fuel tank removal CHRYSLER VOYAGER 2004 User Guide

(5) Clean top of tank to remove loose dirt and
debris.
(6) Using a brass punch and hammer remove lock-
nut to release pump module (Fig. 10).
WARNING: THE FUEL RESERVOIR OF THE FUEL
PUMP MODULE DOES NOT EMPTY OUT WHEN THE
TANK IS DRAINED. THE FUEL IN THE RESERVOIR
MAY SPILL OUT WHEN THE MODULE IS REMOVED.
(7) Remove fuel pump module and O-ring from
tank (Fig. 11). Discard O-ring.
INSTALLATION
NOTE: Be careful not to allow dirt/debris to fall into
the fuel tank.
(1) Wipe seal area of tank clean and place a new
O-ring seal in position on pump.
(2) Position fuel pump module in tank.
(3) Tighten lockring using a brass punch and ham-
mer to install the lockring (Fig. 10).
(4) Install fuel tank, refer to the Fuel Tank instal-
lation section.
(5) Lower vehicle.
(6) Connect negative cable battery.
(7) Fill fuel tank. Use the DRB IIItscan tool to
pressurize the fuel system. Check for leaks.
(8) Install fuel filler cap.
FUEL RAIL
REMOVAL
REMOVAL - 2.4L
(1) Perform fuel system pressure release procedure
before servicing or starting repairs.Refer to
Fuel System Pressure Release Procedure in this sec-
tion.
(2) Disconnect negative cable from battery.
(3) Disconnect the wiring connectors for fuel injec-
tors harness (Fig. 12).
(4) Remove wiring harness from brackets.
(5) Disconnect the connectors from the fuel injec-
tors.
Fig. 10 FUEL PUMP MODULE LOCKING RING
Fig. 11 Fuel Pump Module Removal
1 - FUEL PUMP MODULE
2 - O-RING
Fig. 12 FUEL RAIL AND INJECTORS 2.4L
1 - Fuel Injectors
2 - Fuel Rail
RSFUEL DELIVERY14-9
FUEL PUMP MODULE (Continued)

(6) Remove harness from vehicle.
(7) Remove fuel hose quick connect fitting from the
chassis tube.Refer to Fuel Hoses, Clamps and
Quick Connect Fittings in this Section.Place a
shop towel under the connections to absorb any fuel
spilled from the fitting.
WARNING: WRAP A SHOP TOWEL AROUND HOSES
TO CATCH ANY GASOLINE SPILLAGE.
(8) Remove fuel rail attaching bolts.
(9) Remove fuel rail. Be careful not to damage the
injector O-rings upon removal from their ports.
REMOVAL - 3.3/3.8L
(1) Perform fuel system pressure release procedure
before servicing or starting repairs.Refer to
Fuel System Pressure Release Procedure in this sec-
tion.
(2) Disconnect negative cable from battery.
(3) Remove upper intake manifold, refer to the
Engine/Manifolds/Upper Intake for more informa-
tion..
(4) Cover intake manifold with suitable cover
when servicing.
(5) Remove the fuel hose quick connect fitting from
the chassis tube.Refer to Fuel Hoses, Clamps
and Quick Connect Fittings in this Section.
WARNING: WRAP A SHOP TOWEL AROUND HOSES
TO CATCH ANY GASOLINE SPILLAGE.
(6) Remove the fuel rail attaching bolts (Fig. 13).
(7) Remove fuel rail. Be careful not to damage the
injector O-rings upon removal from their ports.
INSTALLATION
INSTALLATION - 2.4L
(1) Ensure injector holes are clean. Replace
O-rings if damaged.
(2) Lubricate injector O-rings with a drop of clean
engine oil to ease installation.
(3) Put the tip of each injector into their ports.
Push the assembly into place until the injectors are
seated in the ports.
(4) Install the fuel rail mounting bolts. Tighten
bolts to 22 N´m (200 in. lbs.) torque.
(5) Connect the connectors to the fuel injectors.
(6) Install wiring harness to brackets.
(7) Connect the wiring connectors to fuel injectors
harness (Fig. 12).
(8) Connect negative battery cable.
