engine coolant CHRYSLER VOYAGER 2004 Repair Manual

8W-02 COMPONENT INDEX
Component Page
A/C Compressor Clutch................. 8W-42
A/C Compressor Clutch Relay............ 8W-42
A/C Pressure Sensor................... 8W-42
A/C-Heater Control.................... 8W-42
Accelerator Pedal Position Sensor......... 8W-30
Accessory Relay....................... 8W-10
Adjustable Pedals Module............... 8W-30
Adjustable Pedals Motor................ 8W-30
Adjustable Pedals Relay................ 8W-30
Adjustable Pedals Sensor............... 8W-30
Adjustable Pedals Switch............... 8W-30
Airbags............................. 8W-43
Airbag Control Module................. 8W-43
Airbag Squibs........................ 8W-43
Ambient Temperature Sensor............ 8W-49
Antenna............................ 8W-47
ATC Remote Sensor.................... 8W-42
Auto Shut Down Relay................. 8W-30
Auto Temp Control.................... 8W-42
Automatic Day/Night Mirror............. 8W-49
B-Pillar Switches...................... 8W-61
Back-Up Lamp Switch.................. 8W-51
Battery............................. 8W-20
Battery Temperature Sensor............. 8W-20
Blend Door Actuators.................. 8W-42
Blower Motors........................ 8W-42
Blower Motor Relays................... 8W-42
Blower Motor Resistor.................. 8W-42
Body Control Module................... 8W-45
Boost Pressure Sensor.................. 8W-30
Brake Fluid Level Switch............... 8W-40
Brake Lamp Switch................. 8W-30, 51
Brake Transmission Shift Interlock
Solenoid........................... 8W-31
Cabin Heater Assist................... 8W-30
Camshaft Position Sensor............... 8W-30
CD Changer......................... 8W-47
Center High Mounted Stop Lamp......... 8W-51
Cinch/Release Motors.................. 8W-61
Clockspring................. 8W-33, 41, 43, 47
Clutch Pedal Interlock Switch......... 8W-10, 30
Clutch Pedal Upstop Switch............. 8W-30
Controller Antilock Brake............... 8W-35
Crank Case Ventilation Heater........... 8W-30
Crankshaft Position Sensor.............. 8W-30
Cylinder Lock Switches................. 8W-39
Data Link Connector................... 8W-18
Defogger Relay....................... 8W-48
Door Ajar Switches.................... 8W-39
Door Courtesy Lamps.................. 8W-44
Door Lock Switches.................... 8W-61
Dosing Pump......................... 8W-30Component Page
DVD Screen.......................... 8W-47
DVD/CD Changer..................... 8W-47
ECM/PCM Relay...................... 8W-30
EGR Solenoid........................ 8W-30
Electronic Control Unit................. 8W-64
Engine Control Module................. 8W-30
Engine Coolant Temp Sensor............. 8W-30
Engine Oil Pressure Sensor.............. 8W-30
Engine Oil Pressure Switch.............. 8W-30
EVAP/Purge Solenoid.................. 8W-30
Evaporator Temperature Sensor.......... 8W-42
Floor Console Lamp................... 8W-44
Floor Console Power Outlet.............. 8W-41
Fog Lamps.......................... 8W-50
Folding Mirror Relay................... 8W-62
Front Blower Module.................. 8W-42
Front Cigar Lighter.................... 8W-41
Front Control Module.................. 8W-10
Front Fog Lamp Relay................. 8W-50
Front Reading Lamps/Switch............ 8W-44
Front Wiper High/Low Relay............. 8W-53
Front Wiper On/Off Relay............... 8W-53
Fuel Heater.......................... 8W-30
Fuel Heater Relay..................... 8W-30
Fuel Injectors........................ 8W-30
Fuel Pressure Sensor.................. 8W-30
Fuel Pressure Solenoid................. 8W-30
Fuel Pump Module.................... 8W-30
Fuel Pump Relay...................... 8W-30
Full Open Switches.................... 8W-61
Fuselink............................ 8W-10
Fuses............................... 8W-10
Generator........................... 8W-20
