2002 CHRYSLER VOYAGER low oil pressure

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Driver Power Seat Front Riser
MotorRD At Seat N/S
Driver Power Seat Horizontal Motor BK At Seat N/S
Driver Power Seat Rear Riser
MotorRD At Seat N/S
Driver Power Seat Recliner Motor GN At Seat N/S
Driver Power Seat Switch GN At Switch N/S
Driver Power Window Motor RD At Motor N/S
Driver Power Window Switch GN At Switch N/S
Driver Power Window Switch
(RHD)NAT At Switch N/S
Driver Seatbelt Switch WT At Switch on Seat Harness N/S
Driver Seatbelt Tensioner On Seat Harness N/S
EGR Solenoid (Diesel) BK Above Transmission
Right Side of EngineN/S
EGR Solenoid GY Above Transmission
Right Side of Engine9, 10, 11, 13
Electric Wiper De-Icer-C1 WT Right Side Instrument Panel 15, 1923
Electric Wiper De-Icer-C2 WT Left Side Instrument Panel 15, 16, 22
Engine Control Module C1 (Diesel) BK Right Side of Engine 11
Engine Control Module C2 (Diesel) BK Right Side of Engine 11
Engine Coolant Temperature
Sensor (Gas)BK On Cylinder Block N/S
Engine Coolant Temperature
Sensor (Diesel)BL On Cylinder Block 11
Engine Oil Pressure Sensor
(Diesel)BK Rear of Engine 12
Engine Oil Pressure Switch (Gas) LTGN On Cylinder Block 9
Engine Oil Temperature Sensor
(Diesel)BK Rear of Engine 12
EVAP/Purge Solenoid BK Right Motor Mount 9, 13
Evaporator Temperature Sensor BK Right Side of HVAC N/S
Floor Console Lamp BK At Lamp N/S
Floor Console Power Outlet RD At Front Console N/S
Front Blower Module C1 (ATC) BK On HVAC N/S
Front Blower Module C2 (ATC) BK On HVAC N/S
Front Cigar Lighter RD/NAT Rear of Lighter 15, 18, 20
Front Reading Lamps/Switch BK At Switch N/S
Front Washer Pump Motor BK Right Fender Well 3
Fuel Heater (Diesel) BK Left Rear Engine Compartment N/S
Fuel Injector No.1 BK At Fuel Injector N/S
Fuel Injector No.1 (Diesel) BK At Fuel Injector 11
Fuel Injector No.2 BK At Fuel Injector N/S
Fuel Injector No.2 (Diesel) BK At Fuel Injector 11
8W - 91 - 4 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
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CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Fuel Injector No.3 BK At Fuel Injector N/S
Fuel Injector No.3 (Diesel) BK At Fuel Injector 11
Fuel Injector No.4 BK At Fuel Injector N/S
Fuel Injector No.4 (Diesel) BK At Fuel Injector 11
Fuel Injector No.5 BK At Fuel Injector N/S
Fuel Injector No.6 BK At Fuel Injector N/S
Fuel Pump Module LTGY Side of Fuel Tank N/S
Fuel Pressure Sensor (Diesel) BK Top Left of Engine 11
Generator BK Rear of Generator 10, 11, 13, 14
Glove Box Lamp BL Rear of Glove Box 18, 24
Glow Plug Relay (Diesel) BK Near Battery N/S
Halo Lamp WT Steering Column 15, 16, 17, 18, 26
Headlamp Switch BK Rear of Switch 15, 16, 25
Headlamp Washer Pump Motor At Motor N/S
High Note Horn BK Left Frame Rail 5
High Pressure Fuel Pump (Diesel) Rear of Pump 11
Hood Ajar Switch BK Left Fender 6
Idle Air Control Motor (2.4L) BK On Throttle Body 9
Idle Air Control Motor (3.3/3.8L) BK On Throttle Body 13
Ignition Coil Pack 2.4L BK Top of Valve Cover 9, 10
Ignition Coil Pack 3.3L, 3.8L DKGY Top of Engine 14
Ignition Switch BK Rear of Switch at Steering Column 15, 16, 17, 18, 26
Inlet Air Temperature Sensor BK Top Left of Engine N/S
Instrument Cluster BK Rear of Cluster 15, 16, 23
Instrument Panel Switch Bank BK Right Center of Instrument Panel 15, 18, 20
Instrument Panel Power Outlet NAT Center of Instrument Panel N/S
Integrated Power Module C1 LTGN Left Fender Shield 7
Integrated Power Module C2 GN/BL Left Fender Shield 7
Integrated Power Module C3
(Diesel)YL/RD Left Fender Shield 7
Integrated Power Module C3 (Gas) NAT/RD Left Fender Shield 7
Integrated Power Module C4 BL Left Fender Shield 7
Integrated Power Module C5 BK Left Fender Shield 7
Integrated Power Module C6 NAT Left Fender Shield 7
Integrated Power Module C7 BK/RD Left Fender Shield 7
Integrated Power Module C8 OR Left Fender Shield 7
Integrated Power Module C9 BK Left Fender Shield 7
Knock Sensor GY Front of Cylinder Block N/S
Leak Detection Pump LTGY At Pump 9, 10 14
Left B Pillar Switch GY Left B Pillar 34
Left Cinch/Release Motor GY Left Sliding Door N/S
Left Combination Relay BK Left Rear Quarter Panel N/S
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-5
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
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SPECIAL TOOLS
POWER DISTRIBUTION SYSTEMS
ACCESSORY RELAY
DESCRIPTION
The accessory relay is an electromechanical device
that switches fused battery current to the accessory
powered vehicle circuits when the ignition switch is
turned to the Accessory or On positions. The delay
feature will maintain power to the accessories for 45
seconds after the ignition is shut off or until a door is
opened. This allows sufficient time to close windows
and park the windshield wipers. The accessory relay
is located in the Integrated Power Module (IPM) in
the engine compartment.
