2005 CHRYSLER VOYAGER Module

NOTE: Inspect crossover pipe fasteners for damage
from heat and corrosion. The cross-over bolts are
made of a special stainless steel alloy. If replace-
ment is required, OEM bolts are highly recom-
mended.
(3) Install the remaining manifold attaching bolts.
Tighten all bolts to 23 N´m (200 in. lbs.).
(4) Position the power steering pump support strut
and install upper bolt (Fig. 126).
(5) Install heat shield and attaching screws (Fig.
128).
(6) Install and connect upstream oxygen sensor
(Fig. 128).
(7) Raise the vehicle.
(8) Attach catalytic converter pipe to exhaust man-
ifold using new gasket and tighten bolts to 37 N´m
(27 ft. lbs.) (Fig. 127).
(9) Connect downstream oxygen sensor connector.
(10) Tighten the power steering pump support
strut lower bolt (Fig. 126).
(11) Install the belt splash shield and lower the
vehicle.
(12) Install the wiper module. (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
INSTALLATION)
(13) Connect battery negative cable.
EXHAUST MANIFOLD - LEFT
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove bolts attaching crossover pipe to
exhaust manifold (Fig. 130).
(3) Disconnect left cylinder bank spark plug wires.(4) Remove heat shield attaching bolts (Fig. 131).
(5) Remove bolts attaching exhaust manifold to
cylinder head (Fig. 131).
(6) Remove the exhaust manifold (Fig. 131).
(7) Inspect and clean manifold. (Refer to 9 -
ENGINE/MANIFOLDS/EXHAUST MANIFOLD -
INSPECTION) (Refer to 9 - ENGINE/MANIFOLDS/
EXHAUST MANIFOLD - CLEANING)CLEANING
(1) Discard gasket (if equipped) and clean all sur-
faces of manifold and cylinder head.
Fig. 129 Check Exhaust Manifold Mounting
1 - STRAIGHT EDGE
2 - CROSSOVER PIPE MOUNTING SURFACE
3 - FEELER GAUGE
Fig. 130 CROSS-OVER PIPE
1 - CROSS-OVER PIPE
2 - BOLT
3 - GASKET
4 - FLAG NUT
Fig. 131 EXHAUST MANIFOLD - LEFT
1 - EXHAUST MANIFOLD - LEFT BANK
2 - HEAT SHIELD
3 - NUT - HEAT SHIELD
4 - BOLT - EXHAUST MANIFOLD
9 - 154 ENGINE 3.3/3.8LRS
EXHAUST MANIFOLD - RIGHT (Continued)

DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - EXCESSIVE EXHAUST SYSTEM NOISE
CONDITION POSSIBLE CAUSES CORRECTION
EXCESSIVE EXHAUST NOISE
(UNDER HOOD)1. Exhaust manifold cracked or
broken.1. Replace manifold.
2. Manifold to cylinder head leak. 2. Tighten manifold and/or replace
gasket.
3. EGR Valve to manifold gasket
leakage.3. Tighten fasteners or replace
gasket.
4. EGR Valve to EGR tube gasket
leakage.4. Tighten fasteners or replace
gasket.
5. EGR tube to manifold tube
leakage.5. Tighten tube nut.
6. Exhaust flex-joint to manifold
leak.6. Tighten joint fasteners and/or
replace gasket.
7. Exhaust flex-joint. 7. Replace catalytic converter
assembly.
8. Pipe and shell noise from front
exhaust pipe.8. Characteristic of single wall pipe.
EXCESSIVE EXHAUST NOISE 1. Leak at exhaust pipe joints. 1. Tighten clamps at leaking joints.
2. Burned or rusted out muffler
assembly or exhaust pipe.2. Replace muffler resonator tailpipe
assembly or exhaust pipe with
catalytic converter assembly.
3. Burned or rusted out resonator. 3. Replace muffler resonator tailpipe
assembly.
4. Restriction in exhaust system. 4. Perform Exhaust System
Restriction Check. Replace
component as necessary.
5. Converter material in muffler. 5. Replace muffler and converter
assemblies. Check fuel injection and
ignition systems for proper
operation.
DIAGNOSIS AND TESTING - EXHAUST SYSTEM
RESTRICTION CHECK
Exhaust system restriction can be checked by mea-
suring back pressure using the DRB IIItand PEP
module pressure tester.
WARNING: THE NORMAL OPERATING TEMPERA-
TURE OF THE EXHAUST SYSTEM IS VERY HIGH.
THEREFORE, NEVER WORK AROUND OR ATTEMPT
TO SERVICE ANY PART OF THE EXHAUST SYSTEM
UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE
TAKEN WHEN WORKING NEAR THE CATALYTIC
CONVERTER. THE TEMPERATURE OF THE CON-
VERTER RISES TO A HIGH LEVEL AFTER A SHORT
PERIOD OF ENGINE OPERATION TIME.NOTE: For Special Tool identification, (Refer to 11 -
EXHAUST SYSTEM - SPECIAL TOOLS).
(1) Disconnect and remove the upstream (before
catalytic converter) oxygen sensor. (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/O2 SENSOR -
REMOVAL)
(2) Install the Exhaust Back Pressure Fitting
Adaptor CH8519.
(3) Connect the Low Pressure Sensor (15 psi)
CH7063 to the back pressure fitting.
(4) Following the PEP module instruction manual,
connect all required cables to the DRB IIItand PEP
module. Select the available menu options on the
DRBIIItdisplay screen for using the digital pressure
gauge function.
11 - 2 EXHAUST SYSTEMRS
EXHAUST SYSTEM (Continued)

