2001 CHRYSLER VOYAGER wheel bolt torque

SPECIFICATIONS
SPECIFICATIONS - ABS FASTENER TORQUE
(Refer to 5 - BRAKES - BASE - SPECIFICA-
TIONS)
TONE WHEEL RUNOUT
DESCRIPTION SPECIFICATION
Front Tone Wheel
Maximum Runout0.15 mm (0.006 in.)
Rear Tone Wheel
Maximum Runout0.15 mm (0.006 in.)
WHEEL SPEED SENSOR AIR GAP
DESCRIPTION SPECIFICATION
Front Sensor0.35 ± 1.20 mm
0.014 ± 0.047 in.
Rear Sensor0.40 ± 1.20 mm
0.016 ± 0.047 in.
FRONT WHEEL SPEED
SENSOR
REMOVAL - WHEEL SPEED SENSOR (FRONT)
(1) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(2) Remove the tire and wheel assembly.
(3) Remove the sensor cable routing clamp screws.
CAUTION: When disconnecting the wheel speed
sensor from vehicle wiring harness, be careful not
to damage pins on connector
(4) Remove speed sensor cable grommets from
intermediate bracket on strut.
(5) Disconnect speed sensor cable from vehicle wir-
ing harness behind fender well shield.
(6) Remove the wheel speed sensor head mounting
bolt (Fig. 1).
(7) Remove sensor head from steering knuckle. If
sensor has seized due to corrosion,DO NOT USE
PLIERS ON SENSOR HEAD.Use a hammer and a
punch and tap edge of sensor ear, rocking the sensor
side-to-side until free.
(8) Remove front wheel speed sensor from vehicle.
INSTALLATION - WHEEL SPEED SENSOR
(FRONT)
CAUTION: Proper installation of wheel speed sen-
sor cables is critical to continued system operation.
Be sure that cables are installed in retainers. Fail-
ure to install cables in retainers as shown in this
section may result in contact with moving parts and
over extension of cables, resulting in an open cir-
cuit.
(1) Connect the front wheel speed sensor cable to
the vehicle wiring harness connector. Be sure speed
sensor cable connector is fully seated and locked into
vehicle wiring harness connector.
(2) Install the bolts attaching the routing clamps
to the body of the vehicle. Tighten the bolts to a
torque of 11 N´m (95 in. lbs.).
(3) Insert speed sensor cable grommets into inter-
mediate bracket on strut.
(4) Install the wheel speed sensor head mounting
bolt (Fig. 1). Tighten the bolt to a torque of 12 N´m
(105 in. lbs.)
(5) Install the wheel and tire assembly on vehicle.
(6) Lower vehicle.
(7) Road test vehicle to ensure proper operation of
the base and ABS brake systems.
Fig. 1 Front Wheel Speed Sensor Attaching Bolt
1 - MOUNTING BOLT
2 - WHEEL SPEED SENSOR
3 - DRIVESHAFT
4 - TONE WHEEL
5 - STEERING KNUCKLE
RSBRAKES - ABS5-71
BRAKES - ABS (Continued)

REAR WHEEL SPEED SENSOR
-AWD
REMOVAL - WHEEL SPEED SENSOR
(REAR-AWD)
(1) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
CAUTION: When disconnecting speed sensor cable
from vehicle wiring harness be careful not to dam-
age pins on the electrical connectors. Also, inspect
connectors for any signs of previous damage.
(2) Remove grommet from floor pan of vehicle and
disconnect speed sensor cable connector from vehicle
wiring harness (Fig. 2).
CAUTION: When removing rear wheel speed sensor
cable from routing clips, be sure not to damage the
routing clips. Routing clips that are molded onto
the brake hose will require replacement of the brake
hose if damaged during removal or installation of
the speed sensor cable.
(3) Carefully remove speed sensor cable from
press-in routing clips along brake hose and tubing.
(4) Remove bolt securing wheel speed sensor cable
metal clip to rear of axle. Remove metal clip from
cable if necessary.
