2001 CHRYSLER VOYAGER ABS

Component/Ground Color Location Fig.
Left Remote Radio Switch Steering Wheel N/S
Left Repeater Lamp GY Left Front Fender 5
Left Seat Airbag YL Left Seat N/S
Left Side Impact Airbag Control
ModuleYL Left B Pillar 30
Left Sliding Door Control Module
C1BK Left Sliding Door N/S
Left Sliding Door Control Module
C2BK/RD Left Sliding Door N/S
Left Sliding Door Latch Sensing
SwitchBK Left Sliding Door N/S
Left Sliding Door Lock Motor BK Left Sliding Door N/S
Left Sliding Door Lock Motor/Ajar
SwitchBK Left Sliding Door N/S
Left Sliding Door Motor BK Left Sliding Door N/S
Left Speed Control Switch BK Steering Wheel N/S
Left Stop/Turn Signal Relay BK Left Quarter Panel N/S
Left Turn Signal Lamp BK AT Lamp N/S
Left Visor/Vanity Lamp BK At Lamp N/S
License Lamp DKGY At Lamp 38
Lift Pump Motor BK Left Rear Engine Compartment N/S
Liftgate Ajar Switch (Manual
Release)BK At Latch 38
Liftgate Ajar Switch (Power
Release)BK Lower Liftgate 38
Liftgate Cinch/Release Motor BL Liftgate N/S
Liftgate Cylinder Lock Switch BK At Switch 38
Liftgate Left Pinch Sensor BK Left Side of Liftgate N/S
Liftgate Right Pinch Sensor BK Right Side of Liftgate N/S
Low Note Horn BK Left Frame Rail 6
Manifold Absolute Pressure
SensorBK On Intake 11
Mass Air Flow Sensor (Diesel) OR Top of Engine 12, 13
Memory Power Seat Switch GN On Seat N/S
Memory Seat/Mirror Module C1 GY Under Driver Seat N/S
Memory Seat/Mirror Module C2 GY Under Driver Seat N/S
Memory Seat/Mirror Module C3 GY Under Driver Seat N/S
Memory Seat/Mirror Module C4 WT Under Driver Seat N/S
Memory Seat Front Vertical Motor RD Under Seat N/S
Memory Seat Front Vertical
Position SensorBK Under Seat N/S
Memory Seat Horizontal Motor BK Under Seat N/S
Memory Seat Horizontal Position
SensorBK Under Seat N/S
RG8W-90 CONNECTOR/GROUND LOCATIONS BUX8Wa-90-7
CONNECTOR/GROUND LOCATIONS BUX (Continued)

Splice Number Location Fig.
S119 (2.5L) Near T/O for Engine Starter Motor 4
S120 (2.4L) Near T/O for Oxygen Sensors 2
S120 (3.3L/3.8L) Near T/O for Oxygen Sensors 5
S121 (3.3L/3.8L) Near T/O for Output Speed Sensor 5
S122 (2.4L) In T/O to Engine Starter Motor 1
S122 (3.3L/3.8L) In T/O to Engine Starter Motor 5
S123 In T/O to Low Note Horn 8
S124 (2.4L) Near T/O for Fuel Injector No.2 N/S
S124 (3.3L/3.8L) Near T/O for Fuel Injector No.5 and No.6 N/S
S125 (2.4L) In T/O for Manifold Absolute Pressure Sensor N/S
S127 (2.5L) Near T/O for Engine Starter Motor N/S
S128 (2.5L) Near T/O for Engine Starter Motor 4
S129 (2.5L) Near T/O for Battery (+) N/S
S130 (2.5L) Near T/O for Battery (+) N/S
S131 (3.3L/3.8L) Near T/O for Transmission Control Module N/S
S132 (2.5L) Near T/O for Battery (+) N/S
S133 (2.5L) Near T/O for Intelligent Power Module C3 N/S
S135 (2.5L) Near T/O for Glow Plug No.2 4
S136 (2.5L) Between T/O for Radiator Fan No.2 and T/O for G102 N/S
S137 (2.5L) Near T/O for A/C Compressor Clutch 4
S138 (2.5L) Between T/O for Radiator Fan No.2 and T/O for G102 N/S
S139 (2.5L) Between T/O for Engine Starter Motor and T/O for
Engine Control Module C13
S141 (2.4L) Near T/O for Powertrain Control Module N/S
S141 (2.5L) Near /t/O for G100 N/S
S141 (3.3L/3.8L) Near T/O for Powertrain Control Module N/S
S142 (3.3L/3.8L) Near T/O for A/C Compressor Clutch 5
S143 (2.5L) Near T/O for Engine Control Module C1 4
S143 (3.3L/3.8L) Near T/O for Intelligent Power Module - C3 N/S
S144 (2.5L) Between T/O for Battery Temperature Sensor and T/O for
C1034
S145 (2.5L) Near T/O for Battery (+) N/S
S148 (2.5L) Near T/O for Engine Starter Motor 4
S150 (2.5L) Between T/O for Battery Temperature Sensor and T/O for
C103N/S
S151 (2.5L) Near T/O for Radiator Fan Relay No.1 7
S152 (2.5L) Near T/O for Left Fog Lamp N/S
S157 (2.5L) Near T/O for Glow Plug No.1 4
S187 (2.5L) Near T/O for Engine Control Module C1 4
S188 (2.5L) Near T/O for Radiator Fan Relay No.1 7
S201 In T/O to Instrument Panel Speaker 9
S202 Near T/O for Instrument Panel Switch Bank 9, 10
S203 Near T/O for Instrument Panel Switch Bank 9, 10
8Wa - 95 - 2 8W-95 SPLICE LOCATIONS BUXRG
SPLICE LOCATIONS BUX (Continued)