(9) Use the DRBIIItscan tool to pressurize the
fuel system. Check for leaks.
INSTALLATION - 3.3/3.8L
(1) Ensure injector holes are clean. Replace
O-rings if damaged.
(2) Lubricate injector O-rings with a drop of clean
engine oil to ease installation.
(3) Put the tip of each injector into their ports.
Push the assembly into place until the injectors are
seated in the ports.
(4) Install the fuel rail mounting bolts. Tighten
bolts to 22 N´m (200 in. lbs.) torque.
(5) Remove covering on lower intake manifold and
clean surface.
(6) Install the Upper Intake Manifold, refer to
Engine/Manifolds/Upper Intake for more information.
(7) Install fuel hose quick connector fitting to chas-
sis tubes.Refer to Fuel Hoses, Clamps and
Quick Connect Fittings in this Section.Push the
fitting onto the chassis tube until it clicks into place.
Pull on the fitting to ensure complete insertion.
(8) Connect negative cable to battery.
(9) Use the DRBIIItscan tool to pressurize the
fuel system. Check for leaks.
FUEL TANK
DESCRIPTION
The fuel tank is constructed of a plastic material.
Its main functions are for fuel storage and for place-
ment of the fuel pump module. The tank is made
from High density Polyethylene (HDPE) material.If
equipped with ORVR (Onboard Refueling Vapor
Recovery) it has been added to the fuel tank to con-
trol refueling vapor emissions.
Fig. 13 FUEL INJECTORS 3.3/3.8L
14 - 10 FUEL DELIVERYRS
FUEL RAIL (Continued)

OPERATION
All models pass a full 360 degree rollover test
without fuel leakage. To accomplish this, fuel and
vapor flow controls are required for all fuel tank con-
nections.
All models are equipped with either one or two
check valves mounted into the top of the fuel tank (or
pump module).
An evaporation control system is connected to the
check valve(s)/control valve(Refer to 25 - EMIS-
SIONS CONTROL/EVAPORATIVE EMISSIONS/
ORVR - OPERATION) to reduce emissions of fuel
vapors into the atmosphere, when the tank is vented
due to vapor expansion in the tank. When fuel evap-
orates from the fuel tank, vapors pass through vent
hoses or tubes to a charcoal canister where they are
temporarily held. When the engine is running, the
vapors are drawn into the intake manifold. In addi-
tion, fuel vapors produced during vehicle refueling
are allowed to pass through the vent hoses/tubes to
the charcoal canister(s) for temporary storage (prior
to being drawn into the intake manifold). All models
are equipped with a self-diagnosing system using a
Leak Detection Pump (LDP) or Natural Vacuum
Leak Detection (NVLD). Refer to the Emission Con-
trol System for additional information.
INLET CHECK VALVE
All vehicles have an inlet check valve on the inside
of the fuel tank at the filler inlet
The valve prevents fuel from splashing back on
customer during vehicle refueling. The valve is a
non-serviceable item.
REMOVAL
(1) Remove fuel filler cap and perform Fuel Sys-
tem Pressure Release procedure (Fig. 14).
(2) Disconnect negative cable from battery.
(3) Insert fuel siphon hose into fuel filler neck and
push it into the tank.
(4) Drain fuel tank dry into holding tank or a
properly labeledGASOLINEsafety container.
(5) Raise vehicle on hoist and support.
(6) Use a transmission jack to support fuel tank.
Remove bolts from fuel tank straps.
(7) Lower tank slightly.
(8) Disconnect the fuel filler vent tube. Squeeze
tabs and pull apart (Fig. 15).
(9) Disconnect the fuel fill hose at the fuel tank
filler metal tubeNOT AT THE FUEL TANK(Fig.
15).
(10) Disconnect fuel line and vapor line at the
front of the fuel tank.
The fuel pump module electrical connector
has a retainer that locks it in place.(11) Slide fuel pump module electrical connector
lock to unlock.
(12) Push down on connector retainer (Fig. 16) and
pull connector off module.
(13) Lower tank from vehicle. Remove fuel filler
vent tube from frame (Fig. 17).
