2001 CHRYSLER VOYAGER wheel

(4) Install oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION).
(5) Refill engine oil to proper level.
(6) Connect negative battery cable.
INTAKE MANIFOLD
DESCRIPTION
(Refer to 9 - ENGINE/CYLINDER HEAD/CYLIN-
DER HEAD COVER(S) - DESCRIPTION)
REMOVAL
(1) (Refer to 9 - ENGINE/CYLINDER HEAD/CYL-
INDER HEAD COVER(S) - REMOVAL)
INSTALLATION
(1) (Refer to 9 - ENGINE/CYLINDER HEAD/CYL-
INDER HEAD COVER(S) - INSTALLATION)
VALVE TIMING
STANDARD PROCEDURE - LOCKING ENGINE
90É AFTER TDC
(1) Disconnect negative battery cable.
(2) Remove starter motor (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - REMOVAL).
(3) Rotate engine by hand until special tool
VM.1068 can be install in engine block as shown
(Fig. 83). This will lock the engine at 90É after TDC.
(4) Remove front wiper unit (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
REMOVAL).
(5) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
Fig. 82 OIL JET REMOVAL/INSTALLATION
1 - SPECIAL TOOL VM.1060
2 - OIL JET
3 - CONNECTING ROD
4 - CRANKSHAFT
Fig. 83 TDC AND 90 DEGREES AFTER TDC
ALIGNMENT PIN LOCATION
1 - ENGINE BLOCK
2 - VM.1051 TDC PIN OR VM.1068 90 DEGREES ATDC PIN
3 - FLYWHEEL
9a - 54 ENGINE 2.5L TURBO DIESELRG
OIL JET (Continued)

INSTALLATION
(1) Before installation of the balance shaft assem-
bly, the # 1 cylinder must be brought to TDC. Using
special tool VM.1051, roll engine over by hand until
tool can be inserted into engine block locking fly-
wheel from turning (Fig. 88). Once the # 1 cylinder is
brought to TDC, the balance shaft assembly can be
installed.
(2) With balance shaft assembly on work bench.
Insert special tool VM.1056 into balance shaft assem-
bly (Fig. 89). This will ensure proper balance shaft
and crankshaft timing after assembly.
(3) Install balance shaft assembly and retaining
bolts (Fig. 87). Torque bolts to 32.4N´m.
(4) Install oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION).
(5) Refill engine oil to proper level.
(6) Connect negative battery cable.
TIMING BELT / CHAIN
COVER(S)
REMOVAL - TIMING BELT OUTER COVER
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).(3) Remove air cleaner housing.
(4) Support engine and remove right engine mount
and bracket.
(5) Remove power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(6) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(7) Remove vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(8) Remove timing belt outer cover retaining bolts
and remove cover (Fig. 90).
REMOVAL - TIMING BELT INNER COVER
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(3) Remove air cleaner housing.
(4) Support engine and remove right engine mount
and bracket.
(5) Remove power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(6) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
Fig. 88 TDC AND 90 DEGREES AFTER TDC
ALIGNMENT PIN LOCATION
1 - ENGINE BLOCK
2 - VM.1051 TDC PIN OR VM.1068 90 DEGREES ATDC PIN
3 - FLYWHEEL
Fig. 89 BALANCE SHAFT ALIGNMENT PIN VM.1056
1 - VM.1056
2 - BALANCE SHAFT ASSEMBLY
RGENGINE 2.5L TURBO DIESEL9a-57
BALANCE SHAFT (Continued)

