service CHRYSLER VOYAGER 2004 Service Manual

CRANKSHAFT MAIN
BEARINGS
STANDARD PROCEDURE - MAIN BEARING
FITTING
Bearing caps are not interchangeable and should
be marked at removal to insure correct assembly
(Fig. 67). Upper and lower bearing halves are NOT
interchangeable. Lower main bearing halves of 1, 3
and 4 are interchangeable. Upper main bearing
halves of 1, 3 and 4 are interchangeable.
Upper and lower number 2 bearing halves are
flanged to carry the crankshaft thrust loads and are
NOT interchangeable with any other bearing halves
in the engine (Fig. 68). All bearing cap bolts removed
during service procedures are to be cleaned and
lubricated with engine oil before installation. Bearing
shells are available in standard and the following
undersizes: 0.025 mm (0.001 in.) and 0.254 mm
(0.010 in). Never install an undersize bearing that
will reduce clearance below specifications.
CRANKSHAFT BEARING OIL CLEARANCE
Inspect the crankshaft bearing journals. (Refer to 9
- ENGINE/ENGINE BLOCK/CRANKSHAFT -
INSPECTION)
Engine crankshaft bearing clearances can be deter-
mined by use of Plastigage or the equivalent. The fol-
lowing is the recommended procedures for the use of
Plastigage with the engine in the vehicle or engine
on a repair stand.PLASTIGAGE METHODÐENGINE IN-VEHICLE
NOTE: The total clearance of the main bearings can
only be determined with the engine in the vehicle
by removing the weight of the crankshaft. This can
be accomplished by either of two following meth-
ods:
(1) Preferred method:
a. Shim the bearings adjacent to the bearing to be
checked in order to remove the clearance between
upper bearing shell and the crankshaft. This can be
accomplished by placing a minimum of 0.254 mm
(0.010 in.) shim (e. g. cardboard, matchbook cover,
etc.) between the bearing shell and the bearing cap
on the adjacent bearings and tightening bolts to
14±20 N´m (10±15 ft. lbs.).
²When checking #1 main bearing shim #2 main
bearing.
²When checking #2 main bearing shim #1 & #3
main bearing.
²When checking #3 main bearing shim #2 & #4
main bearing.
²When checking #4 main bearing shim #3 main
bearing.
NOTE: Remove all shims before reassembling
engine.
(2) Alternative Method:
a. Support the weight of the crankshaft with a
jack under the counterweight adjacent to the bearing
being checked.
(3) Remove oil film from surface to be checked.
Plastigage is soluble in oil.
Fig. 67 Main Bearing Cap Identification
Fig. 68 Main Bearing Identification
1 - OIL GROOVES
2 - OIL HOLES
3 - UPPER BEARINGS
4 - LOWER BEARINGS
RSENGINE 3.3/3.8L9 - 123

VALVE SEAT
DESCRIPTION SPECIFICATION
Metric Standard
Angle 44.5 - 45É
Seat Diameter -
Intake34.37 - 34.63
mm1.353 - 1.363 in.
Seat Diameter -
Exhaust27.06 - 27.32
mm1.065 - 1.075 in.
Runout (Max.) 0.05 mm 0.002 in.
Valve Seat
Width - Intake
and Exhaust0.9 - 1.3 mm 0.035 - 0.051 in.
Service Limit -
Intake2.0 mm 0.079 in.
Service Limit -
Exhaust2.5 mm 0.098 in.
VALVE GUIDE
DESCRIPTION SPECIFICATION
Metric Standard
Diameter I.D. 5.975 - 6.000
mm0.235 - 0.236 in.
Guide Bore
Diameter11.0 - 11.02
mm0.4330 - 0.4338
in.
Guide Height
(spring seat to
guide tip)13.25 - 13.75
mm0.521 - 0.541 in.
VALVES
DESCRIPTION SPECIFICATION
Metric Standard
Face Angle -
Intake and
Exhaust44.5 - 45É
Head Diameter
- Intake34.67 - 34.93
mm1.364 - 1.375 in.
Head Diameter
- Exhaust28.32 - 28.52
mm1.114 - 1.122 in.
Valve Length
(Overall)
Intake 112.76 - 113.32
mm4.439 - 4.461 in.
Exhaust 110.89 - 111.69
mm4.365 - 4.397 in.
Valve Stem
Diameter
Intake 5.934 - 5.952
mm0.2337 - 0.2344
in.
Exhaust 5.906 - 5.924
mm0.2326 - 0.2333
in.
VALVE MARGIN
DESCRIPTION SPECIFICATION
Metric Standard
Intake 1.2 - 1.7 mm 0.047 - 0.066 in.
Service Limit 0.95 mm .0037 in.
Exhaust 0.985 - 1.315
mm0.038 - 0.051 in.
Service Limit 1.05 mm .039 in.
VALVE STEM TIP
DESCRIPTION SPECIFICATION
Metric Standard
Intake 48.04 mm 1.891 in.
Exhaust 47.99 mm 1.889 in.
9s - 4 ENGINE 2.4L SUPPLEMENTRS
ENGINE 2.4L SUPPLEMENT (Continued)

