2002 CHRYSLER VOYAGER torque

CAUTION: Band clamps should never be tightened
such that the two sides of the clamps are bottomed
out against the center hourglass shaped center
block. Once this occurs, the clamp band has been
stretched and has lost its clamping force and must
be replaced.
To replace the band clamp; remove the nut and peel
back the ends of the clamp until spot weld breaks.
Clean remaining spot weld from the pipe using a
file or grinder until surface is smooth.
NOTE: Maintain proper clamp orientation when
replacing with new clamp.
(5) Tighten the band clamp to 55 N´m (40 ft. lbs.)
(Fig. 12).
(6) Connect the right side half shaft to the rear
differential module (AWD equipped only).
RESONATOR
REMOVAL
(1) (Refer to 11 - EXHAUST SYSTEM/MUFFLER -
REMOVAL)
INSTALLATION
(1) (Refer to 11 - EXHAUST SYSTEM/MUFFLER -
INSTALLATION)
Fig. 12 Band Clamp
1 - BAND CLAMP
2 - TORQUE SPECIFICATION
RSEXHAUST SYSTEM11-9
MUFFLER (Continued)
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EXHAUST SYSTEM AND TURBOCHARGER
TABLE OF CONTENTS
page page
EXHAUST SYSTEM AND TURBOCHARGER
DESCRIPTION..........................1
SPECIFICATIONS - TORQUE...............1
TURBOCHARGER SYSTEM
DESCRIPTION..........................2
OPERATION............................2
TURBOCHARGER
REMOVAL.............................4CLEANING.............................5
INSTALLATION..........................5
HEAT SHIELDS
REMOVAL.............................5
INSTALLATION..........................6
EXHAUST SYSTEM AND
TURBOCHARGER
DESCRIPTION
The basic exhaust system consists of an engine
exhaust manifold, turbocharger, exhaust down pipe,
exhaust pipe, exhaust heat shield(s), muffler and
exhaust tailpipe
The exhaust system uses a single muffler.
The exhaust system must be properly aligned to
prevent stress, leakage and body contact. If the sys-
tem contacts any body panel, it will transfer objec-
tionable noises originating from the engine to the
body.When inspecting an exhaust system, critically
inspect for cracked or loose joints, stripped screw or
bolt threads, corrosion damage and worn, cracked or
broken hangers. Replace all components that are
badly corroded or damaged. DO NOT attempt to
repair.
When replacement is required, use original equip-
ment parts (or equivalent). This will assure proper
alignment and provide acceptable exhaust noise lev-
els.
CAUTION: Avoid application of rust prevention com-
pounds or undercoating materials to exhaust sys-
tem floor pan exhaust heat shields. Light overspray
near the edges is permitted. Application of coating
will result in excessive floor pan temperatures and
objectionable fumes.
SPECIFICATIONS - TORQUE
2.5L DIESEL - TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Exhaust Manifold Nuts 32.4 24 Ð
Exhaust Manifold Heat
shield Bolts27.5 21 Ð
Turbocharger Bracket
Bolts47.1 35 Ð
Turbocharger Downpipe
Nuts32.4 24 Ð
Turbocharger Oil Feed
Line Fitting24.5 18 215
Turbocharger to Exhaust
Manifold Nuts32.4 24 Ð
RGEXHAUST SYSTEM AND TURBOCHARGER11a-1
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(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 be inspected for any tears or
signs of prior leakage. If any gaskets show such indi-
cations, they should be replaced with new gaskets.
All gasket mating surfaces must be cleaned of old
gasket material to produce a smooth and dirt free
sealing surface for the new gasket.
INSTALLATION
(1) Connect exhaust manifold and turbocharger.
Torque nuts to 32.4N´m.
(2) Position new exhaust manifol gasket on
exhaust manifol studs (Fig. 6).
(3) Install exhaust manifold and turbocharger on
engine (Fig. 6). Torque nuts to 32.4N´m.
