2003 CHRYSLER VOYAGER Service Manual

keyless wiring diagram bonnet odometer lights engine coolant

Page 1369 of 2177

CHRYSLER VOYAGER 2003 Service Manual (7) Remove fuel rail. Be careful not to damage the
injector O-rings upon removal from their ports.
INSTALLATION
INSTALLATION - 2.4L
(1) Ensure injector holes are clean. Replace
O-rings if damaged.
(2)

(7) Remove fuel rail. Be careful not to damage the
injector O-rings upon removal from their ports.
INSTALLATION
INSTALLATION - 2.4L
(1) Ensure injector holes are clean. Replace
O-rings if damaged.
(2) Lubricate injector O-rings with a drop of clean
engine oil to ease installation.
(3) Put the tip of each injector into their ports.
Push the assembly into place until the injectors are
seated in the ports.
(4) Install the fuel rail mounting bolts. Tighten
bolts to 22 N´m (200 in. lbs.) torque.
(5) Connect the connectors to the fuel injectors.
(6) Install wiring harness to brackets.
(7) Connect the wiring connectors to fuel injectors
harness (Fig. 13).
(8) Connect negative battery cable.
(9) Use the DRBIIItscan tool to pressurize the
fuel system. Check for leaks.
INSTALLATION - 3.3/3.8L
(1) Ensure injector holes are clean. Replace
O-rings if damaged.
(2) Lubricate injector O-rings with a drop of clean
engine oil to ease installation.
(3) Put the tip of each injector into their ports.
Push the assembly into place until the injectors are
seated in the ports.
(4) Install the fuel rail mounting bolts. Tighten
bolts to 22 N´m (200 in. lbs.) torque.
(5) Remove covering on lower intake manifold and
clean surface.(6) Install the Upper Intake Manifold, refer to
Engine/Manifolds/Upper Intake for more information.
(7) Install fuel hose quick connector fitting to chas-
sis tubes.Refer to Fuel Hoses, Clamps and
Quick Connect Fittings in this Section.Push the
fitting onto the chassis tube until it clicks into place.
Pull on the fitting to ensure complete insertion.
(8) Connect negative cable to battery.
(9) Use the DRBIIItscan tool to pressurize the
fuel system. Check for leaks.
FUEL TANK
DESCRIPTION
The fuel tank is constructed of a plastic material.
Its main functions are for fuel storage and for place-
ment of the fuel pump module. The tank is made
from High density Polyethylene (HDPE) material.If
equipped with ORVR (Onboard Refueling Vapor
Recovery) it has been added to the fuel tank to con-
trol refueling vapor emissions.
OPERATION
All models pass a full 360 degree rollover test
without fuel leakage. To accomplish this, fuel and
vapor flow controls are required for all fuel tank con-
nections.
All models are equipped with either one or two
rollover valves mounted into the top of the fuel tank
(or pump module).
An evaporation control system is connected to the
rollover valve(s)/control valve(Refer to 25 - EMIS-
SIONS CONTROL/EVAPORATIVE EMISSIONS/
ORVR - OPERATION) to reduce emissions of fuel
vapors into the atmosphere, when the tank is vented
due to vapor expansion in the tank. When fuel evap-
orates from the fuel tank, vapors pass through vent
hoses or tubes to a charcoal canister where they are
temporarily held. When the engine is running, the
vapors are drawn into the intake manifold. In addi-
tion, fuel vapors produced during vehicle refueling
are allowed to pass through the vent hoses/tubes to
the charcoal canister(s) for temporary storage (prior
to being drawn into the intake manifold). All models
are equipped with a self-diagnosing system using a
Leak Detection Pump (LDP) or Natural Vacuum
Leak Detection (NVLD). Refer to the Emission Con-
trol System for additional information.
INLET CHECK VALVE
All vehicles have an inlet check valve on the inside
of the fuel tank at the filler inlet
The valve prevents fuel from splashing back on
customer during vehicle refueling. The valve is a
non-serviceable item.
Fig. 14 FUEL INJECTORS 3.3/3.8L
14 - 10 FUEL DELIVERYRS
FUEL RAIL (Continued)
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Page 1370 of 2177