CAUTION: If speed sensor head has seized due to
corrosion, do not use pliers on speed sensor head
in an attempt to remove it. Use a hammer and apunch and tap mounting flange edge side-to-side,
rocking the sensor until free.
(5) Remove wheel speed sensor head attaching
bolt.
(6) Remove wheel speed sensor head from the axle,
and remove sensor from vehicle.
INSTALLATION - WHEEL SPEED SENSOR
(REAR-AWD)
CAUTION: Proper installation of wheel speed sen-
sor cables is critical to continued system operation.
Be sure that cables are installed in retainers. Fail-
ure to install cables in retainers as indicated may
result in contact with moving parts or over-exten-
sion of cables, resulting in an open circuit.
(1) Install wheel speed sensor head in axle flange.
CAUTION: Prior to installing the speed sensor head
attaching bolt, the plastic anti-rotation pin must be
fully seated into the bearing flange.
(2) Install wheel speed sensor head attaching bolt.
Tighten bolt to a torque 12 N´m (105 in. lbs.).
(3) Check the air gap between the face of the
wheel speed sensor and the top surface of the tone
wheel. (Refer to 5 - BRAKES - SPECIFICATIONS)
CAUTION: When installing wheel speed sensor
cable in the routing clips on rear brake flex hose,
be sure not to damage the routing clips. Routing
clips are molded onto the hose and will require
replacement of the brake hose if damaged.
(4) Install speed sensor cable under leaf spring
onto brake hose and tubing utilizing routing clips to
secure it in place.
(5) Install metal routing clip on speed sensor cable
and mount it to rear of axle with mounting bolt.
Tighten mounting bolt to 16 N´m (140 in. lbs.).
(6) Connect wheel speed sensor cable to vehicle
wiring harness (Fig. 2).Be sure speed sensor cable
connector is fully seated and locked into vehi-
cle wiring harness connector.
(7) Install speed sensor cable grommet into the
floor pan, being sure the grommet is fully seated into
the access hole.
(8) Lower vehicle.
(9) Road test vehicle to ensure proper operation of
the base and ABS braking systems.
Fig. 2 WHEEL SPEED SENSOR CONNECTOR
1 - CONNECTOR
2 - FLOOR PAN
3 - GROMMET
5 - 72 BRAKES - ABSRS

(2) Inside the vehicle, install the remaining 2
mounting bolts attaching the ICU to the mounting
bracket (Fig. 11). Tighten all 3 mounting bolts to a
torque of 11 N´m (97 in. lbs.).
(3) Install the dash seal and three mounting
screws (Fig. 10).
(4) Install the silencer on top of the dash seal (Fig.
10).
(5) Connect the steering shaft coupling and install
the pinch bolt (Fig. 10). Tighten the pinch bolt to 28
N´m (250 in. lbs.).
(6) Install the silencer panel below the steering
column under the instrument panel.
(7) Remove the steering wheel holder.
CAUTION: Because of the flexible section in the pri-
mary and secondary brake tubes, the brake tubes
must be held in proper orientation when tightened
and torqued. These tubes must not contact each
other or other vehicle components when installed.
Also, after the brake tubes are installed on the HCU,
ensure all spacer clips are reinstalled on the brake
tubes.
(8) Install the primary and secondary brake tubes
into their correct port locations on the HCU valve
block (Fig. 9). Tighten the tube nuts to a torque of 17
N´m (145 in. lbs.).
CAUTION: When installing the chassis brake tubes
on the HCU valve block, they must be located cor-
rectly in the valve block to ensure proper ABS oper-
ation.
NOTE: The chassis brake tube attachment locations
to the HCU, are marked on the bottom of the CAB.
(9) Install the (4) chassis brake tubes into their
correct port locations on the HCU valve block as
shown (Fig. 9). Tighten the tube nuts to a torque of
17 N´m (145 in. lbs.).NOTE: Before installing the 24±way connector in
the CAB be sure the seal is properly installed in the
connector.