CROSS-OVER PIPE
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove the fasteners attaching the left bank
manifold connection to cross-over pipe (Fig. 6).
(3) Raise vehicle and remove the left front wheel.
(4) Access the lower right bank pipe connection
fastener through the left front wheel opening using a
long ratchet extension. Loosen and remove the lower
fastener.
(5) Remove the upper right bank pipe connection
fastener by accessing though the catalytic converter
floor pan tunnel.
(6) Lower the vehicle.
(7) Remove the cross-over pipe (Fig. 6).
(8) Remove gaskets and discard (Fig. 6).
INSTALLATION
(1) Position cross-over pipe to the manifold connec-
tions (Fig. 6).
(2) Position new gasket on left bank (front) pipe
connection and loosely install fasteners (Fig. 6).
(3) Raise the vehicle.
(4) Position new gasket on the right bank pipe con-
nection and install fasteners.
(5) Tighten right bank upper fastener to 41 N´m
(30 ft. lbs.).
(6) Tighten right bank lower fastener to 41 N´m
(30 ft. lbs.) using a long ratchet extension accessing
through the left wheel opening.
(7) Install the left front wheel and lower vehicle.
(8) Tighten the left bank pipe connection fasteners
to 41 N´m (30 ft. lbs.) (Fig. 6).
HEAT SHIELDS
DESCRIPTION
The exhaust system heat shields (Fig. 7), (Fig. 8),
or (Fig. 9) are attached to the under body of the vehi-
cle. On vehicles equipped with All Wheel Dive
(AWD), an additional heat shield is mounted to the
catalytic converter.
OPERATION
Heat shields are needed to protect both the vehicle
and the environment from the high temperatures
developed near the catalytic converter.
Fig. 6 CROSS-OVER PIPE
1 - CROSS-OVER PIPE
2 - BOLT
3 - GASKET
4 - FLAG NUT
Fig. 7 CATALYTIC CONVERTER HEAT SHIELD
1 - HEAT SHIELD - CATALYTIC CONVERTER
2 - SCREW (QTY. 4)
Fig. 8 MUFFLER HEAT SHIELD
1 - HEAT SHIELD - MUFFLER
2 - SCREW (QTY. 6)
11 - 6 EXHAUST SYSTEMRS

TURBOCHARGER SYSTEM
DESCRIPTION
CAUTION: The turbocharger is a performance part
and must not be tampered with. The wastegate
bracket is an integral part of the turbocharger. Tam-
pering with the wastegate components can reduce
durability by increasing cylinder pressure and ther-
mal loading due to incorrect inlet and exhaust man-
ifold pressure. Poor fuel economy and failure to
meet regulatory emissions laws may result. Increas-
ing the turbocharger boost WILL NOT increase
engine power.
The turbocharger is an exhaust-driven super-
charger which increases the pressure and density of
the air entering the engine. With the increase of air
entering the engine, more fuel can be injected into
the cylinders, which creates more power during com-
bustion.
The turbocharger assembly consists of four (4)
major component systems (Fig. 1) (Fig. 2):
²Turbine section
²Compressor section
²Bearing housing
²Wastegate
OPERATION
Exhaust gas pressure and energy drive the tur-
bine, which in turn drives a centrifugal compressor
that compresses the inlet air, and forces the air into
the engine through the charge air cooler and plumb-
ing. Since heat is a by-product of this compression,
the air must pass through a charge air cooler to cool
the incoming air and maintain power and efficiency.
Increasing air flow to the engine provides:
²Improved engine performance
²Lower exhaust smoke density
²Improved operating economy
²Altitude compensation
²Noise reduction.
The turbocharger also uses a wastegate (Fig. 3),
which regulates intake manifold air pressure and
prevents over boosting at high engine speeds. When
the wastegate valve is closed, all of the exhaust gases
flow through the turbine wheel. As the intake mani-
fold pressure increases, the wastegate actuator opens
the valve, diverting some of the exhaust gases away
from the turbine wheel. This limits turbine shaft
speed and air output from the impeller.
Fig. 1 Turbocharger Operation
1 - TURBINE SECTION
2 - EXHAUST GAS
3 - BEARING HOUSING
4 - COMPRESSOR SECTION
5 - INLET AIR
6 - COMPRESSED AIR TO ENGINE
7 - EXHAUST GAS
8 - EXHAUST GAS TO EXHAUST PIPE
Fig. 2 Turbocharger Wastegate Actuator
1 - TURBOCHARGER
2 - DIAPHRAGM
3 - WASTE GATE ACTUATOR
11a - 2 EXHAUST SYSTEM AND TURBOCHARGERRG