The accessory relay is a International Standards
Organization (ISO) relay. Relays conforming to the
ISO specifications have common physical dimensions,
current capacities, terminal patterns, and terminal
functions.
The accessory relay cannot be repaired or adjusted
and, if faulty or damaged, it must be replaced.
OPERATION
The ISO relay consists of an electromagnetic coil, a
resistor or diode, and three (two fixed and one movable)
electrical contacts. The movable (common feed) relay
contact is held against one of the fixed contacts (normal-
ly closed) by spring pressure. When the electromagnetic
coil is energized, it draws the movable contact away
from the normally closed fixed contact, and holds it
against the other (normally open) fixed contact.
When the electromagnetic coil is de-energized,
spring pressure returns the movable contact to the
normally closed position. The resistor or diode is con-
nected in parallel with the electromagnetic coil in the
relay, and helps to dissipate voltage spikes that are
produced when the coil is de-energized.
DIAGNOSIS AND TESTING
DIAGNOSIS & TESTING - ACCESSORY RELAY
The accessory relay (Fig. 1) is located in the Inte-
grated Power Module (IPM), in the engine compart-
ment. For complete circuit diagrams, refer toWiring
Diagrams.
(1) Remove the accessory relay from the IPM.
Refer toAccessory Relayin the Removal and
Installation section of this group for the procedure.
(2) A relay in the de-energized position should
have continuity between terminals 87A and 30, and
no continuity between terminals 87 and 30. If OK, go
to Step 3. If not OK, replace the faulty relay.
(3) Resistance between terminals 85 and 86 (elec-
tromagnet) should be 75   5 ohms. If OK, go to Step
4. If not OK, replace the faulty relay.
(4) Connect a battery to terminals 85 and 86.
There should now be continuity between terminals
30 and 87, and no continuity between terminals 87A
and 30. If OK, perform the Relay Circuit Test that
follows. If not OK, replace the faulty relay.
DIAGNOSIS & TESTING - RELAY CIRCUIT TEST
(1) The relay common feed terminal cavity (30) of
the IPM is connected to battery voltage and should
be hot at all times. Check for battery voltage at the
fused B(+) circuit cavity in the IPM receptacle for the
accessory relay. If OK, go to Step 2. If not OK, repair
the fused B(+) circuit to the IPM fuse as required.
(2) The relay normally closed terminal (87A) is
connected to terminal 30 in the de-energized position,
but is not used for this application. Go to Step 3.
(3) The relay normally open terminal (87) is con-
nected to the common feed terminal (30) in the ener-
gized position. This terminal supplies battery voltage
to the fused B(+) fuse in the IPM that feeds the
accessories when the relay is energized by the igni-
tion switch. There should be continuity between the
IPM cavity for relay terminal 87 and the fused B(+)
fuse in the IPM at all times. If OK, go to Step 4. If
not OK, repair the open fused B(+) circuit to the IPM
fuse as required.