(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.
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. Alwaysinspect 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.
9 - 10 ENGINE 2.4LRS
ENGINE 2.4L (Continued)

AIR CLEANER ELEMENT
REMOVAL
(1) Unsnap 2 clips.
(2) Lift cover and pull toward the engine and
remove cover tabs from air box.
(3) Lift cover and remove the element (Fig. 11).
INSTALLATION
(1) Install the air filter element into air box (Fig.
11).
(2) Move cover so that the tabs insert into the air
box.
(3) Push cover down and snap the 2 clips.
AIR CLEANER HOUSING
REMOVAL
(1) Disconnect the negative battery cable.(2) Disconnect the inlet air temperature sensor
(Fig. 12).
(3) Remove the inlet hose to throttle body (Fig. 11).
(4) Remove the bolt for air box at upper radiator
cross member.
(5) Pull air box up and off over the single locating
pin.
(6) Remove air box from vehicle
INSTALLATION
(1) Install air box into vehicle and onto the locat-
ing pin.
(2) Install bolt to hold air box to the upper radia-
tor cross member.
(3) Install the inlet hose to the throttle body.
(4) Connect the inlet air temperature sensor (Fig.
12).
(5) Connect the negative battery cable.
CYLINDER HEAD
DESCRIPTION
The cross flow designed, aluminum cylinder head
contains dual over-head camshafts with four valves
per cylinder (Fig. 13). The valves are arrange in two
in-line banks. The intake valves face toward the
front of the vehicle. The exhaust valves face the dash
panel. The cylinder head incorporates powdered
metal valve guides and seats. The cylinder head is
sealed to the block using a multi-layer steel head
gasket and retaining bolts.
Integral oil galleries providing lubrication passages
to the hydraulic lash adjusters, camshafts, and valve
mechanisms.
Cylinder Compression Pressure Adaptor 8116
Fig. 11 AIR BOX COVER
Fig. 12 IAT SENSOR 2.4L
9 - 22 ENGINE 2.4LRS
SPECIAL TOOLS (Continued)

(10) Remove balance shafts and housing assembly.
(Refer to 9 - ENGINE/VALVE TIMING/BALANCE
SHAFT - REMOVAL)
(11) Remove all bedplate bolts from the engine
block (Fig. 49).
(12) Using a mallet gently tap the bedplate loose
from the engine block dowel pins.
CAUTION: Do not pry up on one side of the bed-
plate. Damage may occur to cylinder block to bed-
plate alignment and thrust bearing.
(13) Bedplate should be removed evenly from the
cylinder block dowel pins to prevent damage to the
dowel pins and thrust bearing.
(14) Lift out crankshaft from cylinder block. Do
not damage the main bearings or journals when
removing the crankshaft.
INSPECTION
The crankshaft journals should be checked for
excessive wear, taper and scoring (Fig. 50). Limits of
taper or out of round on any crankshaft journals
should within specitifications. (Refer to 9 - ENGINE -
SPECIFICATIONS) Journal grinding should not
exceed 0.305 mm (0.012 in.) under the standard jour-
nal diameter. DO NOT grind thrust faces of No. 3
main bearing. DO NOT nick crank pin or bearing fil-
lets. After grinding, remove rough edges from crank-
shaft oil holes and clean out all passages.
CAUTION: With the nodular cast iron crankshafts, it
is important that the final paper or cloth polish be
in the same direction as normal rotation in the
engine.
INSTALLATION
(1) Install the main bearing shells with the lubri-
cation groove in the cylinder block (Fig. 51).(2) Make certain oil holes in block line up with oil
hole in bearings and bearing tabs seat in the block
tab slots.
CAUTION: Do not get oil on the bedplate mating
surface. It will affect the sealer ability to seal the
bedplate to cylinder block.
(3) Oil the bearings and journals. Install crank-
shaft.
CAUTION: Use only the specified anaerobic sealer
on the bedplate or damage may occur to the
engine.
Fig. 49 Bedplate Bolt Tightenening Sequence
Fig. 50 Crankshaft Journal Measurements
Fig. 51 Installing Main Bearing Upper Shell
1 - LUBRICATION GROOVES
2 - OIL HOLES
RSENGINE 2.4L9-37
CRANKSHAFT (Continued)