Glow Plug Relay...................... 8W-30
Glow Plugs.......................... 8W-30
Grounds............................ 8W-15
Headlamp Leveling Motors.............. 8W-50
Headlamp Switch..................... 8W-50
Headlamp Washer Pump Motor.......... 8W-53
Headlamp Washer Relay................ 8W-53
Headlamps.......................... 8W-50
Heated Seat Backs.................... 8W-63
Heated Seat Cushions.................. 8W-63
Heated Seat Modules.................. 8W-63
High Beam Lamps..................... 8W-50
High Note Horn....................... 8W-41
Hood Ajar Switch..................... 8W-39
Horn Relay.......................... 8W-41
Horn Switch......................... 8W-41
Idle Air Control Motor.................. 8W-30
Ignition Coil......................... 8W-30
Ignition Switch....................... 8W-10
RS8W-02 COMPONENT INDEX8W-02-1

8W-30 FUEL/IGNITION SYSTEM
Component Page
A/C Compressor Clutch.............. 8W-30-24
A/C Compressor Clutch Relay........ 8W-30-4, 24
A/C Pressure Sensor........... 8W-30-14, 19, 31
Accelerator Pedal Position Sensor...... 8W-30-38
Adjustable Pedals Module............ 8W-30-23
Adjustable Pedals Motor.............. 8W-30-23
Adjustable Pedals Relay.............. 8W-30-22
Adjustable Pedals Sensor............. 8W-30-23
Adjustable Pedals Switch............. 8W-30-22
Ambient Temperature Sensor........... 8W-30-8
Auto Shut Down Relay.... 8W-30-4, 12, 15, 17, 20
Battery........... 8W-30-2, 6, 10, 16, 21, 24, 32
Battery Temperature Sensor......... 8W-30-8, 31
Body Control Module.............. 8W-30-5, 25
Boost Pressure Sensor............... 8W-30-31
Brake Lamp Switch............ 8W-30-7, 27, 37
Cabin Heater Assist................. 8W-30-28
Camshaft Position Sensor........... 8W-30-8, 30
Clockspring................... 8W-30-5, 29, 36
Clutch Pedal Interlock Switch.......... 8W-30-4
Clutch Pedal Upstop Switch........... 8W-30-36
Crank Case Ventilation Heater......... 8W-30-25
Crankshaft Position Sensor...... 8W-30-13, 18, 30
Data Link Connector.............. 8W-30-3, 28
Dosing Pump...................... 8W-30-28
ECM/PCM Relay........ 8W-30-24, 26, 30, 32, 34
EGR Solenoid................... 8W-30-16, 34
Engine Control Module . . . 8W-30-24, 25, 26, 27, 28,
29, 30, 31, 32, 33, 34, 35, 36, 37, 38
Engine Coolant Temp Sensor.... 8W-30-14, 19, 31
Engine Oil Pressure Sensor........... 8W-30-27
Engine Oil Pressure Switch............ 8W-30-7
EVAP/Purge Solenoid................. 8W-30-4
Front Control Module...... 8W-30-2, 5, 22, 28, 36
Fuel Heater....................... 8W-30-35
Fuel Heater Relay................ 8W-30-25, 35
Fuel Injector No. 1............ 8W-30-15, 20, 33
Fuel Injector No. 2............ 8W-30-15, 20, 33
Fuel Injector No. 3............ 8W-30-15, 20, 33
Fuel Injector No. 4............ 8W-30-15, 20, 33
Fuel Injector No. 5.................. 8W-30-20
Fuel Injector No. 6.................. 8W-30-20
Fuel Pressure Sensor................ 8W-30-37
Fuel Pressure Solenoid............... 8W-30-26
Fuel Pump Module................ 8W-30-5, 25
Fuel Pump Relay.................... 8W-30-5
Fuse 14........................... 8W-30-22
Fuse 15..................... 8W-30-21, 28, 35
Fuse 16 . . 8W-30-4, 12, 15, 17, 20, 24, 26, 30, 32, 34
Fuse 17.................... 8W-30-2, 5, 25, 35
Fuse 18........................ 8W-30-22, 24
Fuse 26........................... 8W-30-37Component Page
Fuselink.......................... 8W-30-32
G100................... 8W-30-2, 6, 16, 21, 25
G101.............. 8W-30-2, 6, 7, 10, 16, 21, 24
G103....................... 8W-30-24, 25, 28
G200............................. 8W-30-22
G300................... 8W-30-4, 7, 23, 27, 36
G302........................ 8W-30-5, 25, 35
Generator....................... 8W-30-4, 25
Glow Plug No. 1.................... 8W-30-32
Glow Plug No. 2.................... 8W-30-32
Glow Plug No. 3.................... 8W-30-32
Glow Plug No. 4.................... 8W-30-32
Glow Plug Relay.................... 8W-30-32