Fig. 14 Fuel Tank
1 - ROLLOVER VALVE
2 - FUEL FILLER INLET
3 - ROLLOVER VALVE
4 - FUEL PUMP MODULE
Fig. 15 FUEL FILLER AND VENT TUBE
1 - Filler Tube
2 - Vent Tube
RSFUEL DELIVERY14-11
FUEL TANK (Continued)

INSTALLATION
(1) Position fuel tank on transmission jack. Con-
nect check valve hose. Connect fuel filler tube vent
hose to fuel filler tube.
(2) Feed filler vent line thru frame rail.
(3) Raise tank into position and carefully work fuel
filler metal tube into the rubber hose on fuel tank. A
light coating of clean engine oil on the tube end may
be used to aid assembly.
(4) Tighten strap bolts to 54 N´m (40 ft. lbs.)
torque. Tighten T strap bolt to 28.2 N´m (250 in.
lbs.). Remove transmission jack.
(5) Tighten filler hose clamp to 3.3 N´m (30 in.
lbs.).CAUTION: Ensure straps are not twisted or bent
before or after tightening strap screws.
(6) Connect fuel pump/module electrical connector.
Place retainer in locked position.
(7) Lubricate the fuel supply line with clean 30
weight engine oil, install the quick connect fuel fit-
ting. Refer to Tube/Fitting Assembly in the Fuel
Delivery section of this section.
(8) Connect the control vapor lines at front of
tank.
(9) Pull-pull-push on all connections to make sure
of connection.
(10) Fill fuel tank, replace cap, and connect bat-
tery negative cable.
(11) Use the DRBIIItscan tool to pressurize the
fuel system. Check for leaks.
FUEL TANK FILLER TUBE
REMOVAL
(1) Disconnect the negative battery cable.
(2) Remove the 3 screws at the filler door.
(3) Raise and support vehicle
(4) Remove the left rear tire.
(5) Remove the splash shield (Fig. 19) or (Fig. 18).
(6)For RGRemove the canister from filler tube
(Fig. 20).
(7)For RGDisconnect the vent at the top of the
filler tube.
(8) Remove the ground strap.
(9) Remove filler tube at tank.
Fig. 16 Pump Module Connector Retainer and Lock
1 - PUSH DOWN ON RETAINER
2 - CONNECTOR LOCK
Fig. 17 VENT HOSE
Fig. 18 FUEL FILLER TUBE (RS)
14 - 12 FUEL DELIVERYRS
FUEL TANK (Continued)

INSTALLATION
(1) Install filler tube to tank (Fig. 19).
(2) Install the ground strap.
(3)For RGConnect the vent at the top of the filler
tube.
(4) Install the 3 screws at the filler door.(5)For RGInstall the canister from filler tube
(Fig. 20).
(6) Install the splash shield.
(7) Install the left rear tire.
(8) lower vehicle.
(9) Connect the negative battery cable.
INLET FILTER
REMOVAL
(1) Remove fuel pump module. Refer to Fuel Pump
Module Removal in this section.
(2) Using a thin straight blade screwdriver, pry
back the locking tabs on fuel pump reservoir and
remove the strainer (Fig. 21).
(3) Remove strainer O-ring from the fuel pump
reservoir body.
(4) Remove any contaminants in the fuel tank by
washing the inside of the fuel tank.
INSTALLATION
(1) Lubricate the strainer O-ring with clean engine
oil.
(2) Insert strainer O-ring into outlet of strainer so
that it sits evenly on the step inside the outlet.
(3) Push strainer onto the inlet of the fuel pump
reservoir body. Make sure the locking tabs on the
reservoir body lock over the locking tangs on the
strainer.
(4) Install fuel pump module. Refer to Fuel Pump
Module Installation in this section.
Fig. 19 FUEL FILLER TUBE AND VENT TUBE (RG)
Fig. 20 FUEL TUBE VENT CANISTER (RG)
Fig. 21 Inlet
1 - TABS
2 - INLET STRAINER
RSFUEL DELIVERY14-13
FUEL TANK FILLER TUBE (Continued)

(15) Roll and fold carpet forward away from rear
door opening.
(16) Extract carpet through sliding door opening
(Fig. 5).INSTALLATION
(1) Insert carpet through sliding door opening.