Terminal Pick Kit 6680
Fig. 1 Accessory Relay
8W - 97 - 2 8W-97 POWER DISTRIBUTION SYSTEMRS
POWER DISTRIBUTION SYSTEM (Continued)
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VALVE SPRINGS & SEALS
REMOVAL
REMOVAL - CYLINDER HEAD ON.........32
REMOVAL - CYLINDER HEAD OFF........33
INSPECTION..........................33
INSTALLATION
INSTALLATION - CYLINDER HEAD ON.....33
INSTALLATION - CYLINDER HEAD OFF....33
HYDRAULIC LASH ADJUSTERS
DIAGNOSIS AND TESTING - HYDRAULIC
LASH ADJUSTER NOISE DIAGNOSIS......34
REMOVAL.............................34
INSTALLATION.........................34
ROCKER ARMS
REMOVAL.............................35
INSPECTION..........................35
INSTALLATION.........................35
ENGINE BLOCK
DESCRIPTION.........................35
STANDARD PROCEDURE
STANDARD PROCEDURE - PISTON TO
CYLINDER BORE FITTING..............36
STANDARD PROCEDURE - CYLINDER
BORE HONING.......................36
CLEANING............................37
INSPECTION..........................37
CONNECTING ROD BEARINGS
STANDARD PROCEDURE
CONNECTING ROD - FITTING...........37
CRANKSHAFT
DESCRIPTION.........................38
OPERATION...........................38
STANDARD PROCEDURE - CRANKSHAFT
ENDPLAY ...........................38
REMOVAL.............................38
INSPECTION..........................39
INSTALLATION.........................39
CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDURE - MAIN BEARING -
FITTING.............................41
CRANKSHAFT OIL SEAL - FRONT
REMOVAL.............................42
INSTALLATION.........................43
CRANKSHAFT OIL SEAL - REAR
REMOVAL.............................43
INSTALLATION.........................44
PISTON & CONNECTING ROD
DESCRIPTION.........................45
OPERATION...........................45
REMOVAL.............................45
INSTALLATION.........................46
PISTON RINGS
STANDARD PROCEDURE
PISTON RING - FITTING................47
VIBRATION DAMPER
REMOVAL.............................48
INSTALLATION.........................48STRUCTURAL COLLAR
REMOVAL.............................49
INSTALLATION.........................49
ENGINE MOUNTING
DESCRIPTION.........................49
FRONT MOUNT
REMOVAL.............................49
INSTALLATION.........................50
LEFT MOUNT
REMOVAL.............................50
INSTALLATION.........................50
REAR MOUNT
REMOVAL.............................51
INSTALLATION.........................51
RIGHT MOUNT
REMOVAL.............................52
INSTALLATION.........................52
LUBRICATION
DESCRIPTION.........................53
OPERATION...........................53
DIAGNOSIS AND TESTING - CHECKING
ENGINE OIL PRESSURE................53
OIL
STANDARD PROCEDURE
ENGINE OIL LEVEL CHECK.............53
STANDARD PROCEDURE - ENGINE OIL
AND FILTER CHANGE..................54
OIL FILTER
DESCRIPTION.........................54
REMOVAL.............................54
INSTALLATION.........................55
OIL PAN
REMOVAL.............................55
INSTALLATION.........................55
OIL PRESSURE SWITCH
REMOVAL.............................55
INSTALLATION.........................55
OIL PUMP
REMOVAL.............................55
DISASSEMBLY.........................56
CLEANING............................57
INSPECTION..........................57
ASSEMBLY............................58
INSTALLATION.........................58
INTAKE MANIFOLD
DESCRIPTION.........................59
OPERATION...........................59
DIAGNOSIS AND TESTING - INTAKE
MANIFOLD LEAKS.....................59
INTAKE MANIFOLD - UPPER
REMOVAL.............................60
INSPECTION..........................61
INSTALLATION.........................61
INTAKE MANIFOLD - LOWER
REMOVAL.............................61
INSPECTION..........................61
INSTALLATION.........................61
9 - 2 ENGINE 2.4LRS
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EXHAUST MANIFOLD
DESCRIPTION.........................62
OPERATION...........................62
REMOVAL.............................62
CLEANING............................62
INSPECTION..........................62
INSTALLATION.........................62
TIMING BELT COVER(S)
REMOVAL.............................63
INSTALLATION.........................63
TIMING BELT AND SPROCKET(S)
REMOVAL
REMOVAL - TIMING BELT...............64REMOVAL - CRANKSHAFT SPROCKET....66
CLEANING............................66
INSTALLATION
INSTALLATION - CRANKSHAFT SPROCKET . 66
INSTALLATION - TIMING BELT...........67
TIMING BELT TENSIONER & PULLEY
REMOVAL.............................68
INSTALLATION.........................69
BALANCE SHAFTS AND CARRIER ASSEMBLY
DESCRIPTION.........................69
OPERATION...........................70
REMOVAL.............................70
INSTALLATION.........................71
ENGINE 2.4L
DESCRIPTION
The 2.4 Liter (148 cu. in.) in-line four cylinder
engine is a double over head camshaft with hydraulic
lash adjusters and four valve per cylinder design.