VALVE STEM TO GUIDE CLEARANCE
DESCRIPTION SPECIFICATION
Metric Standard
Intake 0.048 - 0.066
mm0.0018 - 0.0025
in.
Max. Allowable 0.076 mm 0.003 in.
Service Limit 0.25 mm 0.010 in.
Exhaust 0.0736 - 0.094
mm0.0029 - 0.0037
in.
Max. Allowable 0.101 mm 0.004 in.
Service Limit 0.25 mm 0.010 in.
VALVE SPRINGS
DESCRIPTION SPECIFICATION
Metric Standard
Free Length
(Approx.)48.4 mm 1.905 in.
Nominal Force
(Valve Closed)338 N @ 38.0
mm75.98 lbs. @
1.496 in.
Nominal Force
(Valve Open)607 N @ 29.75
mm136 lbs. @
1.172 in.
Installed Height 38.00 mm 1.496 in.
Number of Coils 7.82
Wire Diameter 3.86 mm 1.496 in
OIL PUMP
DESCRIPTION SPECIFICATION
Metric Standard
Clearance Over
Rotors (Max.)0.10 mm 0.004 in.
Cover
Out-of-Flat
(Max.)0.025 mm 0.001 in.
Inner Rotor
Thickness (Min.)9.40 mm 0.370 in.
Outer Rotor
Thickness (Min.)9.40 mm 0.370 in.
Outer Rotor
Clearance
(Max.)0.039 mm 0.015 in.
Outer Rotor
Diameter (Min.)79.95 mm 3.148 in.
Tip Clearance
Between Rotors
(Max.)0.20 mm 0.008 in.
OIL PRESSURE
DESCRIPTION SPECIFICATION
Metric Standard
At Curb Idle
Speed*25 kPa 4 psi
At 3000 rpm 170 - 550 kPa 25 - 80 psi
CAUTION:
*If pressure is ZERO at curb idle, DO NOT run engine
at 3000 rpm.
RSENGINE 2.4L SUPPLEMENT9s-5
ENGINE 2.4L SUPPLEMENT (Continued)

ENGINE 3.3/3.8L
SUPPLEMENT
SPECIFICATIONS
3.3/3.8L ENGINE
GENERAL DESCRIPTION
DESCRIPTION SPECIFICATION
Metric Standard
Engine Type 60É V-6 Engine
Number of
Cylinders6
Displacement
3.3L3.3Liters 201 cu.in.
Displacement
3.8L3.8 Liters 231 cu. in.
Bore 3.3L 93.0 mm 201 cu.in.
Bore 3.8L 96.0 mm 3.779 cu.in.
Stroke 3.3L 81 mm 3.188 in.
Stroke 87 mm 3.425 in.
Compression
Ratio 3.3L- 9.35:1
Compression
Ratio 3.8L- 9.6:1
Firing Order - 1-2-3-4-5-6
Compression
Pressure-
Minimum689.5 kPa 100 psi.
Cylinder
Compression
(Max. Difference
Between
Cylinders- 25%
CYLINDER BLOCK
DESCRIPTION SPECIFICATION
Metric Standard
Cylinder Bore
Diameter
(Standard) 3.3L92.993-93.007
mm3.661-3.6617 in.
Cylinder Bore
Diameter
(Standard) 3.8L95.993-96.007
mm3.7792-3.780 in.
Out of Round
(Service Limits)0.076 mm 0.003 in.
Taper (Service
Limits)0.051 mm 0.002 in.
Lifter Bore
Diameter22.980-23.010
mm0.905-0.906 in.
Deck Surface
Flatness (Max.)0.1 mm 0.004 in.
CRANKSHAFT
DESCRIPTION SPECIFICATION
Metric Standard
Connecting Rod
Journal
Diameter57.979-58.005
mm2.2827-2.2837
in.
Main Bearing
Journal
Diameter63.993-64.013
mm2.5194-2.5202
in.
Journal
Out-of-Round
(Max.)0.025 mm 0.001 in.
Journal Taper
(Max.)0.025 mm 0.001 in
End Play 0.09-0.24 mm 0.0036-0.0095
in.
Wear Limit 0.381 mm 0.015 in.
Main Bearing
Diametrical
Clearance
1-2-3-40.011-0.055
mm0.0005-0.0022
in.
Wear Limit 0.076 mm 0.003 in.
RSENGINE 3.3/3.8L SUPPLEMENT9s-11

