CHRYSLER VOYAGER 2005 Service Manual

SPECIFICATIONS - TORQUE
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Front Cradle Crossmember to Fram Rail Attaching Bolts (4) 163 120 Ð
Reinforcement Plate to Crossmember Attaching Bolt Size M14 (9) 153 113 Ð
Reinforcement Plate to Crossmember Attaching Bolt Size M12 (1) 106 78 Ð
Reinforcement Plate to Crossmember Attaching Bolt Size M10 (4) 61 45 Ð
Rear Engine Mount to Crossmember Attaching Through Bolt 68 50 Ð
Radiator Support Crossmember Attaching Bolts 51 38 Ð
FRONT CRADLE
CROSSMEMBER
DESCRIPTION
DESCRIPTION - FRONT CRADLE
CROSSMEMBER
This vehicle uses a one piece cast aluminum cradle
for the front cradle crossmember. The cradle cross-
member is used as the attaching points for the lower
control arms, stabilizer bar and steering gear. The
cradle also has the power steering hoses and the
chassis brake tubes attached to it.
WARNING: If a threaded hole in the suspension cra-
dle needs to be repaired, only use the type of
thread insert and installation procedure specified
for this application.
The threaded holes in the front cradle crossmem-
ber that are used for attachment of the lower control
arm rear bushing retainer, power steering hose and
chassis brake tubes can be repaired. The repair is
done by the installation of a Heli-Coiltthread insert
which has been specifically developed for this appli-
cation. Refer to the Mopar Parts Catalog for the spec-
ified Heli-Coiltthread insert to be used for this
application. The procedure for installing the Heli-
Coiltthread insert is detailed in the Service Proce-
dures section in this group of the service manual.
DESCRIPTION - FRONT CRADLE
CROSSMEMBER THREAD REPAIR
WARNING: When performing this procedure use
only the thread inserts which are specified in the
Mopar Parts Catalog for this repair procedure.
These thread inserts have been specifically devel-
oped for this application and use of other types of
thread inserts can result in an inferior long term
repair.The threaded holes in the front cradle crossmem-
ber, if damaged, can repaired by installing a Heli-
Coiltthread insert.
The threaded holes that are repairable using the
thread insert, are the lower control arm rear bushing
retainer mounting bolt holes, routing bracket attach-
ing locations for the power steering hoses, and brake
hose attachment holes.
This repair procedure now allows the threaded
holes in the cradle crossmember to be repaired, elim-
inating the need to replace the cradle crossmember if
damage occurs to one of the threaded holes.
The thread inserts for this application are specified
by part number in the Mopar Parts Catalog.Do not
use a substitute thread insert.
The specific tools and equipment required to install
the thread insert are listed below. Refer to the
instructions included with the thread insert for the
detailed procedure used for the installation of the
thread insert.
NOTE: The thread inserts for this application are for
the repair of M8x1.25 and M10x1.5 threads. Be sure
the correct tools are used for the required thread
insert size.
TOOL REQUIREMENT FOR M8x1.25 Thread
²8.3mm (5/16 in.) Drill Bit
²120É Countersink
²Heli-CoiltTap #4863-8
²Heli-CoiltGage #4624-8
²Heli-CoiltHand Inserting Tool 7751-8
²Needle Nose Pliers ± For Removal Of Thread
Insert Driving Tang
TOOL REQUIREMENT FOR M10x1.5 Thread
²10.5mm (25/64 in.) Drill Bit
²120É Countersink
²Heli-CoiltTap #4863-10
²Heli-CoiltGage #4624-10
²Heli-CoiltHand Inserting Tool 7751-10
²Needle Nose Pliers ± For Removal Of Thread
Insert Driving Tang
13 - 14 FRAME & BUMPERSRS
FRAME (Continued)

