2001 CHRYSLER VOYAGER tow

(2) Before installing the ring compressor, make
sure the oil ring expander ends are butted together.
(3) Immerse the piston head and rings in clean
engine oil, slide the ring compressor, over the piston
and tighten (Fig. 56).Ensure position of rings
does not change during this operation.
(4) Face arrow on piston towards front of engine.
NOTE: Be careful not to nick crankshaft journals.
(5) Rotate crankshaft so that the connecting rod
journal is on the center of the cylinder bore. Insert
rod and piston into cylinder bore and guide rod over
the crankshaft journal.
(6) Tap the piston down in cylinder bore, using a
hammer handle. At the same time, guide connecting
rod into position on connecting rod journal.
(7) Install connecting rod caps (Fig. 57). Install rod
bolts and tighten to 30N´m (22 ft.lb.) plus 60É. Then
torque to 88N´m (65 ft.lb).
Fig. 54 PISTON RINGS-INSTALLATION
Fig. 55 PISTON RING GAP LOCATION
3 - TOP COMPRESSION RING GAP POSITION
1 - SECOND COMPRESSION RING GAP POSITION
2 - OIL CONTROL RING GAP POSITION
Fig. 56 PISTON INSTALLATION USING VM.1065
1 - PISTON
2 - VM.1065
3 - ENGINE BLOCK
Fig. 57PISTON AND CONNECTING ROD INSTALLATION
1 - PISTON AND CONNECTING ROD ASSEMBLY
2 - FOUR DIGIT NUMBER
3 - CONNECTING ROD BOLT
4 - FOUR DIGIT NUMBER
RGENGINE 2.5L TURBO DIESEL9a-41
PISTON & CONNECTING ROD (Continued)

The fuel filter is replaceable, it is mounted on the
outside and on top of the fuel tank. Refer to the
Maintenance Schedules in the Introduction section of
this manual for recommended fuel filter replacement
intervals.
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 is provided fuel pressure by an in-
tank pump module. The 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 oper-
ate 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 Diagnositic Information)
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) Place a rag or towel below fuel line quick-con-
nect fitting at fuel rail.
(6) Return fuel pump relay to PDC.
(7) 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
(1) Release fuel system pressure, refer to the Fuel
System Release Procedure in this section.
(2) Insert a 1/4 inch siphon (max. O. D. 5/16) hose
from a portable fuel siphoning tank through the fuel
filler neck opening into the fuel tank. Hose most
have a 30 degree angle cut on the end to bypass the
check valve in the end of the filler neck. Refer to the
siphoning tank's Manufacturing Instructions.
(3) Drain fuel from fuel tank into siphoning tank.
SPECIFICATIONS
FUEL SYSTEM PRESSURE
400 kpa634 kpa (58 psi65 psi)
TORQUE
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Fuel Rail 2.4L 22 200
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
14 - 2 FUEL DELIVERYRS
FUEL DELIVERY (Continued)

FUEL RAIL
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. 13).
(4) Remove wiring harness from brackets.
(5) Disconnect the connectors from the fuel injec-
tors.
(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. 14).
(7) Remove fuel rail. Be careful not to damage the
injector O-rings upon removal from their ports.
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. 13).
(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.
Fig. 13 FUEL RAIL AND INJECTORS 2.4L
1 - Fuel Injectors
2 - Fuel Rail
Fig. 14 FUEL INJECTORS 3.3/3.8L
1 - FUEL INJECTORS
RSFUEL DELIVERY14-9

