2005 CHRYSLER VOYAGER Servo

8W-15 GROUND DISTRIBUTION
Component Page
A/C Compressor Clutch...................8W-15-2, 9
A/C-Heater Control....................8W-15-10, 12
Adjustable Pedals Switch...................8W-15-11
Amplifier............................8W-15-27
Auto Temp Control......................8W-15-10
Back-Up Lamp Switch...................8W-15-2, 4
Battery...........................8W-15-2, 3, 4
Body Control Module.....................8W-15-24
Brake Fluid Level Switch..................8W-15-18
Brake Lamp Switch......................8W-15-18
Cabin Heater Assist......................8W-15-9
CD Changer...........................8W-15-13
Center High Mounted Stop Lamp.............8W-15-30
Clutch Pedal Interlock Switch................8W-15-18
Clutch Pedal Upstop Switch.................8W-15-19
Controller Antilock Brake.................8W-15-2, 4
Crank Case Ventilation Heater................8W-15-9
Crankshaft Position Sensor..................8W-15-4
Data Link Connector..................8W-15-3, 4, 18
Dosing Pump...........................8W-15-9
Driver Door Courtesy Lamp...............8W-15-15, 21
Driver Door Lock Switch.................8W-15-15, 21
Driver Heated Seat Cushion.................8W-15-17
Driver Heated Seat Module.................8W-15-17
Driver Power Seat Switch..................8W-15-17
Driver Power Window Switch..............8W-15-15, 21
DVD/CD Changer.......................8W-15-11
EGR Solenoid..........................8W-15-3
Engine Control Module.....................8W-15-4
Floor Console Lamp......................8W-15-28
Floor Console Power Outlet.................8W-15-28
Front Blower Module.....................8W-15-12
Front Cigar Lighter......................8W-15-10
Front Control Module................8W-15-2, 8, 9, 19
Front Reading Lamps/Switch................8W-15-22
Fuel Heater...........................8W-15-28
Fuel Heater Relay........................8W-15-4
Fuel Pump Module......................8W-15-28
G100..............................8W-15-2, 4
G101..............................8W-15-2, 4
G102.............................8W-15-5, 6, 7
G103................................8W-15-9
G200..........................8W-15-10, 11, 12
G201...............................8W-15-13
G202...............................8W-15-13
G300....................8W-15-12, 14, 16, 17, 18, 19
G301......................8W-15-20, 21, 22, 24, 25
G302..........................8W-15-26, 27, 28
G303..........................8W-15-28, 29, 30
Generator.............................8W-15-2
Hands Free Module......................8W-15-11
Headlamp Switch.......................8W-15-10
Headlamp Washer Pump Motor...............8W-15-7
High Note Horn.........................8W-15-6
Hood Ajar Switch.......................8W-15-19
Horn Switch..........................8W-15-12
Instrument Cluster......................8W-15-10
Instrument Panel Switch Bank...............8W-15-10
Integrated Power Module...........8W-15-2, 3, 4, 8, 9, 19
Left B-Pillar Switch......................8W-15-18
Left Cinch/Release Motor..................8W-15-14
Left Cylinder Lock Switch................8W-15-15, 16
Left Fog Lamp..........................8W-15-6
Left Front Door Ajar Switch.................8W-15-16
Left Front Door Lock Motor/Ajar Switch.......8W-15-15, 16
Left Front Park/Turn Signal Lamp.............8W-15-6
Left Full Open Switch....................8W-15-14
Left Headlamp.........................8W-15-19
Left Headlamp Leveling Motor................8W-15-7
Left High Beam Lamp...................8W-15-8, 19