REMOVAL
The front cradle crossmember must be installed in
the design location to achieve proper front end sus-
pension alignment. If the cradle crossmember is
removed without applying reference marks on the
frame rails, align the cradle crossmember according
to the dimensions provided in this group.
NOTE: If the caged nuts in the frame rails become
damaged and cannot be reused, a replacement nut
can be obtained through MoparT(Fig. 14).
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove steering column lower cover from
instrument panel (Refer to 23 - BODY/INSTRU-
MENT PANEL/STEERING COLUMN OPENING
COVER - REMOVAL).
(3) Remove steering column cover backing plate
(Refer to 23 - BODY/INSTRUMENT PANEL/STEER-
ING COLUMN COVER BACKING PLATE -
REMOVAL).
(4) Position steering so front wheels are straight
ahead.
CAUTION: Do not rotate steering wheel after disen-
gaging lower coupling from steering gear, damage
to air bag clock spring can result.
(5) Remove clinch bolt attaching steering column
coupling to steering gear shaft (Fig. 15).
(6) Remove steering column coupling from tele-
scoping steering gear shaft.(7) Hoist vehicle and support on safety stands.
(8) Position a drain pan under power steering
pump and oil return hose coupling.
(9) Using a hose pinch-off pliers (C-4390), pinch
power steering oil return hose off between the cross-
member coupling and the pump.
(10) Loosen hose clamp at the cradle crossmember
coupling.
(11) Disconnect return hose from metal tube.
(12) While holding pressure relief valve nut on
back of power steering pump, Remove flare nut
attaching high pressure hose to back of pump.
(13) Remove high pressure hose from pump.
(14) Allow power steering fluid to drain into pan.
(15) Remove bolts attaching anti-lock brake sensor
leads to cradle crossmember.
(16) Position anti-lock brake leads out of the way.
(17) Disconnect stabilizer bar links from ends of
stabilizer bar.
(18) Disconnect lower ball joints from lower steer-
ing knuckles (Refer to 2 - SUSPENSION/FRONT/
LOWER BALL JOINT - REMOVAL).
(19) Remove the rear engine mount heat shield
(Fig. 16).
(20) Remove through bolt attaching rear engine
mount to cradle crossmember (Fig. 17).
(21) Using paint or grease pencil, mark outline of
cradle crossmember on frame rails to aid installation.
(22) Support cradle crossmember on suitable lift-
ing device (Fig. 19).
(23) Remove bolts attaching crossmember to front
frame rails (Fig. 18).
(24) Remove cradle crossmember from vehicle (Fig.
19).
Fig. 14 FRONT CRADLE CROSSMEMBER CAGED
NUT
1 - BRACKET
2 - CAGED NUT
Fig. 15 STEERING COUPLING
1 - STEERING SHAFT BOOT
2 - STEERING SHAFT
3 - CROSSMEMBER
4 - STEERING GEAR
5 - MOUNT
6 - TRANSAXLE
RSFRAME & BUMPERS13-15
FRONT CRADLE CROSSMEMBER (Continued)

INSTALLATION
NOTE: If cradle crossmember requires replacement.
Refer to Group 2, Suspension, to transfer suspen-
sion components and Group 19, Steering, to trans-
fer steering components.
(1) Support crossmember on suitable lifting device
(Fig. 19).
(2) Position crossmember to vehicle.
(3) Loosely install bolts attaching cradle cross-
member to front frame rails.(4) Place upper half of bushing on top of cross-
member aligned to receive square tube protruding
upward from lower bushing half.
(5) Align crossmember to previously made marks
on frame rails.
(6) Tighten bolts attaching cradle crossmember to
frame rails.
(7) Install through bolt attaching rear engine
mount to cradle crossmember (Fig. 17) and tighten to
68 N´m (50 ft. lbs.) torque.
(8) Install the rear mount heat shield (Fig. 16).
(9) Connect lower ball joints to steering knuckles
(Refer to 2 - SUSPENSION/FRONT/LOWER BALL
JOINT - INSTALLATION)
(10) Connect stabilizer bar links to ends of stabi-
lizer bar.
(11) Install bolts attaching anti-lock brake sensor
leads to cradle crossmember.
(12) Install high pressure hose to pump.
(13) Connect return hose to metal tube.
(14) Tighten hose clamp at the cradle crossmember
coupling.
(15) Remove pinch-off pliers.
(16) Position steering so front wheels are straight
ahead.
(17) Install steering column coupling to telescoping
steering gear shaft.
(18) Install clinch bolt attaching steering column
coupling to steering gear shaft.
(19) Install steering column cover backing plate
(Refer to 23 - BODY/INSTRUMENT PANEL/STEER-
ING COLUMN COVER BACKING PLATE -
INSTALLATION)
Fig. 16 REAR MOUNT HEAT SHIELD
1 - BOLT
2 - HEAT SHIELD
3 - CLIP
4 - REAR ENGINE MOUNT
Fig. 17 REAR MOUNT
1 - BOLT
2 - REAR MOUNT BRACKET
3 - THROUGH BOLT
4 - REAR MOUNT
Fig. 18 CRADLE CROSSMEMBER MOUNT
1 - CROSSMEMBER MOUNT
2 - BRAKE HOSE MOUNT
3 - STEERING TIE ROD
4 - FRONT CROSSMEMBER
5 - FRAME RAIL
13 - 16 FRAME & BUMPERSRS
FRONT CRADLE CROSSMEMBER (Continued)