(2) Roll carpet rearward toward rear door opening.
(3) Roll carpet under instrument panel.
(4) Install push pins fasteners through carpet and
grommet into floor to attach carpet to floor in front
seat area (Fig. 5).
(5) Install push pins fasteners in the rear area.
CAUTION: Ensure that the correct fasteners are
installed in the proper locations. Damage to the fuel
tank may result.
(6) Install floor escutcheons (Fig. 4).
(7) Install the floor console trays. (Refer to 23 -
BODY/INTERIOR/FLOOR CONSOLE TRAY -
INSTALLATION)
(8) Install Quarter trim panels.
(9) Install D-pillar trim covers.
(10) Install lower B-pillar trim covers.
(11) Install rear door sill plate.
(12) Install sliding door sill plates. (Refer to 23 -
BODY/INTERIOR/SLIDING DOOR SILL PLATE -
INSTALLATION)
(13) Install front cowl panels and sill plates.
(14) Install the passenger seats. Refer to the Own-
er's Manual for proper procedures.
(15) Install front center console.
(16) Install front seats. (Refer to 23 - BODY/
SEATS/SEAT - INSTALLATION)
COWL TRIM
REMOVAL
(1) Remove door sill plate.
(2) Disengage hidden clips holding cowl trim to
cowl panel (Fig. 6).
(3) Remove cowl trim from vehicle.
INSTALLATION
(1) Place cowl trim panel in position on vehicle
(Fig. 1).
(2) Engage hidden clips attaching cowl trim to
cowl panel.
(3) Install door sill plate.
Fig. 4 SEAT ESCUTCHEONS
1 - SEAT ESCUTCHEON
2 - FLOOR CARPET
Fig. 5 FLOOR CARPET
1 - CARPET LOCATOR GROMMET
2 - PUSH PIN
3 - CARPET
4 - CARPET GROMMET
5 - HEEL PROTECTOR PAD
6 - BODY ASSEMBLY
23 - 76 INTERIORRS
CARPETS AND FLOOR MATS (Continued)

CABIN HEATER
TABLE OF CONTENTS
page page
CABIN HEATER
DESCRIPTION........................112
OPERATION
OPERATION - MANUAL TEMPERATURE
CONTROL SYSTEM...................112
OPERATION - AUTOMATIC TEMPERATURE
CONTROL SYSTEM...................112
DIAGNOSIS AND TESTING - DIESEL
SUPPLEMENTAL CABIN HEATER........113
AIR INTAKE PIPE
REMOVAL............................113
INSTALLATION........................114
EXHAUST TUBE
REMOVAL............................114
INSTALLATION........................115FUEL DOSING PUMP
DESCRIPTION........................115
OPERATION..........................115
REMOVAL............................115
INSTALLATION........................116
FUEL LINE
STANDARD PROCEDURE - CLEANING.....117
REMOVAL............................117
INSTALLATION........................118
HEATER UNIT
REMOVAL............................118
INSTALLATION........................119
SUPPLEMENTAL DIESEL HEATER WIRING
REMOVAL............................119
INSTALLATION........................119
CABIN HEATER
DESCRIPTION
Vehicles equipped with the diesel engine are also
equipped with a supplemental cabin heater. This
cabin heater is mounted under the vehicle and oper-
ates similar to an oil fired furnace. The heater burns
small amounts of fuel to provide additional heat to
the coolant. Coolant is routed from the engine, to the
supplemental cabin heater and then to the front
heater core. This provides additional heat to the pas-
senger compartment. The supplemental cabin heater
system is interfaced to the vehicles on-board com-
puter systems and DRBIIItdiagnostics.
The supplemental cabin heater has an electronic
control module that monitors the heat output of the
heater. The cabin heater operates at full load (5 kW),
half load or idle mode (no additional heat) depending
on engine coolant temperature.
OPERATION
OPERATION - MANUAL TEMPERATURE
CONTROL SYSTEM
The supplemental cabin heater is activated via the
temperature slide control or knob on the A/C-heater
control when equipped with the manual temperature
control (MTC) system. If the slide control or knob is
moved to or above the upper set point the cabin
heater is activated. The cabin heater can operate in a
full or partial load range as well as an idle mode alldependent on the engine coolant temperature. The
cabin heater will also turn off if the A/C-heater tem-
perature control is lowered to less than the lower set
point. The cabin heater can take up to three minutes
to completely shut down when either the heater tem-
perature is set below the lower set point or the vehi-
cle ignition is shut down.