The engine is free-wheeling; meaning it has provi-
sions for piston-to-valve clearance. However valve-to-
valve interference can occur, if camshafts are rotated
independently.
The cylinders are numbered from front of the
engine to the rear. The firing order is 1±3±4±2.
The engine identification number is located on the
rear of the cylinder block (Fig. 1).
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION
Engine diagnosis is helpful in determining the
causes of malfunctions not detected and remedied by
routine maintenance.
These malfunctions may be classified as either
mechanical (e.g., a strange noise), or performance
(e.g., engine idles rough and stalls).
Refer to the Engine Mechanical and the Engine
Performance diagnostic charts, for possible causes
and corrections of malfunctions (Refer to 9 - ENGINE
- DIAGNOSIS AND TESTING - MECHANICAL)
(Refer to 9 - ENGINE - DIAGNOSIS AND TESTING
- PERFORMANCE).
For fuel system diagnosis, (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY - DIAGNOSIS AND
TESTING).
Additional tests and diagnostic procedures may be
necessary for specific engine malfunctions that can-
not be isolated with the Service Diagnosis charts.
Information concerning additional tests and diagno-
sis is provided within the following:
²Cylinder Compression Pressure Test
²Cylinder Combustion Pressure Leakage Test
²Engine Cylinder Head Gasket Failure Diagnosis
²Intake Manifold Leakage Diagnosis
²Hydraulic Lash Adjuster Noise Diagnosis
²Engine Oil Leak Inspection
Fig. 1 Engine Identification
1 - ENGINE IDENTIFICATION LOCATION
RSENGINE 2.4L9-3
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DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - MECHANICAL
CONDITION POSSIBLE CAUSES CORRECTION
NOISY VALVES 1. High or low oil level in
crankcase.1. Check and correct engine oil
level.
2. Thin or diluted oil. 2. Change oil to correct viscosity.
3. Thick oil 3. (a) Change engine oil and filter.
(b) Run engine to operating
temperature.
(c) Change engine oil and filter
again.
4. Low oil pressure. 4. Check and correct engine oil
pressure problem.
5. Dirt in hydraulic lifters/lash
adjusters.5. Replace hydraulic lifters/lash
adjusters.
6. Worn rocker arms. 6. Inspect oil supply to rocker arms.
7. Worn hydraulic lifters/lash
adjusters.7. Replace hydraulic lifters/lash
adjusters.
8. Worn valve guides. 8. Replace cylinder head assembly.
9. Excessive runout of valve seats
on valve faces.9. Grind valve seats and valves.
CONNECTING ROD NOISE 1. Insufficient oil supply. 1. Check engine oil level.
2. Low oil pressure. 2. Check engine oil level. Inspect oil
pump relief valve and spring.
3. Thin or diluted oil. 3. Change oil to correct viscosity.
4. Thick oil 4. (a) Change engine oil and filter.
(b) Run engine to operating
temperature.
(c) Change engine oil and filter
again.
5. Excessive bearing clearance. 5. Measure bearings for correct
clearance. Repair as necessary.
6. Connecting rod journal
out-of-round.6. Replace crankshaft or grind
surface.
7. Misaligned connecting rods. 7. Replace bent connecting rods.
9 - 6 ENGINE 2.4LRS
ENGINE 2.4L (Continued)
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CONDITION POSSIBLE CAUSES CORRECTION
MAIN BEARING NOISE 1. Insufficient oil supply. 1. Check engine oil level.
2. Low oil pressure. 2. Check engine oil level. Inspect oil
pump relief valve and spring.
3. Thin or diluted oil. 3. Change oil to correct viscosity.
4. Thick oil 4. (a) Change engine oil and filter.
(b) Run engine to operating
temperature.
(c) Change engine oil and filter
again.
5. Excessive bearing clearance. 5. Measure bearings for correct
clearance. Repair as necessary.
6. Excessive end play. 6. Check thrust bearing for wear on
flanges.
7. Crankshaft journal out-of-round
or worn.7. Replace crankshaft or grind
journals.
8. Loose flywheel or torque
converter.8. Tighten to correct torque.
OIL PRESSURE DROP 1. Low oil level. 1. Check engine oil level.
2. Faulty oil pressure sensor/switch. 2. Replace oil pressure sensor/
switch.
3. Low oil pressure. 3. Check oil pressure sensor/switch
and main bearing oil clearance.