Left Liftgate Flood Lamp...................8W-15-29
Left Low Beam Lamp...................8W-15-8, 19
Left Mid Reading Lamp...................8W-15-23
Left Park Lamp.......................8W-15-8, 19
Left Power Mirror.......................8W-15-12
Left Rear Lamp Assembly..................8W-15-28
Left Rear Reading Lamp...................8W-15-23
Left Sliding Door Control Module.............8W-15-14
Left Sliding Door Latch Sensing Switch..........8W-15-14
Left Sliding Door Lock Motor................8W-15-14
Left Sliding Door Lock Motor/Ajar Switch........8W-15-14
Left Sliding Door Motor...................8W-15-14Component Page
Left Turn Signal Lamp....................8W-15-19
Left Visor/Vanity Lamp....................8W-15-23
License Lamp.......................8W-15-26, 29
Lift Pump Motor........................8W-15-28
Liftgate Ajar Switch......................8W-15-30
Liftgate Cinch/Release Motor..............8W-15-26, 30
Liftgate Right Pinch Sensor.................8W-15-26
Memory Seat/Mirror/Adjustable Pedals Module.....8W-15-17
Natural Vacuum Leak Detection Assembly.......8W-15-2, 3
Occupant Classification Module...............8W-15-24
Occupant Restraint Controller...............8W-15-13
Overhead Console.......................8W-15-22
Oxygen Sensor 1/1 Upstream.................8W-15-3
Oxygen Sensor 1/2 Downstream...............8W-15-3
Park Assist Display......................8W-15-28
Park Assist Module......................8W-15-28
Passenger Door Courtesy Lamp............8W-15-16, 21
Passenger Door Lock Switch..............8W-15-16, 21
Passenger Heated Seat Back................8W-15-25
Passenger Heated Seat Cushion..............8W-15-25
Passenger Heated Seat Module...............8W-15-25
Passenger Power Seat Switch................8W-15-25
Power Folding Mirror Switch................8W-15-12
Power Liftgate Module..................8W-15-26, 28
Power Liftgate Motor.....................8W-15-26
Power Mirror Switch.....................8W-15-12
Power Outlet..........................8W-15-10
Power Window Switch....................8W-15-15
Powertrain Control Module..................8W-15-3
Radiator Fan No. 1.......................8W-15-5
Radiator Fan No. 2.......................8W-15-5
Radiator Fan Relay.......................8W-15-5
Radiator Fan Relay No. 3...................8W-15-5
Radio...............................8W-15-13
Rear Auto Temp Control Switch..............8W-15-18
Rear Blower Front Control Switch.............8W-15-12
Rear Blower Motor Power Module.............8W-15-28
Rear Blower Rear Control Switch.............8W-15-18
Rear Dome Lamp.....................8W-15-22, 23
Rear Power Outlet.......................8W-15-28
Rear View Mirror.....................8W-15-11, 22
Rear Window Defogger Grid.................8W-15-30
Rear Wiper Motor.......................8W-15-29
Right B-Pillar Switch.....................8W-15-24
Right Cinch/Release Motor..................8W-15-20
Right Cylinder Lock Switch.................8W-15-21
Right Fog Lamp.........................8W-15-6
Right Front Door Ajar Switch................8W-15-21
Right Front Door Lock Motor/Ajar Switch........8W-15-21
Right Front Park/Turn Signal Lamp............8W-15-6
Right Full Open Switch...................8W-15-20
Right Headlamp........................8W-15-19
Right Headlamp Leveling Motor...............8W-15-7
Right High Beam Lamp..................8W-15-8, 19
Right Liftgate Flood Lamp..................8W-15-29
Right Low Beam Lamp..................8W-15-8, 19
Right Mid Reading Lamp..................8W-15-23