Idle Air Control Motor................ 8W-30-9
Ignition Coil.................... 8W-30-12, 17
Ignition Switch..................... 8W-30-10
Inlet Air Temperature Sensor....... 8W-30-13, 18
Input Speed Sensor................. 8W-30-21
Integrated Power Module . . 8W-30-2, 3, 4, 5, 10, 12,
15, 17, 20, 21, 22, 24, 25,
26, 28, 30, 32, 34, 35, 36, 37
Knock Sensor....................... 8W-30-9
Left Speed Control Switch.......... 8W-30-5, 29
Lift Pump Motor.................... 8W-30-35
Lift Pump Relay.................... 8W-30-35
Manifold Absolute Pressure Sensor . . . 8W-30-14, 19
Mass Air Flow Sensor................ 8W-30-26
Memory Seat/Mirror Module.......... 8W-30-22
Natural Vacuum Leak Detection
Assembly....................... 8W-30-10
Output Speed Sensor................ 8W-30-21
Oxygen Sensor 1/1 Upstream........... 8W-30-6
Oxygen Sensor 1/2 Downstream......... 8W-30-6
Powertrain Control Module . . 8W-30-2, 3, 4, 5, 6, 7,
8, 9, 10, 11, 12, 13, 14, 15,
16, 17, 18, 19, 20, 21
Radiator Fan Relay............... 8W-30-12, 17
Radiator Fan Relay No. 1............. 8W-30-37
Radiator Fan Relay No. 2............. 8W-30-37
Radiator Fan Relay No. 3............. 8W-30-37
Right Speed Control Switch......... 8W-30-5, 29
Speed Control Servo.................. 8W-30-7
Starter Motor Relay............... 8W-30-5, 25
Throttle Position Sensor........... 8W-30-13, 18
Transmission Control Relay........... 8W-30-21
Transmission Range Sensor........... 8W-30-11
Transmission Solenoid/Pressure Switch
Assembly..................... 8W-30-11, 21
Vehicle Speed Sensor.............. 8W-30-9, 34
Water In Fuel Sensor................ 8W-30-36
RS8W-30 FUEL/IGNITION SYSTEM8W-30-1

8W-40 INSTRUMENT CLUSTER
Component Page
Airbag Control Module................ 8W-40-2
Body Control Module......... 8W-40-2, 3, 4, 5, 6,
7, 8, 9, 11, 12
Brake Fluid Level Switch.............. 8W-40-9
Clockspring........................ 8W-40-10
Controller Antilock Brake.......... 8W-40-10, 14
Engine Control Module.......... 8W-40-8, 10, 14
Engine Coolant Temp Sensor......... 8W-40-7, 8
Engine Oil Pressure Sensor........... 8W-40-14
Engine Oil Pressure Switch........... 8W-40-14
Front Control Module........ 8W-40-9, 10, 13, 14
Fuel Pump Module................... 8W-40-2
Fuse 24............................ 8W-40-2
G200..................... 8W-40-2, 11, 12, 13
G300.............................. 8W-40-9
Instrument Cluster........ 8W-40-2, 3, 4, 5, 6, 7,
8, 9, 11, 12, 13
Integrated Power Module........ 8W-40-2, 7, 8, 9,
10, 13, 14
Left Front Door Ajar Switch............ 8W-40-3
Left Front Door Lock Motor/Ajar Switch . . 8W-40-3Component Page
Left Sliding Door Control Module........ 8W-40-4
Left Sliding Door Latch Sensing Switch . . . 8W-40-4
Left Sliding Door Lock Motor/Ajar Switch . 8W-40-4
Left Speed Control Switch............ 8W-40-10
Liftgate Ajar Switch.................. 8W-40-3
Liftgate Cinch/Release Motor........... 8W-40-3
Message Center.................. 8W-40-6, 13
Multi-Function Switch................ 8W-40-6
Parking Brake Switch............. 8W-40-11, 12
Powertrain Control Module....... 8W-40-7, 10, 14
Right Front Door Ajar Switch........... 8W-40-3
Right Front Door Lock Motor/Ajar
Switch.......................... 8W-40-3
Right Sliding Door Control Module...... 8W-40-5
Right Sliding Door Latch Sensing Switch . . 8W-40-5
Right Sliding Door Lock Motor/Ajar
Switch.......................... 8W-40-5
Right Speed Control Switch........... 8W-40-10
Traction Control Switch............. 8W-40-7, 8
Vehicle Speed Sensor............... 8W-40-7, 8
Washer Fluid Level Switch............. 8W-40-9
RS8W-40 INSTRUMENT CLUSTER8W-40-1

Component Page
C310 (Front Console)................ 8W-80-42
C310 (Front Console)................ 8W-80-42
C311 (3 Zone HVAC)................. 8W-80-42
C311 (3 Zone HVAC)................. 8W-80-43
C312............................. 8W-80-43
C312............................. 8W-80-44