4. Clogged oil filter. 4. Install new oil filter.
5. Worn parts in oil pump. 5. Replace worn parts or pump.
6. Thin or diluted oil. 6. Change oil to correct viscosity.
7. Oil pump relief valve stuck. 7. Remove valve and inspect, clean,
or replace.
8. Oil pump suction tube loose. 8. Remove oil pan and install new
tube or clean, if necessary.
9. Oil pump cover warped or
cracked.9. Install new oil pump.
10. Excessive bearing clearance. 10. Measure bearings for correct
clearance.
OIL LEAKS 1. Misaligned or deteriorated
gaskets.1. Replace gasket(s).
2. Loose fastener, broken or porous
metal part.2. Tighten, repair or replace the
part.
3. Misaligned or deteriorated cup or
threaded plug.3. Replace as necessary.
RSENGINE 2.4L9-7
ENGINE 2.4L (Continued)
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CONDITION POSSIBLE CAUSES CORRECTION
OIL CONSUMPTION OR SPARK
PLUGS FOULED1. PCV system malfunction. 1. Check system and repair as
necessary. (Refer to 25 -
EMISSIONS CONTROL/
EVAPORATIVE EMISSIONS/PCV
VALVE - DIAGNOSIS AND
TESTING)
2. Worn, scuffed or broken rings. 2. Hone cylinder bores. Install new
rings.
3. Carbon in oil ring slots. 3. Install new rings.
4. Rings fitted too tightly in grooves. 4. Remove rings and check
grooves. If groove is not proper
width, replace piston.
5. Worn valve guide(s). 5. Replace cylinder head assembly.
6. Valve stem seal(s) worn or
damaged.6. Replace seal(s).
DIAGNOSIS AND TESTING - ENGINE OIL LEAK
INSPECTION
Begin with a thorough visual inspection of the
engine, particularly at the area of the suspected leak.
If an oil leak source is not readily identifiable, the
following steps should be followed:
(1) Do not clean or degrease the engine at this
time because some solvents may cause rubber to
swell, temporarily stopping the leak.
(2) Add an oil soluble dye (use as recommended by
manufacturer). Start the engine and let idle for
approximately 15 minutes. Check the oil dipstick to
make sure the dye is thoroughly mixed as indicated
with a bright yellow color under a black light.
(3) Using a black light, inspect the entire engine
for fluorescent dye, particularly at the suspected area
of oil leak. If the oil leak is found and identified,
repair as necessary.
(4) If dye is not observed, drive the vehicle at var-
ious speeds for approximately 24 km (15 miles), and
repeat inspection.
(5)If the oil leak source is not positively
identified at this time, proceed with the air leak
detection test method as follows:
²Disconnect the fresh air hose (make-up air) at
the cylinder head cover and plug or cap the nipple on
the cover.
²Remove the PCV valve hose from the cylinder
head cover. Cap or plug the PCV valve nipple on the
cover.
²Attach an air hose with pressure gauge and reg-
ulator to the dipstick tube.
CAUTION: Do not subject the engine assembly to
more than 20.6 kpa (3 PSI) of test pressure.²Gradually apply air pressure from 1 psi to 2.5
psi maximum while applying soapy water at the sus-
pected source. Adjust the regulator to the suitable
test pressure that provides the best bubbles which
will pinpoint the leak source. If the oil leak is
detected and identified, repair per service manual
procedures.
²If the leakage occurs at the crankshaft rear oil
seal area, refer to the section, Inspection for Rear
Seal Area Leak.
(6) If no leaks are detected, turn off the air supply.
Remove the air hose, all plugs, and caps. Install the
PCV valve and fresh air hose (make-up air). Proceed
to next step.
(7) Clean the oil off the suspect oil leak area using
a suitable solvent. Drive the vehicle at various
speeds approximately 24 km (15 miles). Inspect the
engine for signs of an oil leak by using a black light.
NOTE: If oil leakage is observed at the dipstick tube
to block location; remove the tube, clean and reseal
using MoparTStud & Bearing Mount (press fit tube
applications only), and for O-ring style tubes,
remove tube and replace the O-ring seal.
INSPECTION FOR REAR SEAL AREA LEAKS
Since it is sometimes difficult to determine the
source of an oil leak in the rear seal area of the
engine, a more involved inspection is necessary. The
following steps should be followed to help pinpoint
the source of the leak.
If the leakage occurs at the crankshaft rear oil seal
area:
(1) Disconnect the battery.
(2) Raise the vehicle.
9 - 8 ENGINE 2.4LRS
ENGINE 2.4L (Continued)
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