(4) Connect turbocharger oil supply and return
lines at turbocharger (Fig. 6). Torque oil supply line
to 24.5N´m.
(5) Install exhaust manifold shield (Fig. 6). Torque
bolts to 27.5N´m.
(6) Install engine lift hook (Fig. 6). Torque bolts to
32.4N´m.
(7) Install thermostat to upper radiator hose tube
and turbocharger outlet tube (Fig. 5).
(8) Install engine in vehicle (Refer to 9 - ENGINE
- INSTALLATION).
HEAT SHIELDS
REMOVAL
(1) Remove front wiper unit (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
REMOVAL).
(2) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(3) Partially drain cooling system (Refer to 7 -
COOLING/ENGINE/COOLANT - STANDARD PRO-
CEDURE).
(4) Remove thermostat housing to upper radiator
hose tube (Fig. 7).
(5) Remove exhaust manifold heat shield retaining
bolts and remove shield (Fig. 8).
Fig. 7 TURBOCHARGER AND COOLANT PIPES
1 - TURBOCHARGER OUTLET PIPE RETAINING BOLT
2 - TURBOCHARGER OUTLET PIPE
3 - ADAPTER HOSE
4 - HEAT SHIELD
5 - HOSE CLAMPS
6 - TURBOCHARGER INLET PIPE RETAINING BOLT
7 - TURBOCHARGER INLET PIPE
8 - ADAPTER HOSE
9 - HOSE CLAMPS
10 - CLAMP
11 - EGR VALVE TO INTAKE AIR INLET PIPE
12 - CLAMP
13 - THERMOSTAT HOUSING TO UPPER RADIATOR HOSE
PIPE
RGEXHAUST SYSTEM AND TURBOCHARGER11a-5
TURBOCHARGER (Continued)
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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 (Fig. 7).
(4) Refill cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(5) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
(6) Install front wiper unit (Refer to 8 - ELECTRI-
CAL/WIPERS/WASHERS/WIPER MODULE -
INSTALLATION).
Fig. 8 EXHAUST MANIFOLD AND TURBOCHARGER
1 - TURBOCHARGER OIL SUPPLY BANJO BOLT
2 - COPPER WASHER
3 - EXHAUST MANIFOLD GASKET
4 - COPPER WASHER
5 - EXHAUST MANIFOL HEAT SHIEL RETAINING BOLT
6 - TURBOCHARGER
7 - ENGINE LIFT HOOK
8 - ENGINE LIFT HOOK RETAINING BOLT
9 - SPACER
10 - EXHAUST MANIFOLD RETAINING NUT
11 - TURBOCHARGER OIL RETURN HOSE
12 - HOSE CLAMPS
13 - EXHAUST MANIFOLD STUDS
11a - 6 EXHAUST SYSTEM AND TURBOCHARGERRG
HEAT SHIELDS (Continued)
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FRAME & BUMPERS
TABLE OF CONTENTS
page page
BUMPERS
SPECIFICATIONS - TORQUE...............1
FRONT FASCIA
REMOVAL.............................1
INSTALLATION..........................1
FRONT BUMPER REINFORCEMENT
REMOVAL.............................2
INSTALLATION..........................2
REAR FASCIA
REMOVAL.............................3
INSTALLATION..........................3
REAR BUMPER REINFORCEMENT
REMOVAL.............................3
INSTALLATION..........................3
REAR FASCIA - SCUFF PAD
REMOVAL.............................4INSTALLATION..........................4
FRAME
SPECIFICATIONS
FRAME DIMENSIONS...................4
SPECIFICATIONS - TORQUE.............9
FRONT CRADLE CROSSMEMBER
DESCRIPTION
DESCRIPTION - FRONT CRADLE
CROSSMEMBER.......................9
DESCRIPTION - FRONT CRADLE
CROSSMEMBER THREAD REPAIR.........9
REMOVAL.............................10
INSTALLATION.........................12
FRONT CROSSMEMBER MOUNT BUSHINGS
REMOVAL.............................12
INSTALLATION.........................12
BUMPERS
SPECIFICATIONS - TORQUE
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Front bumper reinforcement attaching nut 54 40 Ð
Rear bumper reinforcement attaching nut 27 20 Ð
FRONT FASCIA
REMOVAL
(1) Release hood latch and open hood.