(20) Install steering column lower cover from
instrument panel (Refer to 23 - BODY/INSTRU-
MENT PANEL/STEERING COLUMN OPENING
COVER - INSTALLATION).
(21) Connect battery negative cable.
FRONT CROSSMEMBER
MOUNT BUSHINGS
REMOVAL
(1) Using paint or grease pencil, mark outline of
cradle crossmember on frame rails.
(2) Loosen bolts attaching crossmember to frame
rails.
(3) Remove bolt on bushing that requires replace-
ment.
(4) Allow cradle crossmember to drop down enough
to gain clearance for bushing removal.
(5) Remove bushing from vehicle.
INSTALLATION
(1) Apply rubber lubrication or soap to replace-
ment bushing.
(2) Insert lower half of bushing into square hole in
cradle crossmember.
(3) Place upper half of bushing on top of cross-
member aligned to receive square tube protruding
upward from lower bushing half.
(4) Squeeze bushing halves together to ensure they
are properly mated.
(5) Lift cradle crossmember upward to close gap
between the bushing and frame.
(6) Verify that lower bushing is fully seated into
cradle crossmember and upper bushing.
(7) Install bolt attaching bushing and crossmember
to frame rail hand tight.
(8) Align cradle crossmember to reference marks
on frame rails.
(9) Tighten cradle crossmember to frame rails
attaching bolts to 163 N´m (120 ft. lbs.) torque.
Fig. 19 CRADLE CROSSMEMBER
1 - ENGINE OIL PAN
2 - TRANSAXLE
3 - LOWER CONTROL ARM4 - FRONT CROSSMEMBER
5 - LIFT DEVICE
6 - SPINDLE
RSFRAME & BUMPERS13-17
FRONT CRADLE CROSSMEMBER (Continued)

FUEL SYSTEM
TABLE OF CONTENTS
page page
FUEL DELIVERY..........................1FUEL INJECTION........................21
FUEL DELIVERY
TABLE OF CONTENTS
page page
FUEL DELIVERY
DESCRIPTION
DESCRIPTION........................2
DESCRIPTION - FFV REPLACEMENT
PARTS...............................2
OPERATION............................2
DIAGNOSIS AND TESTING - FUEL DELIVERY
SYSTEM.............................2
STANDARD PROCEDURE
STANDARD PROCEDURE - FUEL SYSTEM
PRESSURE RELEASE PROCEDURE.......2
STANDARD PROCEDURE - DRAINING
FUEL TANK...........................2
STANDARD PROCEDURE - FUEL
PRESSURE GAUGE....................3
SPECIFICATIONS
FUEL SYSTEM PRESSURE..............4
TORQUE.............................4
SPECIAL TOOLS
FUEL................................4
FUEL LEVEL SENDING UNIT / SENSOR
DESCRIPTION..........................5
OPERATION............................5
REMOVAL.............................5
INSTALLATION..........................6
FUEL LINES
DESCRIPTION - FUEL LINES/HOSES AND
CLAMPS.............................7
STANDARD PROCEDURE - HOSES AND
CLAMP..............................7
FUEL PRESSURE REGULATOR
OPERATION............................7
REMOVAL.............................7
INSTALLATION..........................7
FUEL PUMP
DESCRIPTION..........................8OPERATION............................8
FUEL PUMP MODULE
DESCRIPTION..........................8
OPERATION............................9
REMOVAL
REMOVAL............................9
REMOVAL - FOLD-IN-FLOOR............10
INSTALLATION
INSTALLATION.......................10
INSTALLATION - FOLD-IN-FLOOR.........10
FUEL RAIL
REMOVAL
REMOVAL - 2.4L......................11
REMOVAL - 3.3/3.8L...................11
INSTALLATION
INSTALLATION - 2.4L..................11
INSTALLATION - 3.3/3.8L................12
FUEL TANK
DESCRIPTION.........................12
OPERATION...........................12
REMOVAL
REMOVAL...........................12
REMOVAL - FOLD-IN-FLOOR............13
INSTALLATION
INSTALLATION.......................15
INSTALLATION - FOLD-IN-FLOOR.........16
FUEL TANK FILLER TUBE
REMOVAL.............................16
INSTALLATION.........................17
INLET FILTER
REMOVAL.............................17
INSTALLATION.........................17
QUICK CONNECT FITTING
STANDARD PROCEDURE - QUICK-CONNECT
FITTINGS...........................18
RSFUEL SYSTEM14-1