(10) Install the 24±way connector on the CAB by,
first, positioning the 24±way connector in the socket
of the CAB and carefully pushing it down as far as
possible. Once connector is fully seated by hand into
the CAB socket, push down on connector lock. This
will pull the connector into the socket of the CAB
and lock it in the installed position.
(11) Install any routing clips on the brake tubes.
(12) Remove the brake pedal holder.
(13) Install the speed control servo with its mount-
ing nuts.
(14) Connect the wiring harness to the speed con-
trol servo.
(15) Install the battery tray (Refer to 8 - ELEC-
TRICAL/BATTERY SYSTEM/TRAY - INSTALLA-
TION).
(16) Install the screw securing the coolant filler
neck to the battery tray.
(17) Reconnect the vacuum hose connector at the
tank built into the battery tray.
(18) Install the battery (Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/BATTERY - INSTALLA-
TION).
(19) Install the battery shield.
(20) Remove the brake pedal holder.
(21) Connect negative cable back on negative post
of the battery.
(22) Bleed the Base and ABS brake hydraulic sys-
tems (Refer to 5 - BRAKES - STANDARD PROCE-
DURE).
(23) Road test vehicle to ensure proper operation
of the base and antilock brake systems.
5 - 78 BRAKES - ABSRS
ICU (INTEGRATED CONTROL UNIT) (Continued)

DIAGNOSIS AND TESTING - DRIVE PLATE
MISALIGNMENT
Common causes of misalignment are:
²Heat warping
²Mounting drive plate on a dirty crankshaft
flange
²Incorrect bolt tightening
²Improper seating on the crankshaft shoulder
²Loose crankshaft bolts
Clean the crankshaft flange before mounting the
drive plate. Dirt and grease on the flange surface
may misalign the flywheel, causing excessive runout.
Use new bolts when mounting drive plate to crank-
shaft. Tighten drive plate bolts to specified torque
only. Over-tightening can distort the drive plate hub
causing excessive runout.
DIAGNOSIS AND TESTING - CLUTCH COVER
AND DISC RUNOUT
Check condition of the clutch cover before installa-
tion. A warped cover or diaphragm spring will cause
grab and/or incomplete release or engagement. Use
care when handling the clutch assembly. Impact can
distort the cover, diaphragm spring, and release fin-
gers.
DIAGNOSIS AND TESTING - CLUTCH CHATTER
COMPLAINTS
For all clutch chatter complaints, perform the fol-
lowing:
(1) Check for loose, misaligned, or broken engine
and transmission mounts. If present, they should be
corrected at this time. Test vehicle for chatter. If
chatter is gone, there is no need to go any further.
(2) If chatter persists, check hydraulic clutch
release system is functioning properly.
(3) Check for loose connections in drivetrain. Cor-
rect any problems and determine if clutch chatter
complaints have been satisfied. If not:
(a) Remove transaxle.
(b) Check to see if the release bearing is sticky
or binding. Replace bearing, if needed.
(c) Check linkage for excessive wear on the pivot
stud and fork fingers. Replace all worn parts.
(d) Check clutch assembly for contamination
(dirt, oil). Replace clutch assembly, if required.
(e) Check to see if the clutch disc hub splines
are damaged. Replace with new clutch assembly, if
necessary.
(f) Check input shaft splines for damage.
Replace, if necessary.
(g) Check for uneven wear on clutch fingers.
(h) Check for broken clutch cover diaphragm
spring fingers. Replace with new clutch assembly,
if necessary.
SPECIAL TOOLS
SPECIAL TOOLS - T850 TRANSAXLE
CLUTCH RELEASE CABLE -
LHD
REMOVAL
(1) Disconnect battery negative cable.
(2) Raise vehicle on hoist.
(3)Diesel models:Remove underbody splash
shield.
(4) Remove clutch bellhousing cap.
(5) Some models will have a clutch cable retainer
clip at the transaxle to secure it to the case (Fig. 9).
If retainer clip is installed, dislodge clip from from
inside bellhousing using a suitable screwdriver (Fig.