C313 (Rear Console)................. 8W-80-44
C313 (Rear Console)................. 8W-80-44
C314............................. 8W-80-45
C314............................. 8W-80-45
C315 (Power Liftgate)................ 8W-80-46
C315 (Power Liftgate)................ 8W-80-46
C316 (Power Sliding Door)............ 8W-80-46
C316 (Power Sliding Door)............ 8W-80-47
C317 (Power Sliding Door)............ 8W-80-47
C317 (Power Sliding Door)............ 8W-80-47
C318 (Trailer Tow).................. 8W-80-48
C318 (Trailer Tow).................. 8W-80-48
C319 (Trailer Tow).................. 8W-80-48
C319 (Trailer Tow).................. 8W-80-48
C320............................. 8W-80-49
C320............................. 8W-80-49
C321............................. 8W-80-49
C321............................. 8W-80-49
C322 (Memory)..................... 8W-80-49
C322 (Memory)..................... 8W-80-50
C324 (Manual Sliding Door)........... 8W-80-50
C324 (Manual Sliding Door)........... 8W-80-51
C325 (Manual Sliding Door)........... 8W-80-51
C325 (Manual Sliding Door)........... 8W-80-51
C326............................. 8W-80-51
C326............................. 8W-80-52
C327............................. 8W-80-52
C327............................. 8W-80-52
C328 (Sunroof)..................... 8W-80-52
C328 (Sunroof)..................... 8W-80-52
C329 (Diesel)...................... 8W-80-53
C329 (Diesel)...................... 8W-80-53
C330 (Diesel)...................... 8W-80-53
C330 (Diesel)...................... 8W-80-53
C331 (Diesel)...................... 8W-80-54
C331 (Diesel)...................... 8W-80-54
C332 (3 Zone ATC).................. 8W-80-54
C332 (3 Zone ATC).................. 8W-80-54
C333 (Except Export)................ 8W-80-55
C333 (Except Export)................ 8W-80-55
Cabin Heater Assist C1 (Diesel)........ 8W-80-55
Cabin Heater Assist C2 (Diesel)........ 8W-80-55
Camshaft Position Sensor (Diesel)...... 8W-80-56
Camshaft Position Sensor (Gas)........ 8W-80-56
CD Changer....................... 8W-80-56
Center High Mounted Stop Lamp....... 8W-80-56
Clockspring C1..................... 8W-80-57
Clockspring C2..................... 8W-80-57Component Page
Clockspring C3..................... 8W-80-57
Clockspring C4..................... 8W-80-57
Clutch Pedal Interlock Switch (MTX).... 8W-80-57
Clutch Pedal Upstop Switch (Diesel).... 8W-80-58
Controller Antilock Brake............. 8W-80-58
Crank Case Ventilation Heater (Diesel) . . 8W-80-59
Crankshaft Position Sensor (Diesel)..... 8W-80-59
Crankshaft Position Sensor (Gas)....... 8W-80-59
Data Link Connector................ 8W-80-59
Dosing Pump (Diesel)................ 8W-80-60
Driver Airbag Squib 1................ 8W-80-60
Driver Airbag Squib 2................ 8W-80-60
Driver Blend Door Actuator........... 8W-80-60
Driver Door Courtesy Lamp........... 8W-80-61
Driver Door Lock Switch............. 8W-80-61
Driver Heated Seat Back............. 8W-80-61
Driver Heated Seat Cushion........... 8W-80-61
Driver Heated Seat Module C1......... 8W-80-61
Driver Heated Seat Module C2......... 8W-80-62
Driver Heated Seat Module C3......... 8W-80-62
Driver Power Seat Front Riser Motor.... 8W-80-62
Driver Power Seat Front Riser Position
Sensor......................... 8W-80-62
Driver Power Seat Horizontal Motor.... 8W-80-63
Driver Power Seat Horizontal Position
Sensor......................... 8W-80-63
Driver Power Seat Rear Riser Motor.... 8W-80-63
Driver Power Seat Rear Riser Position
Sensor......................... 8W-80-63
Driver Power Seat Recliner Motor...... 8W-80-63
Driver Power Seat Recliner Position
Sensor......................... 8W-80-64
Driver Power Seat Switch............ 8W-80-64
Driver Power Window Motor.......... 8W-80-64
Driver Power Window Switch (LHD Except
Lowline)........................ 8W-80-65
Driver Power Window Switch (LHD
Lowline)........................ 8W-80-65
Driver Power Window Switch (RHD).... 8W-80-65