Right Park Lamp......................8W-15-8, 19
Right Power Mirror....................8W-15-11, 12
Right Rear Lamp Assembly...............8W-15-27, 28
Right Rear Reading Lamp..................8W-15-23
Right Sliding Door Control Module............8W-15-20
Right Sliding Door Latch Sensing Switch.........8W-15-20
Right Sliding Door Lock Motor...............8W-15-20
Right Sliding Door Lock Motor/Ajar Switch.......8W-15-20
Right Sliding Door Motor..................8W-15-20
Right Turn Signal Lamp...................8W-15-19
Right Visor/Vanity Lamp...................8W-15-23
Sentry Key Remote Entry Module.............8W-15-11
Siren...............................8W-15-11
Speed Control Servo......................8W-15-2
Sunroof Module........................8W-15-27
Sunroof Switch.........................8W-15-23
Thatcham Alarm Module...................8W-15-11
Traction Control Switch...................8W-15-11
Trailer Tow Connector....................8W-15-27
Transmission Control Module.................8W-15-4
Transmission Control Relay................8W-15-3, 4
Washer Fluid Level Switch..................8W-15-5
Wiper Module..........................8W-15-18
RS8W-15 GROUND DISTRIBUTION8W-15-1

8W-30 FUEL/IGNITION SYSTEM
Component Page
A/C Compressor Clutch.............. 8W-30-20
A/C Compressor Clutch Relay........ 8W-30-4, 20
A/C Pressure Sensor........... 8W-30-13, 18, 27
Accelerator Pedal Position Sensor.... 8W-30-32, 34
Ambient Temperature Sensor........... 8W-30-8
Auto Shut Down Relay.... 8W-30-4, 11, 14, 16, 19
Battery.............. 8W-30-2, 6, 10, 15, 20, 28
Battery Temperature Sensor......... 8W-30-8, 27
Body Control Module.............. 8W-30-5, 21
Boost Pressure Sensor............... 8W-30-27
Brake Lamp Switch............ 8W-30-7, 23, 33
Cabin Heater Assist................. 8W-30-24
Camshaft Position Sensor........... 8W-30-8, 26
Clockspring................... 8W-30-5, 25, 32
Clutch Pedal Interlock Switch.......... 8W-30-7
Clutch Pedal Upstop Switch........... 8W-30-32
Crank Case Ventilation Heater......... 8W-30-21
Crankshaft Position Sensor...... 8W-30-12, 17, 26
Data Link Connector.............. 8W-30-3, 24
Dosing Pump...................... 8W-30-24
ECM/PCM Relay........ 8W-30-20, 22, 26, 28, 30
EGR Solenoid................... 8W-30-15, 30
Engine Control Module . . . 8W-30-20, 21, 22, 23, 24,
25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35
Engine Coolant Temp Sensor.... 8W-30-13, 18, 27
Engine Oil Pressure Sensor........... 8W-30-23
Engine Oil Pressure Switch............ 8W-30-7
EVAP/Purge Solenoid................. 8W-30-4
Front Control Module......... 8W-30-2, 5, 24, 32
Fuel Heater....................... 8W-30-31
Fuel Heater Relay................ 8W-30-21, 31
Fuel Injector No. 1............ 8W-30-14, 19, 29
Fuel Injector No. 2............ 8W-30-14, 19, 29
Fuel Injector No. 3............ 8W-30-14, 19, 29
Fuel Injector No. 4............ 8W-30-14, 19, 29
Fuel Injector No. 5.................. 8W-30-19
Fuel Injector No. 6.................. 8W-30-19
Fuel Pressure Sensor................ 8W-30-33
Fuel Pressure Solenoid............... 8W-30-22
Fuel Pump Module................ 8W-30-5, 21
Fuel Pump Relay.................... 8W-30-5
Fuse 15........................ 8W-30-24, 31
Fuse 16 . . 8W-30-4, 11, 14, 16, 19, 20, 22, 26, 28, 30
Fuse 17.................... 8W-30-2, 5, 21, 31
Fuse 18........................... 8W-30-20
Fuse 26........................... 8W-30-33
Fuselink.......................... 8W-30-28Component Page
G100...................... 8W-30-2, 6, 15, 21
