two bolts attaching fascia to head-
lamp mounting panel at each side of grille.
(3) Hoist vehicle and support with safety stands.
(4) Install the two bolts and two nuts attaching
fascia to the front fenders (Fig. 1). The fascia should
be flush to fender.
(5) Install front wheelhouse splash shields fasten-
ers. (Refer to 23 - BODY/EXTERIOR/ WHEEL-
HOUSE SPLASH SHIELD - INSTALLATION).
(6) Install front wheels.
(7) Connect fog lamp wire connectors, if necessary.
(8) Install the five bolts attaching bottom of fascia
to radiator closure panel.
(9) Lower the vehicle.
RSFRAME & BUMPERS13-1
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(10) Install the headlamp assemblies. (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
HEADLAMP - INSTALLATION).
FRONT BUMPER
REINFORCEMENT
REMOVAL
(1) Remove front bumper fascia. (Refer to 13 -
FRAMES & BUMPERS/BUMPERS/FRONT FASCIA
- REMOVAL)
(2) Support front bumper reinforcement on a suit-
able lifting device.
(3) Remove the four nuts attaching front bumper
reinforcement to frame rail (Fig. 2).
(4) Remove front bumper reinforcement from vehi-
cle.
INSTALLATION
NOTE: Check position of the arrows molded into
the foam for correct orientation.
(1) Support front bumper reinforcement using a
suitable lifting device and lift into position.
(2) Install the four nuts attaching reinforcement to
frame rails. Tighten nuts to 54 N´m (40 ft. lbs.)
torque.
(3) Install front fascia. (Refer to 13 - FRAMES &
BUMPERS/BUMPERS/FRONT FASCIA - INSTAL-
LATION).
Fig. 1 FRONT BUMPER FASCIA
1 - FRONT BUMPER FASCIA
2 - FRONT BUMPER REINFORCEMENT
3 - RADIATOR ENCLOSURE
Fig. 2 FRT BUMPER REINFORCEMENT
1 - FRONT BUMPER REINFORCEMENT
2 - FRAME RAILS
13 - 2 FRAME & BUMPERSRS
FRONT FASCIA (Continued)
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