PLASTIC RETAINER RING TYPE FITTING
This type of fitting can be identified by the use of a
full-round plastic retainer ring (Fig. 25) usually black
in color.
CAUTION: The interior components (O-rings, spac-
ers, retainers) of this type of quick-connect fitting
are not serviced separately. Do not attempt to repair
damaged fittings or fuel lines/tubes. If repair is nec-
essary, replace the complete fuel tube assembly.
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSES,
FITTINGS OR LINES, THE FUEL SYSTEM PRES-
SURE MUST BE RELEASED. REFER TO THE FUEL
SYSTEM PRESSURE RELEASE PROCEDURE IN
THIS GROUP.DISCONNECTION/CONNECTION
(1) Perform fuel pressure release procedure. Refer
to Fuel Pressure Release Procedure in this section.
(2) Disconnect negative battery cable from battery
or auxiliary jumper terminal.
(3) Clean fitting of any foreign material before dis-
assembly.
(4) To release fuel system component from quick-
connect fitting, firmly push fitting towards compo-
nent being serviced while firmly pushing plastic
retainer ring into fitting (Fig. 25). With plastic ring
depressed, pull fitting from component.The plastic
retainer ring must be pressed squarely into fit-
ting body. If this retainer is cocked during
removal, it may be difficult to disconnect fit-
ting. Use an open-end wrench on shoulder of
plastic retainer ring to aid in disconnection.
(5) After disconnection, plastic retainer ring will
remain with quick-connect fitting connector body.
(6) Inspect fitting connector body, plastic retainer
ring and fuel system component for damage. Replace
as necessary.
(7) Prior to connecting quick-connect fitting to
component being serviced, check condition of fitting
and component. Clean parts with a lint-free cloth.
Lubricate with clean engine oil.
(8) Insert quick-connect fitting into component
being serviced until a click is felt.
(9) Verify a locked condition by firmly pulling on
fuel tube and fitting (15-30 lbs.).
(10) Connect negative battery cable to battery or
auxiliary jumper terminal.
(11) Use the DRB IIItscan tool ASD Fuel System
Test to pressurize the fuel system. Check for leaks.
ROLLOVER VALVE
DESCRIPTION
All vehicles have rollover valve(s) on top of the fuel
tank.
OPERATION
The valves prevent fuel flow through the fuel tank
vent valve hoses should the vehicle rollover.
The rollover valves on the fuel tank are not ser-
viceable.
Fig. 25 Plastic Retainer Ring Type Fitting
1 - FUEL TUBE
2 - QUICK CONNECT FITTING
3 - PUSH
4 - PLASTIC RETAINER
5 - PUSH
6 - PUSH
7 - PUSH
8 - PUSH
RSFUEL DELIVERY14-15
QUICK CONNECT FITTING (Continued)

NOTE: Power steering pump maximum relief pres-
sure is 9,653 to 10,342 kPa (1,400 to 1,500 psi.).
(9) Close analyzer valve fully three times and
record highest pressure indicated each time. All three
readings must be above specifications and within 345
kPa (50 psi) of each other.
²If power steering pump pressures are above
specifications, but not within 345 kPa (50 psi) of each
other, replace pump.
²If power steering pump pressures are within 345
kPa (50 psi) of each other, but are below specifica-
tions, replace pump.
CAUTION: Do not force the pump to operate against
the stops for more than 2 to 4 seconds at a time
because, pump damage will result.
(10) Completely open the valve on the Power
Steering Analyzer. Turn the steering wheel to theextreme left until the stop in the steering gear is
met, then turn the steering wheel to the right until
the right stop is met. Record the highest indicated
pressure at each position. Compare the recorded
readings to the specifications. If the highest output
pressures are not the same against either stop, the
steering gear is leaking internally and must be
replaced.
DIAGNOSIS AND TESTING - STEERING
SYSTEM DIAGNOSIS CHARTS
NOTE: There are three diagnosis charts following
that cover POWER STEERING NOISE, STEERING
WHEEL FEEL, and POWER STEERING FLUID.
POWER STEERING NOISE
CONDITION POSSIBLE CAUSES CORRECTION
OBJECTIONABLE HISS
OR WHISTLE*1. Damaged or mispositioned
steering column shaft/coupling dash
panel seal.1. Reposition or replace steering
column shaft/coupling dash panel seal.
2. Noisy valve in power steering
gear.2. Replace power steering gear.
3. Mis-routed power steering hose. 3. Check routing of power steering
hoses. Ensure hoses do not come in
unwanted contact with other
components and objects.
RATTLE OR CLUNK 1. Power steering gear loose on front
suspension crossmember.1. Inspect power steering gear
mounting bolts. Replace as necessary.
Tighten to the specified torque.
2. Front suspension crossmember
mounting fasteners loose at frame.2. Tighten the front suspension
crossmember mounting fasteners to the
specified torque.
3. Loose tie rod (outer or inner). 3. Check tie rod pivot points for wear.
Replace worn/loose parts as required.
4. Loose lower control arm mounting
bolts at front suspension
crossmember.4. Tighten control arm mounting bolts to
the specified torques.
5. Lower control arm pivot bushing
worn.5. Replace lower control arm pivot
bushing.
6. Loose strut assembly mounting
fasteners at tower.6. Tighten strut assembly fasteners to
the specified torque.
7. Power steering fluid pressure
hose touching the body of the
vehicle.7. Adjust hose to proper position by
loosening, repositioning, and tightening
fitting to specified torque. Do not bend
tubing.
RSSTEERING19-3
STEERING (Continued)