CHRYSLER VOYAGER 2003 Service Manual REMOVAL
(1) Remove fuel filler cap and perform Fuel Sys-
tem Pressure Release procedure (Fig. 15).
(2) Disconnect negative cable from battery.
(3) Insert fuel siphon hose into fuel filler neck and
pus

Page 1371 of 2177

CHRYSLER VOYAGER 2003 Service Manual (4) Tighten strap bolts to 54 N´m (40 ft. lbs.)
torque. Tighten T strap bolt to 28.2 N´m (250 in.
lbs.). Remove transmission jack.
(5) Tighten filler hose clamp to 3.3 N´m (30 in.
lbs.).
CAUTION: E

Page 1372 of 2177

CHRYSLER VOYAGER 2003 Service Manual (5) Install the canister from filler tube (Fig. 22).
(6) Install the splash shield.
(7) Install the left rear tire.
(8) lower vehicle.
(9) Connect the negative battery cable.
INLET FILTER
REMOVAL
(1)

Page 1373 of 2177

CHRYSLER VOYAGER 2003 Service Manual WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE DISCONNECTING A QUICK-CONNECT FIT-
TINGS. REFER TO THE FUEL PRESSURE RELEASE
PROCEDURE.
(1) Perform Fuel Pressure Release Procedure.
Refer to the Fuel Pres

WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE DISCONNECTING A QUICK-CONNECT FIT-
TINGS. REFER TO THE FUEL PRESSURE RELEASE
PROCEDURE.
(1) Perform Fuel Pressure Release Procedure.
Refer to the Fuel Pressure Release Procedure in this
section.
(2) Disconnect negative cable from battery or aux-
iliary jumper terminal.
(3) Squeeze retainer tabs together and pull fuel
tube/quick-connect fitting assembly off of fuel tube
nipple. The retainer will remain on fuel tube.
INSTALLATION
CAUTION: Never install a quick-connect fitting with-
out the retainer being either on the fuel tube or
already in the quick-connect fitting. In either case,
ensure the retainer locks securely into the quick-
connect fitting by firmly pulling on fuel tube and fit-
ting to ensure it is secured.
(1) Using a clean lint free cloth, clean the fuel tube
nipple and retainer.
(2) Prior to connecting the fitting to the fuel tube,
coat the fuel tube nipple with clean engine oil.
(3) Push the quick-connect fitting over the fuel
tube until theretainer seats and a click is heard.
(4) The plastic quick-connect fitting has windows
in the sides of the casing. When the fitting com-
pletely attaches to the fuel tube, the retainer locking
ears and the fuel tube shoulder are visible in the
windows. If they are not visible, the retainer was not
properly installed (Fig. 24).Do not rely upon the
audible click to confirm a secure connection.
(5) Connect negative cable to battery or auxiliary
jumper terminal.CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) Relay remains energized
for several minutes, until the test is stopped, or
until the ignition switch is turned to the Off posi-
tion.
(6) Use the DRB IIItscan tool ASD Fuel System
Test to pressurize the fuel system. Check for leaks.
TWO-TAB TYPE FITTING
This type of fitting is equipped with tabs located on
both sides of the fitting (Fig. 25). These tabs are sup-
plied for disconnecting the quick-connect fitting from
component being serviced.
CAUTION: The interior components (O-rings, spac-
ers) of this type of quick-connect fitting are not ser-
viced separately, but new plastic retainers are
available. Do not attempt to repair damaged fittings
or fuel lines/tubes. If repair is necessary, replace
the complete fuel tube assembly.
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSES,
FITTINGS OR LINES, THE FUEL SYSTEM PRES-
SURE MUST BE RELEASED. REFER TO THE FUEL
PRESSURE RELEASE PROCEDURE IN THIS
GROUP.
DISCONNECTION/CONNECTION
(1) Perform fuel pressure release procedure. Refer
to Fuel Pressure Release Procedure in this group.
(2) Disconnect negative battery cable from battery
or auxiliary jumper terminal.
Fig. 24 Plastic Quick-Connect Fitting/Fuel Tube
Connection
1 - WINDOW
2-TAB(2)
3 - EAR
4 - SHOULDER (ON TUBE)
Fig. 25 Typical Two-Tab Type Quick-Connect Fitting
1 - TAB(S)
2 - QUICK-CONNECT FITTING
14 - 14 FUEL DELIVERYRS
QUICK CONNECT FITTING (Continued)
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Page 1374 of 2177