10), pull outward on cable conduit, guiding cable core
wire through slot in bellhousing and disengaging
cable ªTº from clutch release lever (Fig. 11). If
retainer is not installed, disengage clutch cable from
transaxle by pulling outward on cable conduit, guid-
Disconnect Tool, 6638A
Remover/Installer, 6891
RGCLUTCH6a-7
CLUTCH (Continued)

INSTALLATION
(1) Install modular clutch assembly to transaxle
input shaft (Fig. 31).
(2) Install transaxle to vehicle. (Refer to 21 -
TRANSMISSION/TRANSAXLE/MANUAL - INSTAL-
LATION)
SLAVE CYLINDER - RHD
REMOVAL
(1) Raise vehicle on hoist.Diesel models:Remove
underbody splash shield.
(2) Using Tool 6638A, disconnect hyrdraulic clutch
circuit quick connect fitting.
(3) Remove clutch slave cylinder (Fig. 32) by lifting
nylon tab with a small screwdriver, and then
depressing cylinder inward towards case and rotating
cylinder 60É counter-clockwise.
INSTALLATION
(1) Install clutch slave cylinder into position, not-
ing orientation of different sized lugs. While depress-
ing inward, rotate slave cylinder clockwise until
nylon locating tab rests in transaxle case cutout, and
the hydraulic tube is vertical (Fig. 32).
(2) Connect ªquick-connectº connection until an
audible ªclickº is heard. Verify connection by pulling
outward on connection.
(3)Diesel models:Install underbody splash
shield.
(4) Lower vehicle.
CLUTCH DISC AND PRESSURE
PLATE - 2.5L TD
REMOVAL
(1) Remove transaxle assembly. (Refer to 21 -
TRANSMISSION/TRANSAXLE/MANUAL -
REMOVAL)
(2) Remove six (6) clutch pressure plate-to-fly-
wheel bolts. Remove pressure plate and disc from fly-
wheel (Fig. 33).
(3) Inspect flywheel. Resurface/replace as neces-
sary.
(4) Inspect clutch release bearing and lever.
Replace as necessary. (Refer to 6 - CLUTCH/
CLUTCH RELEASE BEARING - REMOVAL)
INSTALLATION
(1) Install clutch release bearing and lever (if
removed). (Refer to 6 - CLUTCH/CLUTCH RELEASE
BEARING - INSTALLATION)
(2) Install clutch disc and pressure plate to fly-
wheel (Fig. 33). Install clutch alignment tool, and
install and torque pressure plate-to-flywheel bolts to
28 N´m (250 in. lbs.).
(3) Install transaxle assembly. (Refer to 21 -
TRANSMISSION/TRANSAXLE/MANUAL - INSTAL-
LATION)
Fig. 32 Slave Cylinder Removal/Installation
1 - MOUNTING HOLE
2 - SLAVE CYLINDER
3 - ACCESS HOLE
4 - NYLON ANTI-ROTATION TAB
RGCLUTCH6a-15
MODULAR CLUTCH ASSY - 2.4L GAS (Continued)

FLYWHEEL
REMOVAL
(1) Remove transaxle assembly. (Refer to 21 -
TRANSMISSION/TRANSAXLE/MANUAL -
REMOVAL)
(2) Remove clutch pressure plate and disc. (Refer
to 6 - CLUTCH/CLUTCH DISC - REMOVAL)
(3) Remove flywheel assembly (Fig. 34).
INSTALLATION
(1) Install NEW flywheel-to-crankshaft bolts by
hand.
(2) Torque bolts in a criss-cross sequence to 25
N´m (18 ft. lbs.) (Fig. 34).
(3) Torque bolts in a criss-cross sequence an addi-
tional 60É.