FRONT FASCIA
REMOVAL
(1) Release hood latch and open hood.
(2) Remove the headlamp assemblies. Refer to
group 8 exterior lighting.
(3) Remove two bolts attaching the upper grill sup-
port to the headlamp mounting panel at each side of
the grille.
(4) Hoist vehicle and support with safety stands.
(5)
Remove front wheels. Refer to Group 22, Wheels
and Tires, for proper procedures and sequence.
(6) Remove front wheelhouse splash shields fasten-
ers as necessary to gain access to bolts holding front
fascia to fender. Refer to Group 23, Body, for proper
procedures.
(7) Remove the two bolts and two nuts holding fas-
cia to the front fenders (Fig. 1).
(8) Remove the five bolts holding bottom of fascia/
air dam to radiator closure panel.
(9) Disconnect fog lamp/parking and turn signal
lamp wire connector, as necessary.
(10) Remove bumper fascia from vehicle.
INSTALLATION
(1) Position front bumper fascia on vehicle.
(2) Lower vehicle.
(3) Install the two bolts to hold fascia to headlamp
mounting panel at each side of grille.(4) Raise vehicle.
(5) Install the two bolts and two nuts to hold fas-
cia to the front fenders (Fig. 1). The fascia should be
flush to fender.
(6) Install front wheelhouse splash shields fasten-
ers. Refer to Group 23, Body, for proper procedures.
(7) Install front wheels. Refer to Group 22, Wheels
and Tires, for proper procedures and tightening
sequence.
(8) Install the five bolts to hold bottom of fascia to
radiator closure panel.
(9) Lower the vehicle.
(10) Install the headlamp assemblies. Refer to sec-
tion 8 for installation.
FRONT BUMPER
REINFORCEMENT
REMOVAL
(1) Remove front bumper fascia. (Refer to 13 -
FRAMES & BUMPERS/BUMPERS/FRONT FASCIA
- REMOVAL)
(2) Support front bumper reinforcement on a suit-
able lifting device.
(3) Remove the four nuts holding front bumper
reinforcement to frame rail (Fig. 2).
(4) Remove front bumper reinforcement from vehicle.
Fig. 1 FRONT BUMPER FASCIA
1 - FRONT BUMPER FASCIA
2 - FRONT BUMPER REINFORCEMENT
3 - RADIATOR ENCLOSURE
Fig. 2 FRT BUMPER REINFORCEMENT
1 - FRONT BUMPER REINFORCEMENT
2 - FRAME RAILS
13 - 2 FRAMES & BUMPERSRS