FUEL DELIVERY
DESCRIPTION
DESCRIPTION
The front wheel drive car uses a plastic fuel tank
located rear center of the vehicle.
The Fuel Delivery System consists of: the following
items:
²Electric fuel pump module
²Fuel filter
²Tubes/lines/hoses
²Fuel injectors
The in-tank fuel pump module contains the fuel
pump. The pump is serviced as part of the fuel pump
module. Refer to Fuel Pump Module.
The fuel filter is replaceable only as part of the
fuel pump module.
DESCRIPTION - FFV REPLACEMENT PARTS
Many components in a Flexible Fuel Vehicle (FFV)
are designed to be compatible with ethanol. Always
be sure that the vehicle is serviced with correct etha-
nol compatible parts.
CAUTION: Replacing fuel system components with
non-ethanol compatible components can damage
your vehicle and may void the warranty.
OPERATION
The fuel system provides fuel pressure by an
in-tank pump module. The Powertrain Control Mod-
ule (PCM) controls the operation of the fuel system
by providing battery voltage to the fuel pump
through the fuel pump relay. The PCM requires only
three inputs and a good ground to operate the fuel
pump relay. The three inputs are:
²Ignition voltage
²Crankshaft Position (CKP) sensor
²Camshaft Position (CMP) sensor
DIAGNOSIS AND TESTING - FUEL DELIVERY
SYSTEM
(Refer to Appropriate Diagnostic Information)
STANDARD PROCEDURE
STANDARD PROCEDURE - FUEL SYSTEM
PRESSURE RELEASE PROCEDURE
(1) Remove Fuel Pump relay from Power Distribu-
tion Center (PDC). For location of relay, refer to label
on underside of PDC cover.
(2) Start and run engine until it stalls.(3) Attempt restarting engine until it will no
longer run.
(4) Turn ignition key to OFF position.
(5) Return fuel pump relay to PDC.
(6) One or more Diagnostic Trouble Codes (DTC's)
may have been stored in PCM memory due to fuel
pump relay removal. The DRB IIItscan tool must be
used to erase a DTC.
STANDARD PROCEDURE - DRAINING FUEL
TANK
Two different procedures may be used to drain fuel
tank (lowering tank or using DRBIIItscan tool).
The quickest draining procedure involves lowering
the fuel tank.
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL SYSTEM COMPONENTS.
SERVICE VEHICLES IN WELL VENTILATED AREAS
AND AVOID IGNITION SOURCES. NEVER SMOKE
WHILE SERVICING THE VEHICLE. THIS MAY
RESULT IN PERSONAL INJURY OR DEATH.
As an alternative procedure, the electric fuel pump
may be activated allowing tank to be drained at fuel
rail connection. Refer to DRBIIItscan tool for fuel
pump activation procedures. Before disconnecting
fuel line at fuel rail, release fuel pressure. Refer to
the Fuel System Pressure Release Procedure in this
group for procedures. Disconnect the fuel line at the
fuel rail and remove the plastic retainer from the
fuel rail. Take plastic retainer and install it back into
the fuel line from body. Check the O-ring and make
sure that it is in place and not damaged. Attach end
of special test hose tool number 6539 at fuel line con-
nection from the body line. Position opposite end of
this hose tool to an approved gasoline draining sta-
tion. Activate fuel pump and drain tank until empty.
When done remove the special test hose tool number
6539 from the body line. Remove the plastic retainer
from the special test hose tool number 6539 and rein-
stall it into the fuel line from the body. Check the
O-ring and make sure that it is in place and not
damaged. Install the fuel line to the fuel rail.
If electric fuel pump is not operating, tank must be
lowered for fuel draining. Refer to following proce-
dures.
(1) Remove fuel filler cap.
(2) Perform the Fuel System Pressure Release pro-
cedure.
(3) Disconnect negative cable from battery.
(4) Raise vehicle and support.
(5) Certain models are equipped with a separate
grounding wire (strap) connecting the fuel fill tube
assembly to the body. Disconnect wire by removing
screw.
14 - 2 FUEL DELIVERYRS