SPECIAL TOOLS
EXHAUST SYSTEM
CATALYTIC CONVERTER
DESCRIPTION
The toe board three-way catalytic converter is con-
nected to the exhaust manifold by the use of flex
joint and a gasket. The outlet connects to the muffler
inlet pipe and is secured with a band type clamp
(Fig. 1).The exhaust flex-joint coupling (Fig. 3) is used to
secure the catalytic converter to the exhaust mani-
fold. The flex-joint has four bolts, four flag nuts and
a gasket that are separate parts from the exhaust
flex-joint. The flex-joint is welded to the catalytic
converter.
CAUTION: When servicing, care must be exercised
not to dent or bend the bellows or bellows cover of
the flex-joint. Should this occur, the flex-joint will
eventually fail and require the catalytic converter be
replaced.
OPERATION
The three-way catalytic converter simultaneously
converts three exhaust emissions into harmless
gases. Specifically, HC and CO emissions are con-
verted into water (H2O) and carbon dioxide (CO2).
Oxides of Nitrogen (NOx) are converted into Nitrogen
(N) and Oxygen. The three-way catalyst is most effi-
cient in converting HC, CO and NOx at the stoichio-
metric air fuel ratio of 14.7:1.
The oxygen content in a catalyst is important for
efficient conversion of exhaust gases. When a high
oxygen content (lean) air/fuel ratio is present for an
extended period, oxygen content in a catalyst can
reach a maximum. When a rich air/fuel ratio is
present for an extended period, the oxygen content in
the catalyst can become totally depleted. When this
occurs, the catalyst fails to convert the gases. This is
known as catalyst9punch through.9
Back Pressure Test Adapter - CH8519
Pressure Transducer CH7063
DRB III & PEP Module - OT-CH6010A
Fig. 3 Flex-joint
1 - FLANGE
2 - END CAPS
3 - CATALYTIC CONVERTER
4 - FLEXIBLE BELLOWS
11 - 4 EXHAUST SYSTEMRS
EXHAUST SYSTEM (Continued)

CAUTION: When servicing the exhaust system, care
must be exercised not to dent or bend the bellows
of the flex-joint. Should this occur, the flex-joint will
eventually fail, requiring replacement of the cata-
lytic converter.
(3) Disconnect the right side axle half shaft from
the rear differential module (AWD equipped only).
(4) Loosen the band clamp (Fig. 10) at the muffler
to converter pipe connection.
(5) Remove the exhaust hangers to body screws
(Fig. 10).
(6) Separate muffler pipe from converter pipe.
(7) Remove muffler/resonator assembly by moving
assembly forward and guiding the resonator through
the rear axle to body opening.
(8) Clean ends of pipes or muffler to assure mat-
ing of all parts. Discard broken or worn insulators,
rusted clamps, supports and attaching parts.When
replacement is required on any component of
the exhaust system, it is important that original
equipment parts (or equivalent) be used for the
following conditions:²Ensure proper alignment with other components
in the system.
²Provide acceptable exhaust noise levels.
²Provide proper exhaust system back pressure for
maintaining emission and performance levels.
INSTALLATION
(1) Install the muffler/resonator assembly by guid-
ing resonator between the rear axle and body.
(2) Connect the muffler pipe to the converter pipe
but do not tighten band clamp (Fig. 10).
(3) Position hangers to body and install screws
starting at the resonator working forward (Fig. 10).
Tighten hanger screws to 28 N´m (250 in. lbs.).
(4) Insert muffler pipe into catalytic converter pipe
until the hangers are positioned as shown in (Fig. 11)
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.
Fig. 10 Exhaust System - Typical (All Vehicles)
1 - SCREW - RESONATOR HANGER TO BODY 3 - MUFFLER & RESONATOR ASSEMBLY
2 - SCREW - MUFFLER HANGER TO BODY 4 - CATALYTIC CONVERTER PIPE
11 - 8 EXHAUST SYSTEMRS
MUFFLER (Continued)