(4) Install clutch pressure plate and disc. (Refer to
6 - CLUTCH/CLUTCH DISC - INSTALLATION)
(5) Install transaxle assembly. (Refer to 21 -
TRANSMISSION/TRANSAXLE/MANUAL -
INSTALLATION)
Fig. 33 Clutch Disc and Pressure Plate
1 - FLYWHEEL
2 - DISC3 - PRESSURE PLATE
Fig. 34 Flywheel Bolt Torque Sequence
6a - 16 CLUTCHRG
FLYWHEEL (Continued)

CAUTION: Use correct screws when installing the
ORC.
(1) Install the ORC assembly into vehicle.
(2) Connect the wire connector to the ORC.
(3) Install three bolts holding ORC to floor
bracket. Torque bolts to 7.3 - 9.6 N´m (65 to 85 in.
lbs.)
(4) Install the storage bin onto the instrument
panel. Refer to Body, Instrument Panel, Storage Bin,
Installation.
WARNING: DO NOT CONNECT THE BATTERY NEG-
ATIVE CABLE. REFER TO ELECTRICAL,
RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG
SYSTEM FIRST.
PASSENGER AIRBAG
DESCRIPTION
WARNING: NEVER DISASSEMBLE THE PASSEN-
GER AIRBAG, THE PASSENGER AIRBAG HAS NO
SERVICEABLE PARTS.
The Passenger Airbag is located beneath the
instrument panel and pad assembly. The airbag is
mounted to the back side of the instrument panel
reinforcement.
The instrument panel top pad is the most visible
part of the passenger airbag system. Located under
the instrument panel top pad are the airbag door, the
passenger airbag cushion and the airbag cushion
supporting components.
The passenger airbag includes a magnesium hous-
ing within which the cushion and inflator are
mounted and sealed.
Following a passenger airbag deployment, the pas-
senger airbag and the instrument panel must be
replaced. The passenger airbag cannot be repaired,
and must be replaced if deployed or damaged in any
way.
OPERATION
The passenger airbag is equipped with two infla-
tors, each with three levels of pressure output. The
inflators seal the hole in the airbag cushion so it can
discharge the gas it produces directly into the cush-
ion when supplied with the proper electrical signal.
Following an airbag deployment, the airbag cushion
quickly deflates by venting this gas through the
cushion material towards the instrument panel.
The passenger airbag is secured with screws to the
instrument panel beneath the instrument panel top
pad and above the glove box opening. The instrumentpanel top pad above the glove box opening conceals
the airbag door and a predetermined hinge line
beneath its decorative cover. Upon airbag deploy-
ment, the top pad will bend at the hinge line and the
door will fold back out of the way onto the top of the
instrument panel.
WHEN THE FRONT AIRBAG SYSTEM IS
DEPLOYED BECAUSE OF A COLLISION, THE
FOLLOWING MUST BE REPLACED:
²COMPLETE STEERING COLUMN ASSEMBLY
²LOWER STEERING COUPLER
²STEERING WHEEL
²STEERING COLUMN CLOCK SPRING
²DRIVER AIRBAG COVER/HORN SWITCH
²DRIVER AIRBAG
²PASSENGER AIRBAG
²UPPER INSTRUMENT PANEL WITH PAD
CARE OF UNDEPLOYED AIRBAGS
Airbags must be stored in their original special
container until used for service. At no time should a
source of electricity be permitted near the inflator on
the back of an airbag. When carrying or handling an
undeployed airbag, the trim side of the airbag should
be pointing away from the body to minimize possibil-
ity of injury if accidental deployment occurs. Do not
place undeployed airbag face down on a solid surface,
the airbag will propel into the air if accidental
deployment occurs.
STANDARD PROCEDURE - DEPLOYED
PASSENGER AIRBAG CLEAN UP
Roll or fold the passenger airbag towards the
instrument panel surface and close the door over the
folded bag. Then tape the door shut.
Use a vacuum cleaner to remove any residual pow-
der from the vehicle interior. Work from the outside
in to avoid kneeling or sitting in a contaminated
area. Vacuum the heater and A/C outlets as well. If
HVAC was in RECIRC mode at time of airbag
deployment, operate HVAC blower on low speed/heat
and vacuum powder residue expelled from the heat
outlets. Multiple vacuum cleaning may be necessary
to decontaminate the interior of the vehicle.
