2001 CHRYSLER VOYAGER Service Manual

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Page 2857 of 4284

CHRYSLER VOYAGER 2001 Service Manual The turbocharger is lubricated by engine oil that is
pressurized, cooled, and filtered. The oil is delivered
to the turbocharger by a supply line that is tapped
into the oil filter head. The oil trave

Page 2858 of 4284

CHRYSLER VOYAGER 2001 Service Manual TURBOCHARGER
REMOVAL
The exhaust manifold and turbocharger cannot be
remove with the engine in vehicle.
(1) Remove engine from vehicle and mount on
engine stand (Refer to 9 - ENGINE - REMOVAL) .
(2) R

Page 2859 of 4284

CHRYSLER VOYAGER 2001 Service Manual (8) With exhaust manifold and turbocharger
assembly on work bench, remove turbocharger to
exhaust manifold retaining bolts. Separate exhaust
manifold and turbocharger.
CLEANING
All old gaskets should

Page 2860 of 4284

CHRYSLER VOYAGER 2001 Service Manual INSTALLATION
(1) Reposition exhaust heat shield (Fig. 8).
(2) Install exhaust heat shield retaining bolts (Fig.
8). Torque bolts to 27.5N´m.
(3) Install thermostat housing to upper radiator
hose tube

Page 2861 of 4284

CHRYSLER VOYAGER 2001 Service Manual FRAMES & BUMPERS
TABLE OF CONTENTS
page page
BUMPERS
DESCRIPTION............................1
SPECIFICATIONS.........................1
FRONT FASCIA
REMOVAL...............................2
INSTALLATION

Page 2862 of 4284

CHRYSLER VOYAGER 2001 Service Manual 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 headl

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

Page 2863 of 4284

CHRYSLER VOYAGER 2001 Service Manual INSTALLATION
NOTE: Check position of the arrows molded into
the foam for correct orientation.
(1) Position front bumper reinforcement on vehicle.
(2) Install the four nuts to hold reinforcement to
fra

Page 2864 of 4284

CHRYSLER VOYAGER 2001 Service Manual INSTALLATION
(1) Position rear bumper reinforcement on vehicle.
(2) Install the six nuts to hold rear bumper rein-
forcement to frame rail extensions and tighten to 27
N´m (20 ft. lbs.) (Fig. 4).
(3)

INSTALLATION
(1) Position rear bumper reinforcement on vehicle.
(2) Install the six nuts to hold rear bumper rein-
forcement to frame rail extensions and tighten to 27
N´m (20 ft. lbs.) (Fig. 4).
(3) Install rear bumper fascia. (Refer to 13 -
FRAMES & BUMPERS/BUMPERS/REAR FASCIA -
INSTALLATION)
REAR FASCIA - SCUFF PAD
REMOVAL
The scuff pad may not be salvageable during the
removal process. The scuff pad should be replaced if
damaged or broken. Check availability before servic-
ing.
(1) Remove rear bumper fascia.(Refer to 13 -
FRAMES & BUMPERS/BUMPERS/REAR FASCIA -
REMOVAL)
(2) Using a trim stick, pry up the rear edge of the
scuff pad to release tabs from the rear bumper fascia
and pull scuff pad up to release the forward tabs
(Fig. 5).
INSTALLATION
(1) Verify that there are fifteen slots in the fascia.
(2) Place scuff pad in position.
(3) Align and insert the center forward tab.
(4) Align the remaining tabs and press into the
slots, starting in the center and working outboard.
(5) Assure all tabs are fully engaged into the fas-
cia.
FRAME
DESCRIPTION
The vehicle does not have a conventional frame. It
is constructed as a unitized body and frame. The uni-
body is constructed from special high strength steel
and coated metals. This process reduces weight and
provides strength to withstand the forces applied
against structural members. The structural members
provide a unibody that has great structural strength.
SPECIFICATIONS
FRAME DIMENSIONS
Frame dimensions are listed in metric scale. All
dimensions are from center to center of Principal
Locating Point (PLP), or from center to center of PLP
and fastener location.
VEHICLE PREPARATION
Position the vehicle on a frame alignment rack,
refer to instructions provided with equipment being
used. Adjust the vehicle PLP heights to the specified
dimension above the work surface (datum line). Ver-
tical dimensions can be taken from the datum line to
the locations indicated were applicable. Refer to (Fig.
6), (Fig. 7), (Fig. 8), and (Fig. 9) for proper dimen-
sions.
Fig. 5 Scuff Pad
1 - SCUFF PAD
2 - TABS
13 - 4 FRAMES & BUMPERSRS
REAR BUMPER REINFORCEMENT (Continued)

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