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).
(7) Start the engine and inspect for exhaust leaks.
Repair exhaust leaks as necessary.
(8) Check the exhaust system for contact with the
body panels. Make the necessary adjustments, if
needed.
RESONATOR
REMOVAL
(1) (Refer to 11 - EXHAUST SYSTEM/MUFFLER -
REMOVAL)
INSTALLATION
(1) (Refer to 11 - EXHAUST SYSTEM/MUFFLER -
INSTALLATION)
(2) Start the engine and inspect for exhaust leaks.
Repair exhaust leaks as necessary.
(3) Check the exhaust system for contact with the
body panels. Make the necessary adjustments, if
needed.
Fig. 11 Exhaust System Alignment
1 - HANGER BRACKET TO BODY
2 - ISOLATOR
3 - HANGER - MUFFLER/RESONATOR SUPPORT
4-6mm(0.25 in.)
Fig. 12 Band Clamp
1 - BAND CLAMP
2 - TORQUE SPECIFICATION
RSEXHAUST SYSTEM11-9
MUFFLER (Continued)

FRONT BUMPER
REINFORCEMENT
REMOVAL
(1) Remove front bumper fascia. (Refer to 13 -
FRAMES & BUMPERS/BUMPERS/FRONT FASCIA
- REMOVAL)
(2) Disconnect the solid state relay (SSR) for the
cooling module wiring connector. If bumper reinforce-
ment is being replaced, remove the solid state relay.
(3) Support front bumper reinforcement on a suit-
able lifting device.
(4) Remove the four nuts attaching front bumper
reinforcement to frame rail (Fig. 3).
(5) Remove front bumper reinforcement from vehi-
cle.
INSTALLATION
NOTE: Check position of the arrows molded into
the foam for correct orientation.
Fig. 2 FRONT FASCIA
1 - GRILLE
2 - FRONT BUMPER FIASCO
3 - BUMPER REINFORCEMENT4 - RADIATOR ENCLOSURE
5 - AIR DAM
Fig. 3 FRONT BUMPER REINFORCEMENT
1 - FRONT BUMPER REINFORCEMENT
2 - FRAME RAILS
RSFRAME & BUMPERS13-3
FRONT FASCIA (Continued)

FUEL SYSTEM
TABLE OF CONTENTS
page page
FUEL DELIVERY..........................1FUEL INJECTION........................21
FUEL DELIVERY
TABLE OF CONTENTS
page page
FUEL DELIVERY
DESCRIPTION
DESCRIPTION........................2
DESCRIPTION - FFV REPLACEMENT
PARTS...............................2
OPERATION............................2
DIAGNOSIS AND TESTING - FUEL DELIVERY
SYSTEM.............................2
STANDARD PROCEDURE
STANDARD PROCEDURE - FUEL SYSTEM
PRESSURE RELEASE PROCEDURE.......2
STANDARD PROCEDURE - DRAINING
FUEL TANK...........................2
STANDARD PROCEDURE - FUEL
PRESSURE GAUGE....................3
SPECIFICATIONS
FUEL SYSTEM PRESSURE..............4
TORQUE.............................4
SPECIAL TOOLS
FUEL................................4
FUEL LEVEL SENDING UNIT / SENSOR
DESCRIPTION..........................5
OPERATION............................5
REMOVAL.............................5
INSTALLATION..........................6
FUEL LINES
DESCRIPTION - FUEL LINES/HOSES AND
CLAMPS.............................7
STANDARD PROCEDURE - HOSES AND
CLAMP..............................7
FUEL PRESSURE REGULATOR
OPERATION............................7
REMOVAL.............................7
INSTALLATION..........................7
FUEL PUMP
DESCRIPTION..........................8OPERATION............................8
FUEL PUMP MODULE
DESCRIPTION..........................8
OPERATION............................9
REMOVAL
REMOVAL............................9
REMOVAL - FOLD-IN-FLOOR............10
INSTALLATION
INSTALLATION.......................10
INSTALLATION - FOLD-IN-FLOOR.........10
FUEL RAIL
REMOVAL
REMOVAL - 2.4L......................11
REMOVAL - 3.3/3.8L...................11
INSTALLATION
INSTALLATION - 2.4L..................11
INSTALLATION - 3.3/3.8L................12
FUEL TANK
DESCRIPTION.........................12
OPERATION...........................12
REMOVAL
REMOVAL...........................12
REMOVAL - FOLD-IN-FLOOR............13
INSTALLATION
INSTALLATION.......................15
INSTALLATION - FOLD-IN-FLOOR.........16
FUEL TANK FILLER TUBE
REMOVAL.............................16
INSTALLATION.........................17
INLET FILTER
REMOVAL.............................17
INSTALLATION.........................17
QUICK CONNECT FITTING
STANDARD PROCEDURE - QUICK-CONNECT
FITTINGS...........................18
RSFUEL SYSTEM14-1