²Needle Nose Pliers ± For Removal Of Thread
Insert Driving Tang
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.
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove steering column lower cover from
instrument panel. Refer to Group 8E, Instrument
Panel and Systems.
(3) Remove knee blocker reinforcement. Refer to
Group 8E, Instrument Panel and Systems.
(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. 10).
(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 hold-
ing 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. Refer to Group 2, Suspension.
(18) Disconnect lower ball joints from lower steer-
ing knuckles. Refer to Group 2, Suspension.
(19) Remove the rear engine mount heat shield
(Fig. 11).(20) Remove through bolt attaching rear engine
mount to cradle crossmember (Fig. 12).
(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. 14).
(23) Remove bolts attaching crossmember to front
frame rails (Fig. 13).
(24) Remove cradle crossmember from vehicle (Fig.
14).
Fig. 10 STEERING COUPLING
1 - STEERING SHAFT BOOT
2 - STEERING SHAFT
3 - CROSSMEMBER
4 - STEERING GEAR
5 - MOUNT
6 - TRANSAXLE
Fig. 11 REAR MOUNT HEAT SHIELD
1 - BOLT
2 - HEAT SHIELD
3 - CLIP
4 - REAR ENGINE MOUNT
13 - 10 FRAMES & BUMPERSRS
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. 14).
(2) Position crossmember to vehicle.(3) Loosely install bolts attaching cradle cross-
member to front frame rails.
(4) Align crossmember to previously made marks
on frame rails.
(5) Tighten bolts attaching cradle crossmember to
frame rails.
(6) Install through bolt attaching rear engine
mount to cradle crossmember (Fig. 12) and tighten to
68 N´m (50 ft. lbs.) .
(7) Install the rear mount heat shield (Fig. 11).
(8) Connect lower ball joints to steering knuckles.
Refer to Group 2, Suspension.
(9) Connect stabilizer bar links to ends of stabi-
lizer bar. Refer to Group 2, Suspension.
(10) Install bolts attaching anti-lock brake sensor
leads to cradle crossmember.
(11) Install high pressure hose to pump.
(12) Connect return hose to metal tube.
(13) Tighten hose clamp at the cradle crossmember
coupling.
(14) Remove pinch-off pliers.
(15) Position steering so front wheels are straight
ahead.
(16) Install steering column coupling to telescoping
steering gear shaft.
(17) Install clinch bolt attaching steering column
coupling to steering gear shaft.
(18) Install knee blocker reinforcement. Refer to
Group 8E, Instrument Panel and Systems.
(19) Install steering column lower cover from
instrument panel. Refer to Group 8E, Instrument
Panel and Systems.
(20) 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.
Fig. 12 REAR MOUNT
1 - BOLT
2 - REAR MOUNT BRACKET
3 - THROUGH BOLT
4 - REAR MOUNT
Fig. 13 Cradle Crossmember Mount
1 - CROSSMEMBER MOUNT
2 - BRAKE HOSE MOUNT
3 - STEERING TIE ROD
4 - FRONT CROSSMEMBER
5 - FRAME RAIL
RSFRAMES & BUMPERS13-11
FRONT CRADLE CROSSMEMBER (Continued)

FUEL SYSTEM
TABLE OF CONTENTS
page page
FUEL DELIVERY..........................1FUEL INJECTION........................16
FUEL DELIVERY
TABLE OF CONTENTS
page page
FUEL DELIVERY
DESCRIPTION............................1
OPERATION.............................2
DIAGNOSIS AND TESTING..................2
FUEL DELIVERY SYSTEM.................2
STANDARD PROCEDURE...................2
FUEL PRESS RELEASE...................2
STANDARD PROCEDURE.................2
SPECIFICATIONS.........................2
SPECIAL TOOLS..........................3
FUEL FILTER
REMOVAL...............................4
INSTALLATION............................4
FUEL LEVEL SENDING UNIT / SENSOR
DESCRIPTION............................4
OPERATION.............................4
REMOVAL...............................4
INSTALLATION............................5
FUEL LINES
DESCRIPTION............................6
STANDARD PROCEDURE...................6
HOSES & CLAMP........................6
FUEL PRESSURE REGULATOR
OPERATION.............................6
REMOVAL...............................7
INSTALLATION............................7
FUEL PUMP
DESCRIPTION............................7OPERATION.............................7
FUEL PUMP MODULE
DESCRIPTION............................7
OPERATION.............................7
REMOVAL...............................8
INSTALLATION............................8
FUEL RAIL
REMOVAL...............................9
INSTALLATION............................9
FUEL TANK
DESCRIPTION...........................10
OPERATION.............................10
REMOVAL..............................10
INSTALLATION...........................11
FUEL TANK FILLER TUBE
REMOVAL..............................12
INSTALLATION...........................12
INLET FILTER
REMOVAL..............................13
INSTALLATION...........................13
QUICK CONNECT FITTING
STANDARD PROCEDURE..................13
QUICK CONNECT FITTING...............13
ROLLOVER VALVE
DESCRIPTION...........................15
OPERATION.............................15
FUEL DELIVERY
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.
RSFUEL SYSTEM14-1