(6) Open fuel fill door and remove screws mount-
ing fuel filler tube assembly to body. Do not discon-
nect rubber fuel fill or vent hoses from tank at this
time.
(7) Place a transmission jack under center of fuel
tank. Apply a slight amount of pressure to fuel tank
with transmission jack.
(8) Remove fuel tank mounting straps.
(9)Lower the tank just enough so that the
filler tube fitting is the highest point of the fuel
tank.
(10) Remove filler tube from fuel tank. Tank will
be drained through this fitting.
NOTE: WRAP SHOP TOWELS AROUND HOSES TO
CATCH ANY GASOLINE SPILLAGE.
(11) Drain fuel tank into holding tank or a prop-
erly labeledGasolinesafety container.
WARNING: GASOLINE OR GASOLINE VAPORS ARE
HIGHLY FLAMMABLE. A FIRE COULD OCCUR IF AN
IGNITION SOURCE IS PRESENT. NEVER DRAIN OR
STORE GASOLINE OR DIESEL FUEL IN AN OPEN
CONTAINER, DUE TO THE POSSIBILITY OF FIRE
OR EXPLOSION. THIS MAY RESULT IN PERSONAL
INJURY OR DEATH.
(12) If fuel pump module removal is necessary,
refer to Fuel Pump Module Removal/Installation in
this section.
STANDARD PROCEDURE - FUEL PRESSURE
GAUGE
This gauge package (special tool #8974) (Fig. 1)is
designed to check the injectors or fuel pump for leak
down conditions and fuel system pressures. Refer to
the Powertrain Diagnostic Manual for more informa-
tion on the operation of this tool.
(1) Preform the fuel pressure release procedure,
refer to the Fuel Pressure release procedure in this
section.(2) Find a fuel line quick connect fitting that is
accessible and install special tool #8974.
(3) Refer to the Powertrain Diagnostic Manual for
the proper operation of this gauge package.
(4) Preform the fuel pressure release procedure,
refer to the Fuel Pressure release procedure in this
section.
(5) Remove gauge from fuel system and reconnect
fuel lines.
(6) Use the DRBIIItto pressurize the fuel system
to check for leaks
Fig. 1 FUEL SYSTEM PRESSURE TESTER #8978
1 - GAUGES
2 - HANGER
3 - RELEASE TOOL
4 - DRAIN HOSE
5 - DRAIN HOSE VALVE
6 - SHUT-OFF VALVE
RSFUEL DELIVERY14-3
FUEL DELIVERY (Continued)

SPECIFICATIONS
FUEL SYSTEM PRESSURE
400 kpa  34 kpa (58 psi   5 psi)
TORQUE
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Fuel Filler Neck Clamp 3.3 30
Fuel Rail 2.4L 22 195
Fuel Rail 3.3/3.8L 11.8 105
Fuel Tank Strap 54 40
Fuel Tank T Strap 28.2 250
Fuel Filter Bolt 4.5 40
SPECIAL TOOLS
FUEL
Pressure Gauge Assembly C±4799±B
Fuel Pressure Test Adapter 6539
Spanner Wrench 6856
LOCKRING REMOVER/INSTALLER #9340
Fuel Line Adapter 1/4
14 - 4 FUEL DELIVERYRS
FUEL DELIVERY (Continued)

FUEL LEVEL SENDING UNIT /
SENSOR
DESCRIPTION
The fuel gauge level sending unit is attached to the
side of fuel pump module. The level sensor is a vari-
able resistor.
OPERATION
Its resistance changes with the amount of fuel in
the tank. The float arm attached to the sensor moves
as the fuel level changes.
The fuel level input is used as an input for OBD II.
If the fuel level is below 15% or above 85% of total
tank capacity several monitors are disabled. There
are diagnostics for the level circuit open and shorted.
REMOVAL
Remove fuel pump module. Refer to Fuel Pump
Module in this section.
(1) Depress retaining tab and remove the fuel
pump/level sensor connector from theBOTTOMof
the fuel pump module electrical connector (Fig. 2).
NOTE: The pump module harness on TOP of flange
is not serviceable or removable.
(2) Pull off the locking wedge.
(3) Using a small screwdriver lift locking finger
away from terminal and push terminal out of connec-
tor (Fig. 3).
(4) Push level sensor signal and ground terminals
out of the connector (Fig. 4).
O2S (Oxygen Sensor) Remover/InstallerÐC-4907
O2S (Oxygen Sensor) Remover/Installer - 8439
Fig. 2 Fuel Pump/Level Sensor Electrical Connector
1 - ELECTRICAL CONNECTOR
2 - RETAINING TAB
Fig. 3 Wire Terminal Locking Finger
1 - LOCKING FINGER
2 - WIRE TERMINAL
Fig. 4 Removing Wires From
1 - FUEL PUMP FEED (RED B+)
2 - LEVEL SENSOR SIGNAL
3 - LEVEL SENSOR GROUND
4 - FUEL PUMP GROUND (BK)
RSFUEL DELIVERY14-5
FUEL DELIVERY (Continued)