CONNECTING RODS
DESCRIPTION SPECIFICATION
Metric Standard
Bearing
Clearance0.019-0.065
mm.0.017-0.020 in.
Wear Limit 0.074 mm 0.003 in.
Side Clearance 0.13-0.32 mm 0.005-0.013 in.
Wear Limit 0.38 mm 0.015 in.
PISTONS
DESCRIPTION SPECIFICATION
Metric Standard
Piston Diameter
3.3L-Measured
39.8 mm (1.567
in) From Piston
To p92.968-92.998
mm.3.660-3.661 in.
Piston Diameter
3.8L-Measured
33.01 mm (1.30
in) From Piston
To p95.968-95.998
mm.3.778-3.779 in.
Clearance in
Bore @ Size
Location (New)-0.005-0.039
mm-0.0002±0.0015
in.
Weight 3.3L 362   5 grams 12.77   0.1764
oz.
Weight 3.8L 426   5 grams 15.03   0.1764
oz.
PISTON PINS
DESCRIPTION SPECIFICATION
Metric Standard
Type Press Fit in Rod (Serviced as a
Assembly)
Clearance in
Piston @ 21C
(70ÉF)0.006-0.019
mm0.0002-0.0007
in.
Clearance in
Connecting RodInterference Fit
Diameter 22.87-22.88
mm0.9007-0.9009
in.
Length 3.3L 67.25-67.75
mm2.648-2.667 in.
Length 3.8L 71.25-71.75
mm2.805-2.824 in.
PISTON RINGS
DESCRIPTION SPECIFICATION
Metric Standard
Ring End Gap
To p
Compression
Ring0.18-0.38 mm 0.007-0.015 in.
Second
Compression
Ring0.28-0.57 mm 0.011-0.022 in.
Oil Control
(Steel Rails)0.23-0.78 mm 0.009-0.030 in.
Wear Limit-
Compression
Rings1.0 mm 0.039 in.
Wear Limit-Oil
Control Steel
Rails1.88 mm 0.074 in.
Ring Side
Clearance
To p
Compression
Ring 3.3L0.030-0.080
mm0.0012-0.0031
in.
To p
Compression
Ring 3.8L0.030-0.069
mm0.0012-0.0027
in.
Second
Compression
Ring 3.3L0.030-0.095
mm0.0012-0.0037
in.
Second
Compression
Ring 3.8L0.041-0.085
mm0.0016-0.0033
in.
Oil Ring (Steel
Ring)0.039-0.200
mm0.0015-0.0078
in.
Wear Limit- Top
Ring0.10 mm 0.004 in.
Wear Limit-2nd
Ring0.13 mm 0.005
Wear Limit Oil
Ring Pack0.266 mm 0.009
Ring Width-Top
Compression
Ring 3.3L1.46-1.49 mm 0.0575-0.058 in.
Ring Width-Top
Compression
Ring 3.8L1.175-1.190
mm0.0462-0.0468
9s - 12 ENGINE 3.3/3.8L SUPPLEMENTRS
ENGINE 3.3/3.8L SUPPLEMENT (Continued)