Driver Seat Belt Switch.............. 8W-80-66
Driver Seat Belt Tensioner............ 8W-80-66
DVD Screen....................... 8W-80-66
DVD/CD Changer C1................ 8W-80-66
DVD/CD Changer C2................ 8W-80-67
DVD/CD Changer C3................ 8W-80-67
EGR Solenoid (3.3L)................. 8W-80-67
EGR Solenoid (Diesel)............... 8W-80-68
Engine Control Module C1 (Diesel)..... 8W-80-68
Engine Control Module C2 (Diesel)..... 8W-80-70
Engine Coolant Temp Sensor (Diesel).... 8W-80-71
Engine Coolant Temp Sensor (Gas)..... 8W-80-71
Engine Oil Pressure Sensor (Diesel)..... 8W-80-71
Engine Oil Pressure Switch (Gas)...... 8W-80-71
EVAP/Purge Solenoid (Gas)........... 8W-80-72
Evaporator Temperature Sensor........ 8W-80-72
8W - 80 - 2 8W-80 CONNECTOR PIN-OUTSRS

EGR SOLENOID (DIESEL) - LT. GRAY 2 WAY
CAV CIRCUIT FUNCTION
1 K35 20GY/YL EGR SOLENOID CONTROL
2 K342 16BR/WT ECM/PCM RELAY OUTPUT
ENGINE CONTROL MODULE C1 (DIESEL) - BLACK 81 WAY
CAV CIRCUIT FUNCTION
1 Z130 14BK/BR GROUND
2 Z131 14BK/DG GROUND
3 K20 14BR/GY GENERATOR FIELD CONTROL
4 K342 14BR/WT ECM/PCM RELAY OUTPUT
5 K342 14BR/WT ECM/PCM RELAY OUTPUT
6- -
7 D25 20WT/VT PCI BUS
8 K944 20BK/GY CAMSHAFT POSITION SENSOR SHIELD GROUND
9 K44 20DB/GY CAMSHAFT POSITION SENSOR SIGNAL
10 - -
11 K37 20DB/YL BOOST PRESSURE SENSOR SIGNAL
12 K55 20DB/OR MASS AIR FLOW SENSOR SIGNAL
13 K78 20GY FUEL PRESSURE SENSOR SIGNAL
14 - -
15 K22 20OR/DB ACCELERATOR PEDAL POSITION SENSOR SIGNAL
16 K80 20DB/TN FUEL PRESSURE SENSOR GROUND
17 - -
18 - -
19 K342 20BR/WT ECM/PCM RELAY OUTPUT
20 Z138 20BK/OR GROUND
21 K900 20DB/DG SENSOR GROUND
22 F202 20PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START)
23 F851 20LB/PK SENSOR REFERENCE VOLTAGE B
24 K3 20BR/OR CRANKSHAFT POSITION SENSOR SIGNAL NO. 1
25 - -
26 - -
27 - -
28 - -
29 - -
30 G6 20VT/GY ENGINE OIL PRESSURE SENSOR SIGNAL
31 F853 20LG/PK WATER IN FUEL SENSOR SIGNAL
32 K25 20BR/TN BATTERY TEMPERATURE SENSOR SIGNAL
33 - -
34 K4 20BK/LB LOW IDLE POSITION SWITCH GROUND
35 F852 20VT/PK ACCELERATOR PEDAL POSITION SENSOR 5 VOLT
SUPPLY
36 C18 20LB/BR A/C PRESSURE SENSOR SIGNAL
37 - -
38 V37 20VT/TN SPEED CONTROL SWITCH SIGNAL
39 - -
40 K2 20TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
41 K21 20DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL
42 Z122 18WT GROUND (DRAIN)
43 K24 20BR/LB CRANKSHAFT POSITION SENSOR SIGNAL NO. 2
8W - 80 - 68 8W-80 CONNECTOR PIN-OUTSRS

ENGINE COOLANT TEMP SENSOR (DIESEL) - BLUE 2 WAY
CAV CIRCUIT FUNCTION
1 K2 20TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
2 K900 20DB/DG SENSOR GROUND
ENGINE COOLANT TEMP SENSOR (GAS) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 K900 18DB/DG SENSOR GROUND
2 K2 18VT/OR ECT SIGNAL
ENGINE OIL PRESSURE SENSOR (DIESEL) - BLACK 3 WAY
CAV CIRCUIT FUNCTION
1 F855 20PK/YL SENSOR REFERENCE VOLTAGE A
2 G6 20VT/GY ENGINE OIL PRESSURE SENSOR SIGNAL
3 K936 20BR/YL ENGINE OIL PRESSURE SENSOR GROUND
ENGINE OIL PRESSURE SWITCH (GAS) - LT. GREEN 2 WAY
CAV CIRCUIT FUNCTION
1 G6 16VT/GY OIL PRESSURE SIGNAL
2- -
RS8W-80 CONNECTOR PIN-OUTS8W-80-71

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Engine Control Module C2
(Diesel)BK Right Side of Engine N/S
Engine Coolant Temp Sensor
(Gas)BK On Cylinder Block N/S
Engine Coolant Temp Sensor
(Diesel)BL On Cylinder Block 15
Engine Oil Pressure Sensor
(Diesel)BK Rear of Engine 16
Engine Oil Pressure Switch (Gas) LTGN On Cylinder Block 12, 18
EVAP/Purge Solenoid (Gas) BK Right Motor Mount 10, 17
Evaporator Temperature Sensor BK Right Side of HVAC N/S
Floor Console Lamp BK At Lamp N/S
Floor Console Power Outlet RD At Front Console N/S
Front Blower Module C1 (ATC) BK On HVAC N/S
Front Blower Module C2 (ATC) BK On HVAC N/S
Front Cigar Lighter RD/NAT Rear of Lighter 20, 23, 25
Front Control Module BK In Integrated Power Module N/S
Front Intrusion Sensor (United
Kingdom)BK At Sensor N/S
Front Reading Lamps/Switch BK At Switch N/S
Fuel Heater (Diesel) BK Left Rear Engine Compartment N/S