G101................. 8W-30-2, 6, 7, 10, 15, 20
G103....................... 8W-30-20, 21, 24
G300........................ 8W-30-7, 23, 32
G302........................ 8W-30-5, 21, 31
Generator....................... 8W-30-4, 21
Glow Plug No. 1.................... 8W-30-28
Glow Plug No. 2.................... 8W-30-28
Glow Plug No. 3.................... 8W-30-28
Glow Plug No. 4.................... 8W-30-28
Glow Plug Relay.................... 8W-30-28
Idle Air Control Motor................ 8W-30-9
Ignition Coil.................... 8W-30-11, 16
Ignition Switch..................... 8W-30-10
Inlet Air Temperature Sensor....... 8W-30-12, 17
Integrated Power Module . . 8W-30-2, 3, 4, 5, 10, 11,
14, 16, 19, 20, 21, 22, 24,
26, 28, 30, 31, 32, 33
Knock Sensor....................... 8W-30-9
Left Speed Control Switch.......... 8W-30-5, 25
Lift Pump Motor.................... 8W-30-31
Lift Pump Relay.................... 8W-30-31
Manifold Absolute Pressure Sensor . . . 8W-30-13, 18
Mass Air Flow Sensor................ 8W-30-22
Natural Vacuum Leak Detection
Assembly....................... 8W-30-10
Oxygen Sensor 1/1 Upstream........... 8W-30-6
Oxygen Sensor 1/2 Downstream......... 8W-30-6
Powertrain Control Module . . 8W-30-2, 3, 4, 5, 6, 7,
8, 9, 10, 11, 12, 13, 14,
15, 16, 17, 18, 19
Radiator Fan Relay............... 8W-30-11, 16
Radiator Fan Relay No. 1............. 8W-30-33
Radiator Fan Relay No. 2............. 8W-30-33
Radiator Fan Relay No. 3............. 8W-30-33
Right Speed Control Switch......... 8W-30-5, 25
Speed Control Servo.................. 8W-30-7
Starter Motor Relay............... 8W-30-5, 21
Throttle Position Sensor........... 8W-30-12, 17
Transmission Control
Module................ 8W-30-28, 32, 34, 35
Transmission Control Relay........... 8W-30-28
Transmission Range Sensor........... 8W-30-32
Vehicle Speed Sensor.............. 8W-30-9, 30
Water In Fuel Sensor................ 8W-30-32
RS8W-30 FUEL/IGNITION SYSTEM8W-30-1

8W-33 VEHICLE SPEED CONTROL
Component Page
Brake Lamp Switch.................. 8W-33-3
Clockspring....................... 8W-33-2, 4
Engine Control Module................ 8W-33-4
G101.............................. 8W-33-3
Input Speed Sensor.................. 8W-33-2
Left Speed Control Switch........... 8W-33-2, 4
Output Speed Sensor................. 8W-33-2Component Page
Powertrain Control Module.......... 8W-33-2, 3
Right Speed Control Switch.......... 8W-33-2, 4
Speed Control Servo.................. 8W-33-3
Transmission Control Module........... 8W-33-4
Transmission Range Sensor............ 8W-33-4
Vehicle Speed Sensor................. 8W-33-2
RS8W-33 VEHICLE SPEED CONTROL8W-33-1

Component Page
Rear Blower Front Control Switch (3 Zone
MTC)......................... 8W-80-124
Rear Blower Motor Power Module C1 (3 Zone
ATC) .......................... 8W-80-125
Rear Blower Motor Power Module C2 (3 Zone
ATC) .......................... 8W-80-125
Rear Blower Rear Control Switch C1 (3 Zone
MTC)......................... 8W-80-125
Rear Blower Rear Control Switch C2 (3 Zone
MTC)......................... 8W-80-125
Rear Dome Lamp (Except Luxury)..... 8W-80-126
Rear Intrusion Sensor (United
Kingdom)...................... 8W-80-126
Rear Mode Motor (3 Zone ATC)....... 8W-80-126
Rear Power Outlet................. 8W-80-126
Rear Temperature Motor (3 Zone ATC) . . 8W-80-127
Rear View Mirror C1 (Luxury)........ 8W-80-127
Rear View Mirror C2 (Hands Free)..... 8W-80-127
Rear Wiper Motor.................. 8W-80-128
Recirculation Door Actuator.......... 8W-80-128
Right B-Pillar Switch (Power Sliding