CYLINDER HEAD
DESCRIPTION SPECIFICATION
Metric Standard
Gasket
Thickness
(Compressed)0.65-0.75 mm 0.0007-0.0024
in.
VALVES
DESCRIPTION SPECIFICATION
Metric Standard
Face Angle-
Intake- 45-45.5É
Face Angle-
Exhaust- 45-45.5É
Head Diameter-
Intake47.87-48.13
mm1.88-1.89 in.
Head Diameter-
Exhaust35.37-35.63
mm1.39-1.40 in.
Valve Lift (Zero
Lash)-Intake
and Exhaust-
3.3L9.80 mm 0.385 in.
Valve Lift (Zero
Lash)-Intake
and Exhaust-
3.8L11.0 mm 0.433 in.
Valve Length-
Intake125.84-126.6
mm4.95-4.98 in.
Valve Length-
Exhaust127.20-127.96 5.00-5.04 in.
Valve Stem to
Tip Height
(valve tip to
spring seat
washer)-Intake48.1-49.7 mm 1.89-1.95 in.
Valve Stem to
Tip Height
(valve tip to
spring seat
washer)-
Exhaust48.53-50.09
mm1.91-1.97 in.
VALVE SEAT
DESCRIPTION SPECIFICATION
Metric Standard
Angle - 44.5-45É
Run Out
(Service Limits)0.0762 mm 0.003 in.
Width-Intake
and Exhaust1.50-2.00 mm 0.057-0.078 in.
VALVE GUIDE
DESCRIPTION SPECIFICATION
Metric Standard
Guide Bore
Diameter (Std.)6.975-7.00 mm 0.274-0.275 in.
VALVE MARGIN
DESCRIPTION SPECIFICATION
Metric Standard
Intake 0.825-0.973
mm0.032-0.038 in.
Exhaust 1.565-1.713
mm0.061-0.067 in.
VALVE STEM DIAMETER
DESCRIPTION SPECIFICATION
Metric Standard
Intake
(Standard)6.935-6.953
mm0.2718-0.2725
in.
Exhaust
(Standard)6.906-6.924
mm0.2718-0.2725
in.
9s - 14 ENGINE 3.3/3.8L SUPPLEMENTRS
ENGINE 3.3/3.8L SUPPLEMENT (Continued)

²Standard dimension = less than 0.05 mm (0.002
inch.)
²Service Limit = 0.2 mm (0.008 inch.)
²Grinding Limit = Maximum of 0.2 mm (0.008
inch.) is permitted.
CAUTION: 0.20 mm (0.008 in.) MAX is a combined
total dimension of the stock removal limit from cyl-
inder head and block top surface (Deck) together.
INSTALLATION - CYLINDER HEAD
(1) Clean all sealing surfaces of engine block and
cylinder heads. (Refer to 9 - ENGINE - STANDARD
PROCEDURE)
(2) Position new gasket(s) on engine block (Fig. 4).
The left bank gasket is identified with the ªLº
stamped in the exposed area of the gasket located at
front of engine (shown in (Fig. 4)). The right bank
gasket is identified with a ªRº stamped in the
exposed area of the gasket also, but is located at the
rear of the engine.(3)The cylinder head bolts are torqued using
the torque yield method, they should be exam-
ined BEFORE reuse. If the threads are necked
down, the bolts must be replaced(Fig. 5).
(4) Necking can be checked by holding a scale or
straight edge against the threads. If all the threads
do not contact the scale the bolt should be replaced.
(5) Tighten the cylinder head bolts 1±8 in the
sequence shown in (Fig. 6). Using the 4 step torque
turn method, tighten according to the following val-
ues:
²Step 1: Bolts1±8to61N´m(45ft.lbs.)
²Step 2: Bolts1±8to88N´m(65ft.lbs.)
²Step 3: Bolts1±8(again) to 88 N´m (65 ft. lbs.)
²Step 4: Bolts1±8turn an additional 1/4 Turn.
(Do not use a torque wrench for this step.)
NOTE: Bolt torque after 1/4 turn should be over 122
N´m (90 ft. lbs.). If not, replace the bolt.
(6) Inspect push rods and replace worn or bent
rods.
(7) Install the push rods.
(8) Install the rocker arm and shaft assemblies.
(Refer to 9 - ENGINE/CYLINDER HEAD/ROCKER
ARMS - INSTALLATION)
(9) Install the cylinder head covers. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION)
Fig. 3 Checking Cylinder Head FlatnessÐTypical
Fig. 4 Head Gasket Installation
1 - CYLINDER HEAD GASKET
2 - LOCATION IDENTIFICATION (L = LEFT BANK, R = RIGHT
BANK)
Fig. 5 Checking Bolts for Stretching (Necking)
1 - STRETCHED BOLT
2 - THREADS ARE NOT STRAIGHT ON LINE
3 - THREADS ARE STRAIGHT ON LINE
4 - UNSTRETCHED BOLT
Fig. 6 CYLINDER HEAD TIGHTENING SEQUENCE
9s - 18 ENGINE 3.3/3.8L SUPPLEMENTRS
CYLINDER HEAD (Continued)