Fuel Injector No.1 BK At Fuel Injector N/S
Fuel Injector No.1 (Diesel) BK At Fuel Injector 15
Fuel Injector No.2 BK At Fuel Injector N/S
Fuel Injector No.2 (Diesel) BK At Fuel Injector 15
Fuel Injector No.3 BK At Fuel Injector N/S
Fuel Injector No.3 (Diesel) BK At Fuel Injector 15
Fuel Injector No.4 BK At Fuel Injector N/S
Fuel Injector No.4 (Diesel) BK At Fuel Injector 15
Fuel Injector No.5 BK At Fuel Injector N/S
Fuel Injector No.6 BK At Fuel Injector N/S
Fuel Pressure Sensor (Diesel) BK Top Left of Engine 15
Fuel Pressure Solenoid (Diesel) Right Front Engine 15
Fuel Pump Module LTGY Side of Fuel Tank 34
Generator BK Rear of Generator 11, 15, 17, 18
Glow Plug Relay (Diesel) BK Near Transmission 15, 16
Headlamp Switch BK Rear of Switch 20, 21, 30
Headlamp Washer Pump Motor
(Export)BK At Motor 3
High Note Horn BK Left Frame Rail 5
High Pressure Fuel Pump
(Diesel)Rear of Pump 15
Hood Ajar Switch (Export) BK Left Fender 6
Idle Air Control Motor (Gas) BK On Throttle Body 10, 11 17
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-5
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

(3) Remove torque converter or clutch housing
cover and inspect rear of block for evidence of oil.
Use a black light to check for the oil leak. If a leak is
present in this area, remove transmission for further
inspection.
(a) Circular spray pattern generally indicates
seal leakage or crankshaft damage.
(b) Where leakage tends to run straight down,
possible causes are a porous block, oil gallery cup
plug, bedplate to cylinder block mating surfaces
and seal bore. See proper repair procedures for
these items.
(4) If no leaks are detected, pressurize the crank-
case as previously described.
CAUTION: Do not exceed 20.6 kPa (3 psi).
(5) If the leak is not detected, very slowly turn the
crankshaft and watch for leakage. If a leak is
detected between the crankshaft and seal while
slowly turning the crankshaft, it is possible the
crankshaft seal surface is damaged. The seal area on
the crankshaft could have minor nicks or scratches
that can be polished out with emery cloth.
CAUTION: Use extreme caution when crankshaft
polishing is necessary to remove minor nicks and
scratches. The crankshaft seal flange is especially
machined to complement the function of the rear oil
seal.
(6) For bubbles that remain steady with shaft
rotation, no further inspection can be done until dis-
assembled.
(7) After the oil leak root cause and appropriate
corrective action have been identified, replace compo-
nent(s) as necessary.
DIAGNOSIS AND TESTING - CYLINDER
COMPRESSION PRESSURE TEST
The results of a cylinder compression pressure test
can be utilized to diagnose several engine malfunc-
tions.
Ensure the battery is completely charged and the
engine starter motor is in good operating condition.
Otherwise the indicated compression pressures may
not be valid for diagnosis purposes.
(1) Check engine oil level and add oil if necessary.
(2) Drive the vehicle until engine reaches normal
operating temperature. Select a route free from traf-
fic and other forms of congestion, observe all traffic
laws, and accelerate through the gears several times
briskly.
(3) Remove all spark plugs from engine. As spark
plugs are being removed, check electrodes for abnor-
mal firing indicators fouled, hot, oily, etc. Record cyl-
inder number of spark plug for future reference.(4) Remove the Auto Shutdown (ASD) relay from
the PDC.
(5) Be sure throttle blade is fully open during the
compression check.
(6) Insert compression gauge adaptor Special Tool
8116 or the equivalent, into the #1 spark plug hole in
cylinder head. Connect the 0±500 psi (Blue) pressure
transducer (Special Tool CH7059) with cable adap-
tors to the DRBIIIt. For Special Tool identification,
(Refer to 9 - ENGINE - SPECIAL TOOLS).
(7) Crank engine until maximum pressure is
reached on gauge. Record this pressure as #1 cylin-
der pressure.