CHRYSLER VOYAGER 2003 Service Manual (3) Clean fitting of any foreign material before dis-
assembly.
(4) To disconnect quick-connect fitting, squeeze
plastic retainer tabs (Fig. 25) against sides of quick-
connect fitting with your finge

(3) Clean fitting of any foreign material before dis-
assembly.
(4) To disconnect quick-connect fitting, squeeze
plastic retainer tabs (Fig. 25) against sides of quick-
connect fitting with your fingers. Tool use is not
required for removal and may damage plastic
retainer. Pull fitting from fuel system component
being serviced. The plastic retainer will remain on
component being serviced after fitting is discon-
nected. The O-rings and spacer will remain in quick-
connect fitting connector body.
(5) Inspect quick-connect fitting body and compo-
nent for damage. Replace as necessary.
CAUTION: When the quick-connect fitting was dis-
connected, the plastic retainer will remain on the
component being serviced. If this retainer must be
removed, very carefully release the retainer from
the component with two small screwdrivers. After
removal, inspect the retainer for cracks or any dam-
age.
(6) Prior to connecting quick-connect fitting to
component being serviced, check condition of fitting
and component. Clean parts with a lint-free cloth.
Lubricate with clean engine oil.
(7) Insert quick-connect fitting to component being
serviced and into plastic retainer. When a connection
is made, a click will be heard.
(8) Verify a locked condition by firmly pulling on
fuel tube and fitting (15-30 lbs.).
(9) Connect negative cable to battery or auxiliary
jumper terminal.
(10) Use the DRB IIItscan tool ASD Fuel System
Test to pressurize the fuel system. Check for leaks.
PLASTIC RETAINER RING TYPE FITTING
This type of fitting can be identified by the use of a
full-round plastic retainer ring (Fig. 26) usually black
in color.
CAUTION: The interior components (O-rings, spac-
ers, retainers) of this type of quick-connect fitting
are not serviced separately. Do not attempt to repair
damaged fittings or fuel lines/tubes. If repair is nec-
essary, replace the complete fuel tube assembly.
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSES,
FITTINGS OR LINES, THE FUEL SYSTEM PRES-
SURE MUST BE RELEASED. REFER TO THE FUEL
SYSTEM PRESSURE RELEASE PROCEDURE IN
THIS GROUP.DISCONNECTION/CONNECTION
(1) Perform fuel pressure release procedure. Refer
to Fuel Pressure Release Procedure in this section.
(2) Disconnect negative battery cable from battery
or auxiliary jumper terminal.
(3) Clean fitting of any foreign material before dis-
assembly.
(4) To release fuel system component from quick-
connect fitting, firmly push fitting towards compo-
nent being serviced while firmly pushing plastic
retainer ring into fitting (Fig. 26). With plastic ring
depressed, pull fitting from component.The plastic
retainer ring must be pressed squarely into fit-
ting body. If this retainer is cocked during
removal, it may be difficult to disconnect fit-
ting. Use an open-end wrench on shoulder of
plastic retainer ring to aid in disconnection.
(5) After disconnection, plastic retainer ring will
remain with quick-connect fitting connector body.
(6) Inspect fitting connector body, plastic retainer
ring and fuel system component for damage. Replace
as necessary.
(7) Prior to connecting quick-connect fitting to
component being serviced, check condition of fitting
and component. Clean parts with a lint-free cloth.
Lubricate with clean engine oil.
Fig. 26 Plastic Retainer Ring Type Fitting
1 - FUEL TUBE
2 - QUICK CONNECT FITTING
3 - PUSH
4 - PLASTIC RETAINER
5 - PUSH
6 - PUSH
7 - PUSH
8 - PUSH
RSFUEL DELIVERY14-15
QUICK CONNECT FITTING (Continued)
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Page 1375 of 2177