FUEL DELIVERY
DESCRIPTION
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
²Fuel filter
²Tubes/lines/hoses
²Fuel injectors
The in-tank fuel pump module contains the fuel
pump. The pump is serviced as part of the fuel pump
module. Refer to Fuel Pump Module.
The fuel filter is replaceable only as part of the
fuel pump module.
DESCRIPTION - FFV REPLACEMENT PARTS
Many components in a Flexible Fuel Vehicle (FFV)
are designed to be compatible with ethanol. Always
be sure that the vehicle is serviced with correct etha-
nol compatible parts.
CAUTION: Replacing fuel system components with
non-ethanol compatible components can damage
your vehicle and may void the warranty.
OPERATION
The fuel system provides fuel pressure by an
in-tank pump module. The Powertrain Control Mod-
ule (PCM) controls the operation of the fuel system
by providing battery voltage to the fuel pump
through the fuel pump relay. The PCM requires only
three inputs and a good ground to operate the fuel
pump relay. The three inputs are:
²Ignition voltage
²Crankshaft Position (CKP) sensor
²Camshaft Position (CMP) sensor
DIAGNOSIS AND TESTING - FUEL DELIVERY
SYSTEM
(Refer to Appropriate Diagnostic Information)
STANDARD PROCEDURE
STANDARD PROCEDURE - FUEL SYSTEM
PRESSURE RELEASE PROCEDURE
(1) Remove Fuel Pump relay from Power Distribu-
tion Center (PDC). For location of relay, refer to label
on underside of PDC cover.
(2) Start and run engine until it stalls.(3) Attempt restarting engine until it will no
longer run.
(4) Turn ignition key to OFF position.
(5) Return fuel pump relay to PDC.
(6) One or more Diagnostic Trouble Codes (DTC's)
may have been stored in PCM memory due to fuel
pump relay removal. The DRB IIItscan tool must be
used to erase a DTC.
STANDARD PROCEDURE - DRAINING FUEL
TANK
Two different procedures may be used to drain fuel
tank (lowering tank or using DRBIIItscan tool).
The quickest draining procedure involves lowering
the fuel tank.
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL SYSTEM COMPONENTS.
SERVICE VEHICLES IN WELL VENTILATED AREAS
AND AVOID IGNITION SOURCES. NEVER SMOKE
WHILE SERVICING THE VEHICLE. THIS MAY
RESULT IN PERSONAL INJURY OR DEATH.
As an alternative procedure, the electric fuel pump
may be activated allowing tank to be drained at fuel
rail connection. Refer to DRBIIItscan tool for fuel
pump activation procedures. Before disconnecting
fuel line at fuel rail, release fuel pressure. Refer to
the Fuel System Pressure Release Procedure in this
group for procedures. Disconnect the fuel line at the
fuel rail and remove the plastic retainer from the
fuel rail. Take plastic retainer and install it back into
the fuel line from body. Check the O-ring and make
sure that it is in place and not damaged. Attach end
of special test hose tool number 6539 at fuel line con-
nection from the body line. Position opposite end of
this hose tool to an approved gasoline draining sta-
tion. Activate fuel pump and drain tank until empty.
When done remove the special test hose tool number
6539 from the body line. Remove the plastic retainer
from the special test hose tool number 6539 and rein-
stall it into the fuel line from the body. Check the
O-ring and make sure that it is in place and not
damaged. Install the fuel line to the fuel rail.
If electric fuel pump is not operating, tank must be
lowered for fuel draining. Refer to following proce-
dures.
(1) Remove fuel filler cap.
(2) Perform the Fuel System Pressure Release pro-
cedure.
(3) Disconnect negative cable from battery.
(4) Raise vehicle and support.
(5) Certain models are equipped with a separate
grounding wire (strap) connecting the fuel fill tube
assembly to the body. Disconnect wire by removing
screw.
14 - 2 FUEL DELIVERYRS