(8) Repeat the previous step for all remaining cyl-
inders.
(9) Compression should not be less than 689 kPa
(100 psi) and not vary more than 25 percent from cyl-
inder to cylinder.
(10) If one or more cylinders have abnormally low
compression pressures, repeat the compression test.
(11) If the same cylinder or cylinders repeat an
abnormally low reading on the second compression
test, it could indicate the existence of a problem in
the cylinder in question.The recommended com-
pression pressures are to be used only as a
guide to diagnosing engine problems. An engine
should not be disassembled to determine the
cause of low compression unless some malfunc-
tion is present.
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE TEST
The combustion pressure leakage test provides an
accurate means for determining engine condition.
Combustion pressure leakage testing will detect:
²Exhaust and intake valve leaks (improper seat-
ing).
²Leaks between adjacent cylinders or into water
jacket.
²Any causes for combustion/compression pressure
loss.
WARNING: DO NOT REMOVE THE PRESSURE CAP
WITH THE SYSTEM HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM COOLANT CAN
OCCUR.
Check the coolant level and fill as required. DO
NOT install the pressure cap.
Start and operate the engine until it attains nor-
mal operating temperature, then turn the engine
OFF.
Clean spark plug recesses with compressed air.
Remove the spark plugs.
Remove the oil filler cap.
Remove the air cleaner.
RSENGINE 2.4L9-9
ENGINE 2.4L (Continued)

Calibrate the tester according to the manufactur-
er's instructions. The shop air source for testing
should maintain 483 kPa (70 psi) minimum, 1,379
kPa (200 psi) maximum, with 552 kPa (80 psi) rec-
ommended.
Perform the test procedures on each cylinder
according to the tester manufacturer's instructions.
While testing, listen for pressurized air escaping
through the throttle body, tailpipe and oil filler cap
opening. Check for bubbles in the coolant.
All gauge pressure indications should be equal,
with no more than 25% leakage per cylinder.
FOR EXAMPLE:At 552 kPa (80 psi) input pres-
sure, a minimum of 414 kPa (60 psi) should be main-
tained in the cylinder.
STANDARD PROCEDURE
STANDARD PROCEDURE - ENGINE CORE AND
OIL GALLERY PLUGS
Using a blunt tool such as a drift and a hammer,
strike the bottom edge of the cup plug. With the cup
plug rotated, grasp firmly with pliers or other suit-
able tool and remove plug (Fig. 2).
CAUTION: Do not drive cup plug into the casting as
restricted cooling can result and cause serious
engine problems.Thoroughly clean inside of cup plug hole in cylin-
der block or head. Be sure to remove old sealer.
Lightly coat inside of cup plug hole with Mopart
Stud and Bearing Mount. Make certain the new plug
is cleaned of all oil or grease. Using proper drive
plug, drive plug into hole so that the sharp edge of
the plug is at least 0.5 mm (0.020 in.) inside the
lead-in chamfer.
It is not necessary to wait for curing of the sealant.
The cooling system can be refilled and the vehicle
placed in service immediately.
STANDARD PROCEDURE - REPAIR OF
DAMAGED OR WORN THREADS
Damaged or worn threads (excluding spark plug
and camshaft bearing cap attaching threads) can be
repaired. Essentially, this repair consists of drilling
out worn or damaged threads, tapping the hole with
a special Heli-Coil Tap, (or equivalent) and installing
an insert into the tapped hole. This brings the hole
back to its original thread size.
CAUTION: Be sure that the tapped holes maintain
the original center line.
Heli-Coil tools and inserts are readily available
from automotive parts jobbers.
STANDARD PROCEDURE - HYDROSTATIC
LOCKED ENGINE
When an engine is suspected to be hydrostatically
locked, regardless of what caused the problem, the
following steps should be used.
CAUTION: DO NOT use starter motor to rotate the
engine, severe damage may occur.
(1) Inspect air cleaner, induction system and
intake manifold to insure system is dry and clear of
foreign material.
(2) Remove negative battery cable.
(3) Place a shop towel around the spark plugs
when removing them from the engine. This will catch
any fluid that may possibly be in the cylinder under
pressure.
(4) With all spark plugs removed, rotate engine
crankshaft using a breaker bar and socket.
(5) Identify the fluid in the cylinder(s) (i.e., cool-
ant, fuel, oil or other).
(6) Make sure all fluid has been removed from the
cylinders. Inspect engine for damage (i.e., connecting
rods, pistons, valves, etc.)
(7) Repair engine or components as necessary to
prevent this problem from re-occurring.
