2004 CHRYSLER VOYAGER engine

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Page 1507 of 2585

CHRYSLER VOYAGER 2004  Service Manual FRONT CROSSMEMBER
MOUNT BUSHINGS
REMOVAL
(1) Using paint or grease pencil, mark outline of
cradle crossmember on frame rails.
(2) Loosen bolts attaching crossmember to frame
rails.
(3) Remove bolt on

Page 1509 of 2585

CHRYSLER VOYAGER 2004  Service Manual FUEL DELIVERY
DESCRIPTION
The front wheel drive car uses a plastic fuel tank
located rear center of the vehicle.
The Fuel Delivery System consists of: the following
items:
²Electric fuel pump module

Page 1513 of 2585

CHRYSLER VOYAGER 2004  Service Manual (4) Install level sensor wires in connector. Push
the wires up through the connector and then pull
them down until they lock in place. Ensure signal
and ground wires are installed in the correct posi-

Page 1514 of 2585

CHRYSLER VOYAGER 2004  Service Manual nated fuel in this system. If it is necessary to replace
these lines/tubes/hoses, use new original equipment
lines/tubes/hoses.
If equipped:The hose clamps used to secure rub-
ber hoses on vehicles ar

Page 1515 of 2585

CHRYSLER VOYAGER 2004  Service Manual FUEL PUMP
DESCRIPTION
The electric fuel pump is located in and is part of
the fuel pump module. It is a positive displacement,
gerotor type, immersible pump with a permanent
magnet electric motor. The

Page 1517 of 2585

CHRYSLER VOYAGER 2004  Service Manual (6) Remove harness from vehicle.
(7) Remove fuel hose quick connect fitting from the
chassis tube.Refer to Fuel Hoses, Clamps and
Quick Connect Fittings in this Section.Place a
shop towel under the co

Page 1518 of 2585

CHRYSLER VOYAGER 2004  Service Manual 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 w

Page 1519 of 2585

CHRYSLER VOYAGER 2004  Service Manual INSTALLATION
(1) Position fuel tank on transmission jack. Con-
nect check valve hose. Connect fuel filler tube vent
hose to fuel filler tube.
(2) Feed filler vent line thru frame rail.
(3) Raise tank