Door).......................... 8W-80-128
Right Cinch/Release Motor (Power Sliding
Door).......................... 8W-80-128
Right Curtain Airbag Squib.......... 8W-80-129
Right Cylinder Lock Switch (Export) . . . 8W-80-129
Right Door Speaker................ 8W-80-129
Right Fog Lamp................... 8W-80-129
Right Front Door Ajar Switch (Base) . . . 8W-80-130
Right Front Door Lock Motor/Ajar Switch (Except
Base).......................... 8W-80-130
Right Front Impact Sensor........... 8W-80-130
Right Front Park/Turn Signal Lamp.... 8W-80-130
Right Front Wheel Speed Sensor...... 8W-80-131
Right Full Open Switch (Power Sliding
Door).......................... 8W-80-131
Right Headlamp (Caravan/Voyager Except
Export)........................ 8W-80-131
Right Headlamp (Town And Country) . . . 8W-80-131
Right Headlamp Leveling Motor
(Export)....................... 8W-80-132
Right High Beam Lamp (Export)...... 8W-80-132
Right Instrument Panel Speaker...... 8W-80-132
Right Liftgate Flood Lamp........... 8W-80-132
Right Low Beam Lamp (Export)....... 8W-80-133
Right Mid Reading Lamp (Premium/
Luxury)........................ 8W-80-133
Right Park Lamp (Export)........... 8W-80-133
Right Power Mirror................ 8W-80-133
Right Rear Lamp Assembly.......... 8W-80-134
Right Rear Pillar Speaker (Highline
Audio)......................... 8W-80-134Component Page
Right Rear Reading Lamp (Luxury).... 8W-80-134
Right Rear Speaker................ 8W-80-134
Right Rear Vent Motor.............. 8W-80-135
Right Rear Wheel Speed Sensor....... 8W-80-135
Right Remote Radio Switch.......... 8W-80-135
Right Repeater Lamp (Export)........ 8W-80-135
Right Side Impact Sensor 1 (Export) . . . 8W-80-135
Right Side Impact Sensor 1 (Except
Export)........................ 8W-80-136
Right Side Impact Sensor 2.......... 8W-80-136
Right Side Impact Sensor 3.......... 8W-80-136
Right Sliding Door Control Module C1 (Power
Sliding Door)................... 8W-80-136
Right Sliding Door Control Module C2 (Power
Sliding Door)................... 8W-80-137
Right Sliding Door Latch Sensing Switch (Power
Sliding Door)................... 8W-80-137
Right Sliding Door Lock Motor (Power Sliding
Door).......................... 8W-80-137
Right Sliding Door Lock Motor/Ajar Switch (Manual
Sliding Door)................... 8W-80-138
Right Sliding Door Motor (Power Sliding
Door).......................... 8W-80-138
Right Speed Control Switch.......... 8W-80-138
Right Turn Signal Lamp (Export)...... 8W-80-138
Right Visor/Vanity Lamp (Except Base/
Export)........................ 8W-80-139
Sentry Key Remote Entry Module
(SKREEM)..................... 8W-80-139
Siren (United Kingdom)............. 8W-80-139
Speed Control Servo (Gas)........... 8W-80-139
Sunroof Module (Except Export)....... 8W-80-140
Sunroof Switch (Except Export)....... 8W-80-140
Thatcham Alarm Module (United
Kingdom)...................... 8W-80-140
Throttle Position Sensor (Gas)........ 8W-80-141
Traction Control Switch............. 8W-80-141
Trailer Tow Connector (Except Export) . . 8W-80-141
Transmission Control Module (Diesel) . . 8W-80-141
Transmission Control Relay (Diesel).... 8W-80-143
Transmission Range Sensor.......... 8W-80-143
Transmission Solenoid/Pressure Switch
Assembly...................... 8W-80-143
Vehicle Speed Sensor (MTX).......... 8W-80-144
Washer Fluid Level Switch........... 8W-80-144
Washer Pump Motor................ 8W-80-144
Water In Fuel Sensor (Diesel)......... 8W-80-144
Wiper Module..................... 8W-80-144
RS8W-80 CONNECTOR PIN-OUTS8W-80-5