Fig. 2 Core Hole Plug Removal
1 - CYLINDER BLOCK
2 - REMOVE PLUG WITH PLIERS
3 - STRIKE HERE WITH HAMMER
4 - DRIFT PUNCH
5 - CUP PLUG
9 - 10 ENGINE 2.4LRS
ENGINE 2.4L (Continued)

CAUTION: Squirt approximately one teaspoon of oil
into the cylinders, rotate engine to lubricate the cyl-
inder walls to prevent damage on restart.
(8) Install new spark plugs.
(9) Drain engine oil and remove oil filter.
(10) Install a new oil filter.
(11) Fill engine with specified amount of approved
oil.
(12) Connect negative battery cable.
(13) Start engine and check for any leaks.
STANDARD PROCEDURE - FORM-IN-PLACE
GASKETS AND SEALERS
There are numerous places where form-in-place
gaskets are used on the engine. Care must be taken
when applying form-in-place gaskets to assure
obtaining the desired results.Do not use form-in-
place gasket material unless specified.Bead size,
continuity, and location are of great importance. Too
thin a bead can result in leakage while too much can
result in spill-over which can break off and obstruct
fluid feed lines. A continuous bead of the proper
width is essential to obtain a leak-free gasket.
There are numerous types of form-in-place gasket
materials that are used in the engine area. Mopart
Engine RTV GEN II, MopartATF-RTV, and Mopart
Gasket Maker gasket materials, each have different
properties and can not be used in place of the other.
MOPARtENGINE RTV GEN IIis used to seal
components exposed to engine oil. This material is a
specially designed black silicone rubber RTV that
retains adhesion and sealing properties when
exposed to engine oil. Moisture in the air causes the
material to cure. This material is available in three
ounce tubes and has a shelf life of one year. After one
year this material will not properly cure. Always
inspect the package for the expiration date before
use.
MOPARtATF RTVis a specifically designed
black silicone rubber RTV that retains adhesion and
sealing properties to seal components exposed to
automatic transmission fluid, engine coolants, and
moisture. This material is available in three ounce
tubes and has a shelf life of one year. After one year
this material will not properly cure. Always inspect
the package for the expiration date before use.
MOPARtGASKET MAKERis an anaerobic type
gasket material. The material cures in the absence of
air when squeezed between two metallic surfaces. It
will not cure if left in the uncovered tube. The
anaerobic material is for use between two machined
surfaces. Do not use on flexible metal flanges.
MOPARtBED PLATE SEALANTis a unique
(green-in-color) anaerobic type gasket material that
is specially made to seal the area between the bed-plate and cylinder block without disturbing the bear-
ing clearance or alignment of these components. The
material cures slowly in the absence of air when
torqued between two metallic surfaces, and will rap-
idly cure when heat is applied.
MOPARtGASKET SEALANTis a slow drying,
permanently soft sealer. This material is recom-
mended for sealing threaded fittings and gaskets
against leakage of oil and coolant. Can be used on
threaded and machined parts under all tempera-
tures. This material is used on engines with multi-
layer steel (MLS) cylinder head gaskets. This
material also will prevent corrosion. MopartGasket
Sealant is available in a 13 oz. aerosol can or 4oz./16
oz. can w/applicator.
SEALER APPLICATION
MopartGasket Maker material should be applied
sparingly 1 mm (0.040 in.) diameter or less of sealant
to one gasket surface. Be certain the material sur-
rounds each mounting hole. Excess material can eas-
ily be wiped off. Components should be torqued in
place within 15 minutes. The use of a locating dowel
is recommended during assembly to prevent smear-
ing material off the location.
MopartEngine RTV GEN II or ATF RTV gasket
material should be applied in a continuous bead
approximately 3 mm (0.120 in.) in diameter. All
mounting holes must be circled. For corner sealing, a
3.17 or 6.35 mm (1/8 or 1/4 in.) drop is placed in the
center of the gasket contact area. Uncured sealant
may be removed with a shop towel. Components
should be torqued in place while the sealant is still
wet to the touch (within 10 minutes). The usage of a
locating dowel is recommended during assembly to
prevent smearing material off the location.
MopartGasket Sealant in an aerosol can should be
applied using a thin, even coat sprayed completely
over both surfaces to be joined, and both sides of a
gasket. Then proceed with assembly. Material in a
can w/applicator can be brushed on evenly over the
sealing surfaces. Material in an aerosol can should be
used on engines with multi-layer steel gaskets.
STANDARD PROCEDURE - ENGINE GASKET
SURFACE PREPARATION
To ensure engine gasket sealing, proper surface
preparation must be performed, especially with the
use of aluminum engine components and multi-layer
steel cylinder head gaskets.
Neveruse the following to clean gasket surfaces:
²Metal scraper
²Abrasive pad or paper to clean cylinder block
and head
²High speed power tool with an abrasive pad or a
wire brush (Fig. 3)
RSENGINE 2.4L9-11
ENGINE 2.4L (Continued)