(4) Apply 1.5 to 2.0 mm (0.059 to 0.078 in.) bead of
MopartBed Plate Sealant to cylinder block as shown
in (Fig. 52).
(5) Install lower main bearings into main bearing
cap/bedplate. Make certain the bearing tabs are
seated into the bedplate slots. Install the main bear-
ing/bedplate into engine block.
(6) Before installing the bolts the threads should
be oiled with clean engine oil, wipe off any excess oil.
(7) Install main bearing bedplate to engine block
bolts 11, 17, and 20 finger tight. Tighten these bolts
down together until the bedplate contacts the cylin-
der block.
(8) To ensure correct thrust bearing alignment,
perform the following steps:
²Step 1: Rotate crankshaft until number 4 piston
is at TDC.
²Step 2: Move crankshaft rearward to limits of
travel.
²Step 3: Then, move crankshaft forward to limits
of travel.
²Step 4: Wedge an appropriate tool between the
rear of the cylinder block(NOT BED PLATE)andthe rear crankshaft counterweight. This will hold the
crankshaft in it's furthest forward position.
²Step 5: Install and tighten bolts (1±10) in
sequence shown in (Fig. 53) to 41 N´m (30 ft. lbs.).
²Step 6: Remove wedge tool used to hold crank-
shaft.
(9) Tighten bolts (1±10) again to 41 N´m (30 ft.
lbs.) +1/4 turn in sequence shown in (Fig. 53).
(10) Install main bearing bedplate to engine block
bolts (11±20), and torque each bolt to 28 N´m (20 ft.
lbs.) in sequence shown in (Fig. 53).
(11) After the main bearing bedplate is installed,
check the crankshaft turning torque. The turning
torque should not exceed 5.6 N´m (50 in. lbs.).
(12) Install balance shafts and housing assembly.
(Refer to 9 - ENGINE/VALVE TIMING/BALANCE
SHAFT - INSTALLATION)
(13) Install the oil pump. (Refer to 9 - ENGINE/
LUBRICATION/OIL PUMP - INSTALLATION)
(14) Install the timing belt rear cover. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION)
(15) Install the timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION)
(16) Install the timing belt front covers. (Refer to 9
- ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION)
(17) Install engine support bracket.
(18) Install the oil pan. (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - INSTALLATION)
(19) Install the oil filter.
(20) Install crankshaft rear oil seal. (Refer to 9 -
ENGINE/ENGINE BLOCK/CRANKSHAFT OIL
SEAL - REAR - INSTALLATION)
(21) Install flex plate. Apply MopartLock & Seal
Adhesive to bolt threads and tighten to 95 N´m (70
ft. lbs.).
(22) Attach transaxle to engine. Tighten attaching
bolts to 101 N´m (75 ft. lbs.).
(23) Install the engine assembly. (Refer to 9 -
ENGINE - INSTALLATION)
CRANKSHAFT MAIN
BEARINGS
STANDARD PROCEDURE - MAIN BEARING
FITTING
For crankshaft specifications (Refer to 9 - ENGINE
- SPECIFICATIONS).
CRANKSHAFT MAIN BEARINGS
The crankshaft is supported in five main bearings.
All upper and lower bearing shells in the crankcase
have oil grooves. Crankshaft end play is controlled by
Fig. 52 Bedplate Sealing
Fig. 53 Bedplate Bolt Torque Sequence
9 - 38 ENGINE 2.4LRS
CRANKSHAFT (Continued)