RIGHT VISOR/VANITY LAMP (EXCEPT BASE/EXPORT) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
A Z327 20BK/OR GROUND
B M27 20YL/LB READING LAMPS DRIVER
SENTRY KEY REMOTE ENTRY MODULE (SKREEM) - BLACK 6 WAY
CAV CIRCUIT FUNCTION
1- -
2 D25 20WT/VT PCI BUS
3- -
4 F20 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
5 Z120 22BK/WT GROUND
6 A114 20GY/RD FUSED B(+) (I.O.D.)
SIREN (UNITED KINGDOM) - BLACK 4 WAY
CAV CIRCUIT FUNCTION
1- -
2 D96 18WT/LB SIREN SIGNAL CONTROL
3 A114 18GY/RD FUSED B(+) (I.O.D.)
4 Z109 18BK/GY GROUND
SPEED CONTROL SERVO (GAS) - BLACK 4 WAY
CAV CIRCUIT FUNCTION
1 V36 18VT/YL S/C VACUUM CONTROL
2 V35 18VT/OR S/C VENT CONTROL
3 V30 20VT/WT S/C BRAKE SWITCH OUTPUT
4 Z155 18BK/LG GROUND
RS8W-80 CONNECTOR PIN-OUTS8W - 80 - 139

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Right Sliding Door Motor BK At Sliding Door 45
Right Speed Control Switch WT At Steering Wheel N/S
Right Turn Signal Lamp (Export) OR At Lamp N/S
Right Visor/Vanity Lamp BK At Lamp N/S
Sentry Key Remote Entry Module
(SKREEM)BK At Steering Column 20, 21, 22, 23, 31
Siren (United Kingdom) BK Left Front Body N/S
Speed Control Servo (Gas) BK Near Controller Antilock Brake 11, 17, 18
Sunroof Module (Except Export) BK At Sunroof N/S
Sunroof Switch (Except Export) NAT Near Overhead Console N/S
Thatcham Alarm Module (United
Kingdom)BK Top Right Side of Instrument Panel
Near SpeakerN/S
Throttle Position Sensor (Gas) GY On Throttle Body 10, 11, 17
Traction Control Switch BK Rear of Swtich 21, 22, 31
Trailer Tow Connector (Except
Export)Left Quarter Panel N/S
Transmission Control Relay
(Diesel)Near Transmission 16
Transmission Range Sensor DKGY Top of Transmission 14, 19
Transmission Solenoid/Pressure
Switch AssemblyBK Side of Transmission 14, 19
Vehicle Speed Sensor (MTX) BK Rear of Transmission 16
Washer Fluid Level Switch BK Bottom of Reservoir 3
Washer Pump Motor BK Right Fender Well 3
Water in Fuel Sensor (Diesel) BK Left Rear Engine Compartment N/S
Wiper Module DKGY Left Side Cowl 6
GROUNDS
GROUND NUMBER LOCATION FIG.
G100 Body Ground Near Powertrain Control Module N/S
G101 Above Starter 13, 15, 18
G102 Left Headlamp Area 1
G103 Above Starter 15
G200 Left Side of Instrument Panel 20, 21 29
G201 Right Side of Instrument Panel 20, 24, 29
G202 Near Radio N/S
G300 Left B Pillar 32
G301 Right B Pillar 33, 39
G302 Left Rear Quarter 47
G303 Liftgate Ground 49
8W - 91 - 12 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

CYLINDER-TO-CYLINDER LEAKAGE TEST
To determine if an engine cylinder head gasket is
leaking between adjacent cylinders, follow the proce-
dures in Cylinder Compression Pressure Test (Refer
to 9 - ENGINE - DIAGNOSIS AND TESTING). An
engine cylinder head gasket leaking between adja-
cent cylinders will result in approximately a 50±70%
reduction in compression pressure.
CYLINDER-TO-WATER JACKET LEAKAGE TEST
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING WITH COOLANT PRES-
SURE CAP REMOVED.
VISUAL TEST METHOD
With the engine cool, remove the coolant pressure
cap. Start the engine and allow it to warm up until
thermostat opens.
If a large combustion/compression pressure leak
exists, bubbles will be visible in the coolant.
COOLING SYSTEM TESTER METHOD
WARNING: WITH COOLING SYSTEM TESTER IN
PLACE, PRESSURE WILL BUILD UP FAST. EXCES-
SIVE PRESSURE BUILT UP, BY CONTINUOUS
ENGINE OPERATION, MUST BE RELEASED TO A
SAFE PRESSURE POINT. NEVER PERMIT PRES-
SURE TO EXCEED 138 kPa (20 psi).
Install Cooling System Tester 7700 or equivalent to
pressure cap neck. Start the engine and observe the
tester's pressure gauge. If gauge pulsates with every
power stroke of a cylinder a combustion pressure
leak is evident.
CHEMICAL TEST METHOD
Combustion leaks into the cooling system can also
be checked by using Bloc-Chek Kit C-3685-A or
equivalent. Perform test following the procedures
supplied with the tool kit.
REMOVAL - CYLINDER HEAD
(1) Perform fuel system pressure release procedure
before attempting any repairs.(Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY - SPECIFICA-
TIONS)
(2) Disconnect battery negative cable.
(3) Drain cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(4) Remove air filter housing and inlet tube.
(5) Remove upper intake manifold. (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
REMOVAL)(6) Remove heater tube support bracket from cyl-
inder head.
(7) Disconnect radiator upper and heater supply
hoses from intake manifold water outlet connections.