SERVICE OF DEPLOYED AIRBAG
If a Passenger Airbag has been deployed, but not
due to a collision, replace the following:
²Passenger Airbag
²Upper instrument panel with pad
The component above must be replaced because
they cannot be reused. Inspect the heat duct near the
passenger airbag for any damage replace as neces-
sary. Replace any other passenger airbag system
components if damaged.
8O - 6 RESTRAINTSRS
OCCUPANT RESTRAINT CONTROLLER (Continued)

SEAT BELT FIRST ROW
OUTBOARD - LWB FOUR DOOR
REMOVAL
(1) Remove first and second row seats. Refer to
Owner's manual for proper procedures.
(2) Remove shoulder harness height adjuster knob
by pulling it straight away from adjuster.
(3) Slide floor anchor cover from over the anchor
bolt.
(4) Remove floor anchor bolt.
(5) Remove anchor from floor.
(6) Open clam shell cover from over seat belt turn-
ing loop.
(7) Remove bolt attaching turning loop to shoulder
belt height adjuster.
(8) Remove turning loop from C-pillar.
(9) Remove lower quarter trim panel.
(10) Route seat belt webbing and turning loop
through access hole in lower quarter trim panel.
(11) Remove bolt attaching seat belt retractor to
quarter panel.(12) Lift retractor upward and disengage arrow
head retainer attaching retractor to quarter panel.
(13) Remove seat belt from vehicle.
INSTALLATION
(1) Position seat belt to vehicle.
(2) Install arrow head retainer to quarter panel
and push downward to seat retainer.
(3) Install bolt attaching seat belt retractor to
quarter panel.
(4) Route seat belt webbing and turning loop
through access hole in lower quarter trim panel.
(5) Install lower quarter trim panel.
(6) Position turning loop to C-pillar.
(7) Install bolt attaching turning loop to shoulder
belt height adjuster.
(8) Close clam shell cover from over seat belt turn-
ing loop.
(9) Position anchor to floor.
(10) Install floor anchor bolt.
(11) Slide floor anchor cover over the anchor bolt.
(12) Install shoulder harness height adjuster knob
by pushing it straight onto adjuster.
(13) Install first and second row seats. Refer to
Owner's manual for proper procedures.
NOTE: The tightening specification for all seat belt
anchor bolts is 39 N´m (29 ft. lbs.) torque.
SEAT BELT SECOND RIGHT
ROW OUTBOARD - LWB
REMOVAL
(1) Remove second row seat from vehicle. Refer to
Owner's Manual for proper procedures.
(2) Slide lower anchor cover from over the anchor
shoulder-nut.
(3) Remove lower anchor shoulder-nut (Fig. 5).
(4) Remove lower anchor from wheelhouse.
(5) Fold upper turning loop extension cover down-
ward to gain access to anchor bolt.
(6) Remove bolt attaching turning loop to exten-
sion bracket above quarter glass (Fig. 5).
(7) Remove turning loop from extension bracket.
(8) Remove D-pillar trim panel.
(9) Remove quarter trim bolster.
(10) Route seat belt webbing and turning loop
through access hole in quarter trim.
(11) Remove bolt attaching retractor to inner quar-
ter panel (Fig. 5).
(12) Remove screw attaching retractor to inner
quarter panel.
(13) Remove second row seat belt retractor from
vehicle.
Fig. 4 SEAT BELT FIRST ROW OUTBOARD - SWB
FOUR DOOR
1 - UPPER C-PILLAR TRIM
2 - KNOB
3 - HEIGHT ADJUSTER
4 - C-PILLAR
5 - RETRACTOR
6 - FLOOR ANCHOR
7 - QUARTER TRIM PANEL
8 - TURNING LOOP
8O - 10 RESTRAINTSRS
SEAT BELT FIRST ROW OUTBOARD - SWB FOUR DOOR (Continued)