CHRYSLER VOYAGER 2003 Service Manual (8) Insert quick-connect fitting into component
being serviced until a click is felt.
(9) Verify a locked condition by firmly pulling on
fuel tube and fitting (15-30 lbs.).
(10) Connect negative batte

Page 1376 of 2177

CHRYSLER VOYAGER 2003 Service Manual FUEL INJECTION
TABLE OF CONTENTS
page page
FUEL INJECTION
OPERATION
OPERATION - INJECTION SYSTEM.......18
OPERATION - MODES OF OPERATION....18
FUEL CORRECTION or ADAPTIVE
MEMORIES.....................

FUEL INJECTION
TABLE OF CONTENTS
page page
FUEL INJECTION
OPERATION
OPERATION - INJECTION SYSTEM.......18
OPERATION - MODES OF OPERATION....18
FUEL CORRECTION or ADAPTIVE
MEMORIES..........................20
PROGRAMMABLE COMMUNICATIONS
INTERFACE (PCI) BUS.................21
SYSTEM DIAGNOSIS..................22
SPECIFICATIONS
TORQUE............................22
SPECIAL TOOLS
FUEL...............................23
ACCELERATOR PEDAL
REMOVAL.............................23
INSTALLATION.........................24
CRANKSHAFT POSITION SENSOR
DESCRIPTION.........................24
OPERATION...........................24
REMOVAL.............................25
INSTALLATION - 2.4L....................25
ENGINE SPEED SENSOR
DESCRIPTION.........................25
OPERATION...........................26
FUEL INJECTOR
DESCRIPTION.........................26
OPERATION...........................26
REMOVAL
REMOVAL - 2.4L......................26
REMOVAL - 3.3/3.8L...................27
INSTALLATION
INSTALLATION - 2.4L..................27
INSTALLATION - 3.3/3.8L................27
FUEL PUMP RELAY
DESCRIPTION.........................28
OPERATION...........................28
IDLE AIR CONTROL MOTOR
DESCRIPTION.........................28
OPERATION...........................28
REMOVAL.............................29INSTALLATION.........................29
INLET AIR TEMPERATURE SENSOR
DESCRIPTION.........................29
OPERATION...........................29
MAP SENSOR
DESCRIPTION.........................30
OPERATION...........................30
REMOVAL
REMOVAL - 2.4L......................31
REMOVAL - 3.3/3.8L...................31
INSTALLATION
INSTALLATION - 2.4L..................31
INSTALLATION - 3.3/3.8L................31
O2 SENSOR
DESCRIPTION.........................31
OPERATION...........................31
REMOVAL
REMOVAL - UPSTREAM 1/1 - 2.4L........33
REMOVAL - UPSTREAM 1/1 - 3.3/3.8L.....33
REMOVAL - DOWNSTREAM 1/2 - 2.4/3.3/
3.8L................................33
INSTALLATION
INSTALLATION - UPSTREAM 1/1 - 2.4L.....33
INSTALLATION - UPSTREAM 1/1 - 3.3/3.8L . . 34
INSTALLATION DOWNSTREAM 2/1 -
2.4/3.3/3.8L..........................34
THROTTLE BODY
DESCRIPTION.........................34
OPERATION...........................34
REMOVAL.............................35
INSTALLATION.........................35
THROTTLE CONTROL CABLE
REMOVAL.............................35
INSTALLATION.........................35
THROTTLE POSITION SENSOR
DESCRIPTION.........................36
OPERATION...........................36
REMOVAL - 3.3/3.8L.....................36
INSTALLATION - 3.3/3.8L.................36
RSFUEL INJECTION14-17
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