(8) Remove accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)
(9) Raise vehicle and remove exhaust pipe from
manifold.
(10) Remove power steering pump reservoir and
line support bracket from lower intake manifold and
set aside. Do not disconnect lines.
(11) Remove ignition coil and wires from engine.
(12) Disconnect cam sensor and fuel injector wir-
ing connectors.
(13) Remove timing belt and camshaft sprockets.
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT/CHAIN AND SPROCKETS - REMOVAL)
(14) Remove timing belt idler pulley and rear tim-
ing belt cover. (Refer to 9 - ENGINE/VALVE TIM-
ING/TIMING BELT / CHAIN COVER(S) -
REMOVAL)
(15) Remove cylinder head cover. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL)
(16) Remove camshafts (Refer to 9 - ENGINE/
CYLINDER HEAD/CAMSHAFT(S) - REMOVAL).
NOTE: Identify rocker arm position to ensure cor-
rect re-installation in original position, if reused.
(17) Remove rocker arms. (Refer to 9 - ENGINE/
CYLINDER HEAD/ROCKER ARMS - REMOVAL)
(18) Remove cylinder head bolts in REVERSE
sequence of tightening (Fig. 19).
(19) Remove cylinder head from engine block.
(20) Inspect and clean cylinder head. (Refer to 9 -
ENGINE/CYLINDER HEAD - INSPECTION) (Refer
to 9 - ENGINE/CYLINDER HEAD - CLEANING)
CLEANING
To ensure engine gasket sealing, proper surface
preparation must be performed, especially with the
use of aluminum engine components and multi-layer
steel cylinder head gaskets.
NOTE: Multi-Layer Steel (MLS) head gaskets require
a scratch free sealing surface.
Remove all gasket material from cylinder head and
block (Refer to 9 - ENGINE - STANDARD PROCE-
DURE). Be careful not to gouge or scratch the alumi-
num head sealing surface.
Clean all engine oil passages.
9 - 26 ENGINE 2.4LRS
CYLINDER HEAD (Continued)

(5) Install rocker arms. (Refer to 9 - ENGINE/
CYLINDER HEAD/ROCKER ARMS - INSTALLA-
TION)
(6) Install camshafts. (Refer to 9 - ENGINE/CYL-
INDER HEAD/CAMSHAFT(S) - INSTALLATION).
(7) Install cylinder head cover. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION)
(8) Install timing belt rear cover and timing belt
idler pulley. (Refer to 9 - ENGINE/VALVE TIMING/
TIMING BELT / CHAIN COVER(S) - INSTALLA-
TION)
(9) Install timing belt and camshaft sprockets.
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT/CHAIN AND SPROCKETS - INSTALLATION)
(10) Connect cam sensor and fuel injectors wiring
connectors.
(11) Install ignition coil and wires. Connect igni-
tion coil wiring connector.
(12) Install power steering pump reservoir and
line support bracket to cylinder head.
(13) Raise vehicle and install the exhaust pipe to
the manifold.(14) Install accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION)
(15) Install heater tube support bracket to cylinder
head.
(16) Connect radiator upper and heater hoses to
intake manifold water outlet connections.
(17) Install upper intake manifold. (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSTALLATION)
(18) Using new gaskets, install EGR tube and
tighten fasteners to 11 N´m (95 in. lbs.).
(19) Install air inlet tube and housing.
(20) Connect all vacuum lines, electrical wiring,
ground straps and fuel line.
(21) Fill cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(22) Connect battery negative cable.
CAMSHAFT OIL SEAL(S)
REMOVAL
(1) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
REMOVAL).
(2) Hold each camshaft sprocket with Special Tool
6847 while removing center bolt (Fig. 20).
(3) Remove camshaft sprockets.
(4) Remove rear timing belt cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT COVER(S)
- REMOVAL).
(5) Remove camshaft seal using Special Tool
C-4679A (Fig. 21).
Fig. 18 Cylinder Head Gasket Positioning
1 - PART NUMBER FACES UP
2 - NO. 1 CYLINDER
Fig. 19 Cylinder Head Tightening Sequence
Fig. 20 Camshaft Sprocket - Removal/Installation
1 - SPECIAL TOOL 6847
9 - 28 ENGINE 2.4LRS
CYLINDER HEAD (Continued)