(2) Remove the headlamp assemblies (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
HEADLAMP - REMOVAL).
(3) Hoist vehicle and support with safety stands.
(4) Remove the five bolts attaching bottom of fas-
cia/air dam to radiator closure panel.
(5) Remove front wheels.
(6) Remove front wheelhouse splash shields fasten-
ers as necessary to gain access to bolts attaching
front fascia to fender. (Refer to 23 - BODY/EXTERI-
OR/ WHEELHOUSE SPLASH SHIELD - REMOV-
AL).
(7) Remove the two bolts and two nuts attaching
fascia to the front fenders (Fig. 1).
(8) Disconnect fog lamp wire connectors, if neces-
sary.
(9) Lower vehicle.(10) Remove two bolts attaching the upper grille
support to the headlamp mounting panel at each side
of the grille.
(11) Remove bumper fascia from vehicle.
INSTALLATION
(1) Position front bumper fascia on vehicle.
(2) Install the two bolts attaching fascia to head-
lamp mounting panel at each side of grille.
(3) Hoist vehicle and support with safety stands.
(4) Install the two bolts and two nuts attaching
fascia to the front fenders (Fig. 1). The fascia should
be flush to fender.
(5) Install front wheelhouse splash shields fasten-
ers. (Refer to 23 - BODY/EXTERIOR/ WHEEL-
HOUSE SPLASH SHIELD - INSTALLATION).
(6) Install front wheels.
(7) Connect fog lamp wire connectors, if necessary.
(8) Install the five bolts attaching bottom of fascia
to radiator closure panel.
(9) Lower the vehicle.
RSFRAME & BUMPERS13-1
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(10) Install the headlamp assemblies. (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
HEADLAMP - 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 attaching front bumper
reinforcement to frame rail (Fig. 2).
(4) Remove front bumper reinforcement from vehi-
cle.
INSTALLATION
NOTE: Check position of the arrows molded into
the foam for correct orientation.
(1) Support front bumper reinforcement using a
suitable lifting device and lift into position.
(2) Install the four nuts attaching reinforcement to
frame rails. Tighten nuts to 54 N´m (40 ft. lbs.)
torque.
(3) Install front fascia. (Refer to 13 - FRAMES &
BUMPERS/BUMPERS/FRONT FASCIA - INSTAL-
LATION).
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 FRAME & BUMPERSRS
FRONT FASCIA (Continued)
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(3) Install the six nuts attaching rear bumper rein-
forcement to frame rail extensions and tighten to 27
N´m (20 ft. lbs.) torque (Fig. 4).
(4) 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. The scuff pad serviceability is improved if the
rear fascia is to be removed for service.
NOTE: If the rear fascia is to be removed for other
service issues or If the scuff pad is to be reused
use the steps below.
(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 while squeezing the rear locking tabs from
underneath the fascia to release the rear edge of
scuff pad from the rear bumper fascia. Pull the scuff
pad up and squeeze the remaining tabs to release the
remaining of the scuff pad. (Fig. 5).
NOTE: If the rear fascia is to not to be removed for
other service issues use the step below.
(3) 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 to release the forward tabs (Fig.
5).
INSTALLATION
(1) Verify that there are fifteen slots in the fascia.
(2) Place scuff pad in position (Fig. 5).
(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.(6) If rear bumper fascia has been removed install.
(Refer to 13 - FRAME & BUMPERS/BUMPERS/
REAR FASCIA - INSTALLATION).
FRAME
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.