(3) Assemble gasket to cylinder cover by inserting
the bolt assemblies through each bolt hole on the
cover and gasket (Fig. 9).
(4) Install cylinder head cover and bolts (Fig. 10).
(5) Tighten cylinder head cover bolts to 12 N´m
(105 in. lbs.) (Fig. 10).
(6) Connect PCV hose to cylinder head cover.
(7) Connect spark plug wires to spark plugs.
(8) Install wiper module. (Refer to 8 - ELECTRI-
CAL/WIPERS/WASHERS/WIPER MODULE -
INSTALLATION)
(9) Connect negative cable to battery.
CYLINDER HEAD COVER-LEFT
REMOVAL
(1) Disconnect spark plug wires from spark plugs.
(2) Disconnect crankcase vent hose from cylinder
head cover.
(3) Remove cylinder head cover bolts.(4) Remove cylinder head cover and gasket.
INSTALLATION
(1) Clean cylinder head and cover mating surfaces.
Inspect cylinder head cover surface for flatness.
Replace gasket as necessary.
(2) Assemble gasket to cylinder cover by inserting
the fasteners through each bolt hole on cover and
gasket (Fig. 9).
(3) Install the cylinder head cover and bolts (Fig.
10).
(4) Tighten cylinder head cover bolts to 12 N´m
(105 in. lbs.) (Fig. 10).
(5) Connect crankcase vent hose.
(6) Connect spark plug wires to spark plugs.
Fig. 9 CYLINDER HEAD COVER GASKET
1 - CYLINDER HEAD COVER
2 - BOLT
3 - SEAL (SERVICED WITH BOLT)
4 - GASKET
Fig. 10 Cylinder Head Cover
1 - CYLINDER HEAD COVER
2 - BOLT
9s - 20 ENGINE 3.3/3.8L SUPPLEMENTRS
CYLINDER HEAD COVER-RIGHT (Continued)

EXHAUST SYSTEM
TABLE OF CONTENTS
page page
EXHAUST SYSTEM
DESCRIPTION..........................1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - EXCESSIVE
EXHAUST SYSTEM NOISE...............2
DIAGNOSIS AND TESTING - EXHAUST
SYSTEM RESTRICTION CHECK...........2
INSPECTION...........................3
ADJUSTMENTS.........................3
SPECIFICATIONS
TORQUE.............................3
SPECIAL TOOLS
EXHAUST SYSTEM.....................4
CATALYTIC CONVERTER
DESCRIPTION..........................4
OPERATION............................4
REMOVAL.............................5INSPECTION...........................5
INSTALLATION..........................6
CROSS-OVER PIPE - 3.3/3.8L
REMOVAL.............................6
INSTALLATION..........................6
HEAT SHIELDS
DESCRIPTION..........................6
OPERATION............................7
REMOVAL.............................7
INSTALLATION..........................7
MUFFLER
REMOVAL.............................7
INSTALLATION..........................7
RESONATOR
REMOVAL.............................9
INSTALLATION..........................9
EXHAUST SYSTEM
DESCRIPTION
The exhaust system consists of a catalytic con-
verter, muffler, and a resonator with connecting pipes
in-between (Fig. 1). The system is serviced in two
sections; the catalytic converter and pipe, and the
muffler and resonator with connecting pipe. A band
clamp is used to connect the joint between the twocomponents. Three support hanger rods with rubber
isolators are used to support and isolate the exhaust
system. A flexible joint, integral to the catalytic con-
verter, allows for engine movement. On vehicles
equipped with AWD, an additional heat shield is
mounted to the catalytic converter. The exhaust sys-
tem is tuned for each vehicle/powertrain combination.
Fig. 1 Exhaust System - Typical (All Vehicles)
1 - CATALYTIC CONVERTER 4 - SUPPORT - RESONATOR
2 - BAND CLAMP 5 - RESONATOR
3 - SUPPORTS - MUFFLER 6 - MUFFLER
RSEXHAUST SYSTEM11-1

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.
11 - 2 EXHAUST SYSTEMRS
EXHAUST SYSTEM (Continued)