NOTE: Do not apply a strong vacuum source such
as a garage ventilation system directly on the sup-
plemental cabin heater exhaust line. Too strong of a
vacuum can prevent the supplemental cabin heater
from starting. If required, place the vacuum source
at least 75 mm (3 in.) away from the exhaust line.
The supplemental cabin heater only operates when
the engine is running, the mileage exceeds 8 kilome-
ter (5 mph) and the fuel tank volume exceeds 1/8 of a
tank. The supplemental heater control module moni-
tors blower speed and combustion during its start-up.
The cabin heater should operate if the coolant tem-
perature is below 40É C (104É F).
OPERATION - AUTOMATIC TEMPERATURE
CONTROL SYSTEM
The automatic temperature control (ATC) system
will activate the supplemental cabin heater based on
engine coolant temperature and interior component
settings. The cabin heater can operate in a full or
partial load range as well as an idle mode all depen-
dent on the engine coolant temperature. The cabin
heater will also turn off if the A/C-heater tempera-
ture control is lowered to less than the lower set
24 - 112 CABIN HEATERRS

point. The cabin heater can take up to three minutes
to completely shut down when either the heater tem-
perature is set below the lower set point or the vehi-
cle ignition is shut down.
NOTE: Do not apply a strong vacuum source such
as a garage ventilation system directly on the sup-
plemental cabin heater exhaust line. Too strong of a
vacuum can prevent the supplemental cabin heater
from starting. If required, place the vacuum source
at least 75 mm (3 in.) away from the exhaust line.
The supplemental cabin heater only operates when
the engine is running, the mileage exceeds 8 kilome-ter (5 mph) and the fuel tank volume exceeds 1/8 of a
tank. The supplemental heater control module moni-
tors blower speed and combustion during its start-up.
The cabin heater should operate if the coolant tem-
perature is below 40É C (104É F).
DIAGNOSIS AND TESTING - DIESEL
SUPPLEMENTAL CABIN HEATER
Refer to the Symptoms Diagnosis table for basic
checks of the diesel fueled supplemental cabin heater.
SYMPTOMS DIAGNOSIS
Symptom Possible Causes
Smell of diesel fuel. Check cabin heater system integration in vehicle's fuel system. Check
fuel lines for leakage, kinks or obstructions. If OK, Inspect the inlet
muffler, drain as necessary. Re-test the cabin heater and re-inspect.
Inspect the exhaust tube and cabin heater for the presence of external
fuel. If presence of external fuel is observed on the heater unit or in the
exhaust tube or after draining and testing. Remove the cabin heater
from vehicle and repair or replace components as required.
Heater does not achieve full load
operation.Check cabin heater operation with DRBIIITscan tool and replace
components as required.
Continuous white smoke from heater
exhaust during combustion operation.Check cabin heater operation with DRBIIITscan tool and replace
components as required. White smoke is typical in extreme weather
conditions.
Heater can not be switched off. Check cabin heater operation with DRBIIITscan tool and replace
components as required.
Heater does not operate. Diagnosis cabin heater control module using the DRBIIITscan tool and
the procedures listed in Vehicle Performance under Cabin Heater
Diagnosis in Group 18.
Loss of coolant (Leakage) or heater
develops smoke during combustion
operation and exhaust has an
extremely sweet smell.Inspect coolant hoses for leakage, kinks or loose hose connection.
Inspect the exhaust tube assembly for continuous flow, if OK there is an
internal heater leak and cabin heater should be inspected and
components should be replaced as required.
Loss of fuel (dripping). Check cabin heater system integration in vehicles fuel system. Check
fuel line connection for leakage. If OK there is an internal leak and
cabin heater should be inspected and replaced as required.
AIR INTAKE PIPE
REMOVAL
NOTE: The air intake tube for the supplemental
cabin heater is part of an assembly that includes
the heater cooling intake and return pipes. If the
cabin heater air intake tube requires removal or
replacement the entire cabin heater assembly will
require removal or replacement.(1) Drain the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE).