INDEX
DESCRIPTION FIGURE
CROSSMEMBER DIMENSIONS 6
ENGINE BOX - TOP VIEW 7
ENGINE COMPARTMENT AND FRAME RAIL - SIDE VIEW 8
FULL VEHICLE - BOTTOM VIEW 9
Fig. 5 SCUFF PAD
1 - SCUFF PAD
2 - TABS
13 - 4 FRAME & BUMPERSRS
REAR BUMPER REINFORCEMENT (Continued)
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SPECIFICATIONS - TORQUE
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Front Cradle Crossmember to Fram Rail Attaching Bolts (4) 163 120 Ð
Reinforcement Plate to Crossmember Attaching Bolt Size M14 (9) 153 113 Ð
Reinforcement Plate to Crossmember Attaching Bolt Size M12 (1) 106 78 Ð
Reinforcement Plate to Crossmember Attaching Bolt Size M10 (4) 61 45 Ð
Rear Engine Mount to Crossmember Attaching Through Bolt 68 50 Ð
Radiator Support Crossmember Attaching Bolts 51 38 Ð
FRONT CRADLE
CROSSMEMBER
DESCRIPTION
DESCRIPTION - FRONT CRADLE
CROSSMEMBER
This vehicle uses a one piece cast aluminum cradle
for the front cradle crossmember. The cradle cross-
member is used as the attaching points for the lower
control arms, stabilizer bar and steering gear. The
cradle also has the power steering hoses and the
chassis brake tubes attached to it.
WARNING: If a threaded hole in the suspension cra-
dle needs to be repaired, only use the type of
thread insert and installation procedure specified
for this application.
The threaded holes in the front cradle crossmem-
ber that are used for attachment of the lower control
arm rear bushing retainer, power steering hose and
chassis brake tubes can be repaired. The repair is
done by the installation of a Heli-Coiltthread insert
which has been specifically developed for this appli-
cation. Refer to the Mopar Parts Catalog for the spec-
ified Heli-Coiltthread insert to be used for this
application. The procedure for installing the Heli-
Coiltthread insert is detailed in the Service Proce-
dures section in this group of the service manual.
DESCRIPTION - FRONT CRADLE
CROSSMEMBER THREAD REPAIR
WARNING: When performing this procedure use
only the thread inserts which are specified in the
Mopar Parts Catalog for this repair procedure.
These thread inserts have been specifically devel-
oped for this application and use of other types of
thread inserts can result in an inferior long term
repair.The threaded holes in the front cradle crossmem-
ber, if damaged, can repaired by installing a Heli-
Coiltthread insert.
The threaded holes that are repairable using the
thread insert, are the lower control arm rear bushing
retainer mounting bolt holes, routing bracket attach-
ing locations for the power steering hoses, and brake
hose attachment holes.
This repair procedure now allows the threaded
holes in the cradle crossmember to be repaired, elim-
inating the need to replace the cradle crossmember if
damage occurs to one of the threaded holes.
The thread inserts for this application are specified
by part number in the Mopar Parts Catalog.Do not
use a substitute thread insert.
The specific tools and equipment required to install
the thread insert are listed below. Refer to the
instructions included with the thread insert for the
detailed procedure used for the installation of the
thread insert.
NOTE: The thread inserts for this application are for
the repair of M8x1.25 and M10x1.5 threads. Be sure
the correct tools are used for the required thread
insert size.
TOOL REQUIREMENT FOR M8x1.25 Thread
²8.3mm (5/16 in.) Drill Bit
²120É Countersink
²Heli-CoiltTap #4863-8
²Heli-CoiltGage #4624-8
²Heli-CoiltHand Inserting Tool 7751-8
²Needle Nose Pliers ± For Removal Of Thread
Insert Driving Tang
TOOL REQUIREMENT FOR M10x1.5 Thread
²10.5mm (25/64 in.) Drill Bit
²120É Countersink
²Heli-CoiltTap #4863-10
²Heli-CoiltGage #4624-10
²Heli-CoiltHand Inserting Tool 7751-10
²Needle Nose Pliers ± For Removal Of Thread
Insert Driving Tang
RSFRAME & BUMPERS13-9
FRAME (Continued)
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