a flanged bearing on the number three main bearing
journal (Fig. 54).
Upper and lower Number 3 bearing halves are
flanged to carry the crankshaft thrust loads and are
NOT interchangeable with any other bearing halves
in the engine (Fig. 54). All bearing cap bolts removed
during service procedures are to be cleaned and oiled
before installation. Bearing shells are available in
standard and the following undersized: 0.025 mm
(0.001 in.) and 0.250 mm (0.010 in.). Never install an
undersize bearing that will reduce clearance below
specifications. Replace or machine the crankshaft as
necessary to obtain proper bearing clearances.
MAIN BEARING INSTALLATION
(1) Install the main bearing shells with the lubri-
cation groove in the cylinder block (Fig. 55).
(2) Make certain oil holes in block line up with oil
holes in bearings. Bearing tabs must seat in the
block tab slots.
CAUTION: Do not get oil on the bedplate mating
surface. It will may effect the sealer ability to seal
the bedplate to cylinder block.
(3) Oil the bearings and journals and install
crankshaft.
CAUTION: Use only the specified anaerobic sealer
on the bedplate or damage may occur to the
engine. Ensure that both cylinder block and bed-
plate surfaces are clean.
(4) Apply 1.5 to 2.0 mm (0.059 to 0.078 in.) bead
of anaerobic sealer MopartBed Plate Sealant to cyl-
inder block as shown in (Fig. 56).
Fig. 54 Main Bearing Identification
1 - OIL GROOVE
2 - MAIN BEARINGS
3 - OIL HOLE
Fig. 55 Installing Main Bearing Upper Shell
1 - LUBRICATION GROOVES
2 - OIL HOLES
Fig. 56 Main Bearing Caps/Bedplate Sealing
Fig. 57 Main Bearing Caps/Bedplate Tightening
Sequence
RSENGINE 2.4L9-39
CRANKSHAFT MAIN BEARINGS (Continued)

(5) Install lower main bearings into main bearing
cap/bedplate. Make certain the bearing tabs are
seated into the bedplate slots.
(6) Position the main bearing/bedplate onto the
engine block.
(7) Before installing bolts, lubricate the threads
with clean engine oil, wipe off any excess oil.
(8) Install main bearing bedplate to engine block
bolts 11, 17 and 20 finger tight. Tighten these bolts
down together until the bedplate contacts the cylin-
der block.
(9) To ensure correct thrust bearing alignment,
perform the following steps:
²Step 1: Rotate crankshaft until number 4 piston
is at TDC.
²Step 2: Move crankshaft rearward to limits of
travel.
²Step 3: Then, move crankshaft forward to limits
of travel.
²Step 4: Wedge an appropriate tool between the
rear of the cylinder block(NOT BED PLATE)and
the rear crankshaft counterweight. This will hold the
crankshaft in it's furthest forward position.
²Step 5: Install and tighten bolts (1±10) in
sequence shown in (Fig. 57) to 41 N´m (30 ft. lbs.).
²Step 6: Remove wedge tool used to hold crank-
shaft.
(10) Tighten bolts (1±10) again to 41 N´m (30 ft.
lbs.)PLUS1/4 turn in sequence shown in (Fig. 57).
(11) Install main bearing bedplate to engine block
bolts (11±20), and torque each bolt to 28 N´m (20 ft.
lbs.) in sequence shown in (Fig. 57).
(12) After the main bearing bedplate is installed,
check the crankshaft turning torque. The turning
torque should not exceed 5.6 N´m (50 in. lbs.).
CRANKSHAFT OIL SEAL -
FRONT
REMOVAL
(1) Remove the crankshaft vibration damper.
(Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL)
(2) Remove timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL)
(3) Remove crankshaft sprocket using Special Tool
6793 and insert C-4685-C2 (Fig. 58).
CAUTION: Do not nick shaft seal surface or seal
bore.
(4) Using Tool 6771 to remove front crankshaft oil
seal (Fig. 59). Be careful not to damage the seal sur-
face of cover.INSTALLATION
(1) Install new seal by using Special Tool 6780
(Fig. 60).
(2) Place seal into opening with seal spring
towards the inside of engine. Install seal until flush
with cover.
(3) Install crankshaft sprocket using Special Tool
6792 (Fig. 61).
(4) Install timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION)
(5) Install crankshaft vibration damper. (Refer to 9
- ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
INSTALLATION)
Fig. 58 Crankshaft Sprocket - Removal
1 - SPECIAL TOOL 6793
2 - CRANKSHAFT SPROCKET
Fig. 59 Front Crankshaft Oil Seal - Removal
1 - SPECIAL TOOL 6771
2 - REAR TIMING BELT COVER
9 - 40 ENGINE 2.4LRS
CRANKSHAFT MAIN BEARINGS (Continued)