(2) Remove clamps from the cabin 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 cabin
heater air intake muffler connection (Refer to 24 -
HEATING & AIR CONDITIONING/CABIN HEAT-
ER/INLET MUFFLER - REMOVAL).
(4) Remove the clamp at the flexible tube to steel
tube connection (Fig. 1).
RSCABIN HEATER24 - 113
CABIN HEATER (Continued)

INSTALLATION
(1) Install the flexible exhaust pipe to the cabin
heater. Tighten the mounting clamp securely.
(2) Position the steel exhaust pipe to the flexible
exhaust. Tighten the mounting clamp securely.
(3) Loosely install the three exhaust pipe screws
and adjust pipe placement as required. Tighten the
screws securely.
(4) Install the clamp that secures the steel exhaust
pipe to the flexible exhaust pipe. Tighten the clamp
securely.
(5) Check exhaust end placement of the exhaust
pipe and make any final adjustments.
(6) Lower the vehicle.
FUEL DOSING PUMP
DESCRIPTION
The dosing pump is a combined delivery, dosing
and shut-off system for the fuel supply to the supple-
mental cabin heater from the vehicle fuel tank.
OPERATION
The dosing pump is an electrically operated pump
that receives its operation instructions from the sup-
plemental cabin heater control module. The pump
supplies diesel fuel from the vehicle fuel tank to the
cabin heater.
REMOVAL
NOTE: The dosing pump is serviceable without
removing the component from the vehicle.
(1) Disconnect the rubber hose at the fuel line to
heater fuel pump. Leave the rubber hose on the fuel
line (Refer to 24 - HEATING & AIR CONDITION-
ING/CABIN HEATER/FUEL LINE - REMOVAL)
(Fig. 4).
(2) Disconnect the fuel line between the dosing
pump and the cabin heater unit.
NOTE: Position and retain the heater fuel line to
prevent fuel leakage while servicing the dosing
pump.
Fig. 3 Cabin Heater Exhaust System
1 - MOUNTING SCREWS (3)
2 - STEEL HEATER EXHAUST PIPE
3 - EXHAUST CLAMP (2)4 - FLEXIBLE HEATER EXHAUST PIPE
5 - CABIN HEATER AND SHIELD
6 - EXHAUST PIPE MOUNTING CLIPS (3) (IF EQUIPPED)
RSCABIN HEATER24 - 115
EXHAUST TUBE (Continued)

FUEL LINE
STANDARD PROCEDURE - CLEANING
(1) Remove the cabin heater fuel line (Refer to 24 -
HEATING & AIR CONDITIONING/CABIN HEAT-
ER/FUEL LINE - REMOVAL).
(2) With the cabin heater fuel line removed from
the vehicle, place a shop cloth on the fuel tank end of
the fuel line to catch any residue, then apply a small
amount of air pressure to the other end of the fuel
line.
(3) Check to see if air pressure is coming from the
tank end of the line. If pressure is flowing unre-
stricted the line is clean.
(4) If the fuel line shows any signs of being
restricted after air pressure is applied, the fuel line
should be replaced.
(5) Install the cabin heater fuel line (Refer to 24 -
HEATING & AIR CONDITIONING/CABIN HEAT-
ER/FUEL LINE - INSTALLATION).
(6) Verify function of the cabin heater.
REMOVAL
(1) Raise and support the vehicle. Take note of the
location of the flexible section of the cabin heater
exhaust tube.NOTE: Have an approved fuel holding device ready
to capture any diesel fuel that drains from the fuel
line or cabin heater unit.
(2) Remove clamps on dosing pump end of fuel line
and separate line from the pump (Fig. 5).
(3) Remove clamp from the fuel line at the fuel
tank connection and separate the line from the tank.
(4) Remove any retaining clips and remove the
fuel line from vehicle.
Fig. 5 Cabin Heater Dosing Pump Fuel Line
1 - FUEL LINE
2 - RETAINING CLAMP3 - DOSING PUMP
4 - HEATER AIR INTAKE PIPE
RSCABIN HEATER24 - 117