INSTALLATION
The power transfer unit input shaft cover seal is
the larger of the two seals located on the inside of
the end cover. The differential bearing cup must be
removed to service this seal.
(1) Clean and inspect seal area.
(2) Use special tool No. MD998803 and install seal
(Fig. 34). When installing seal the spring side of the
seal must face toward the special tool.
(3) Reinstall the original bearing race and shim
using special tool No. 6522 (Fig. 35) and (Fig. 36).
Fig. 30 P.T.U. End Cover Bolts
1 - POWER TRANSFER UNIT
2 - FILL PLUG
3 - END COVER
4 - OUTPUT SHAFT
Fig. 31 End Cover Removal
1 - END COVER EARS
2 - HAMMER
3 - POWER TRANSFER UNIT
Fig. 32 Bearing Race Removal
1 - END COVER
2 - SPECIAL TOOL No. 6514
Fig. 33 Seal Removal
1 - END COVER
2 - SPECIAL TOOL 7794±A
3 - SLIDE HAMMER
4 - SOFT JAW VICE
21 - 14 POWER TRANSFER UNITRS
INPUT SHAFT COVER SEAL (Continued)

INSTALLATION
The Power Transfer Unit must be removed from
the vehicle to service this seal. Refer to Power Trans-
fer Unit Removal in this section for procedures.(1) Clean and inspect seal area.
(2) Lay housing on bench and install new seal with
seal driver C-4657 and handle C-4171 (Fig. 47). The
seal must be installed with the spring side facing
towards the ring gear. Drive the seal in until it bot-
toms against the case shoulder.
(3) Install input shaft.
(4) Install oil trough.
(5) Apply Moparž Gasket Maker or equivalent to
sealing surfaces of end cover and reinstall. Tighten
bolts to 28 N´m (250 in. lbs.)
CAUTION: When end cover is installed be careful
not to damage the P.T.U. Input Shaft Cover Seal.
(6) Reinstall P.T.U. assembly into vehicle.
(7) Check and fill fluids as required.
OUTER HALF SHAFT SEAL
REMOVAL
The outer half shaft seal is located on the outside
of the end cover. The P.T.U. does not have to be
removed to replace this seal.
(1) Lift vehicle on hoist.
(2) Remove right front half shaft from vehicle.
(3) Remove seal with a chisel and hammer (Fig.
48).
Fig. 44 Oil Trough
1 - OIL TROUGH
2 - POWER TRANSFER UNIT
Fig. 45 Input Shaft and Ring Gear Removal
1 - POWER TRANSFER UNIT
2 - RING GEAR
Fig. 46 Seal Removal
1 - POWER TRANSFER UNIT
2 - SPECIAL TOOL
7794±A
21 - 18 POWER TRANSFER UNITRS
INPUT SHAFT SEAL (Continued)

CLEANING
Clean the servo piston components (Fig. 201) with
solvent and dry them with compressed air. Wipe the
band clean with lint free shop towels.
Replace the front band if distorted, lining is
burned, flaking off, or worn to the point where the
grooves in the lining material are no longer visible.
Replace any servo component if doubt exists about
condition. Do not reuse suspect parts.
INSPECTION
Inspect the servo components (Fig. 202). Replace
the springs if collapsed, distorted or broken. Replace
the guide, rod and piston if cracked, bent, or worn.
Discard the servo snap-ring if distorted or warped.
Check the servo piston bore for wear. If the bore is
severely scored, or damaged, it will be necessary to
replace the case.
Fig. 200 Controlled Load Kickdown Servo
1 - KICKDOWN PISTON
2 - O-RING
3 - SNAP RING
4 - PISTON ROD GUIDE
5 - SNAP RING
6 - O-RING
7 - PISTON RETURN SPRING
8 - PISTON ROD
9 - SEAL RINGS
Fig. 201 Front Servo Piston
1 - PISTON RINGS
2 - O-RING
3 - SNAP-RING
4 - SEAL RING
5 - PISTON ROD GUIDE
6 - SNAP-RING
7 - SERVO SPRING
8 - PISTON ROD
9 - SERVO PISTON
Fig. 202 Front Servo Piston
1 - PISTON RINGS
2 - O-RING
3 - SNAP-RING
4 - SEAL RING
5 - PISTON ROD GUIDE
6 - SNAP-RING
7 - SERVO SPRING
8 - PISTON ROD
9 - SERVO PISTON
RSAUTOMATIC - 31TH21 - 111
SERVO - KICKDOWN (Continued)