2004 CHRYSLER VOYAGER oil pressure

INSTALLATION - ENGINE ASSEMBLY
(1) Position engine and transmission assembly
under vehicle. Slowly lower the vehicle down over the
engine and transmission. It is necessary to move the
engine/transmission assembly with the dolly for
clearance around body flanges.
(2)
Align engine and transmission mounts to attach-
ing points. Install mounting bolts at the right engine
mount (Fig. 13) and left transmission mount (Fig. 14).
(3) Remove the safety straps from around engine.
(4) Slowly raise vehicle enough to remove the
engine dolly and cradle Special Tools 6135, 6710,
6848 and 6909 (Fig. 12).
(5) Remove Special Tools 6912 and 8444 (Fig. 9).
(6) Lower the vehicle.
(7) Install power steering pump and pressure line
support.
Fig. 11 Special Tools 6848 with Adapters 6909
1 - OIL FILTER
2 - SPECIAL TOOLS 6909
3 - OIL PAN
4 - SPECIAL TOOLS 6848
Fig. 12 Positioning Engine Cradle Support Post Mounts
1 - SPECIAL TOOL 8444
2 - SPECIAL TOOLS 6848
3 - SPECIAL TOOL 6912
4 - SPECIAL TOOLS 6135 & 67105 - SPECIAL TOOLS 6848
6 - SAFETY STRAPS
7 - SPECIAL TOOLS 6909
RSENGINE 3.3/3.8L9-89
ENGINE 3.3/3.8L (Continued)

(8) Install the generator and wiring harness (Refer
to 8 - ELECTRICAL/CHARGING/GENERATOR -
INSTALLATION).
(9) Raise vehicle.
(10) Attach wiring harness support clip to the
engine oil dipstick tube.
(11) Connect oil pressure switch electrical connec-
tor.
(12) Install the A/C compressor.
(13) Install the water pump pulley.
(14) Connect the radiator lower hose.(15) Install the accessory drive belt and splash
shield (Refer to 7 - COOLING/ACCESSORY DRIVE/
DRIVE BELTS - INSTALLATION).
(16) Connect the engine block heater electrical con-
nector (if equipped).
(17) Connect the knock sensor electrical connector
(3.8L only).
(18) Install the torque converter to flex plate bolts.
(19) Install the transaxle case cover (Fig. 8).
(20) Install the powertrain struts (Fig. 8).
(21) Install the engine rear mount bracket.
(22) Install the engine front mount and bracket
assembly.
(23)AWD equipped;Install the power transfer
unit (PTU) (Refer to 21 - TRANSMISSION/TRANS-
AXLE/POWER TRANSFER UNIT - INSTALLA-
TION).
(24) Install the axle shafts (Refer to 3 - DIFFER-
ENTIAL & DRIVELINE/HALF SHAFT - INSTALLA-
TION).
(25) Connect exhaust pipe to manifold (Fig. 7).
(26) Install crossmember cradle plate (Fig. 6).
(27) Lower vehicle.
(28) Connect transaxle shift linkage.
(29) Connect transaxle electrical connectors.
(30) Remove plugs from transmission cooler hoses
and install transaxle oil cooler line service splice kit.
Refer to instructions included with kit.
(31) Install transaxle dipstick tube and attach
electrical harness clip.
(32) Connect the A/C lines to compressor.
(33) Connect the A/C compressor electrical connec-
tor.
(34) Evacuate and recharge A/C system.
(35) Connect crankshaft and camshaft position
sensors.
(36) Connect the fuel injector electrical harness
connector and engage clip to support bracket.
(37) Connect engine coolant temperature (ECT)
sensor and ignition coil electrical connectors.
(38) Connect the ground strap to rear of cylinder
head.
(39) Install power steering reservoir.
(40) Engage wire harness clip to engine right side
mount.
(41) Connect the brake booster and speed control
vacuum hoses.
(42) Connect the vacuum hoses to the throttle
body.
(43) Connect the EGR transducer electrical connec-
tor (if equipped).
(44) Connect the TPS, IAC, and MAP sensor elec-
trical connectors.
(45) Connect throttle cables to throttle body.
(46) Install the radiator fans (Refer to 7 - COOL-
ING/ENGINE/RADIATOR FAN - INSTALLATION).
Fig. 13 Right Mount to Engine
1 - BOLT
2 - MOUNT BRACKET
3 - ENGINE RIGHT MOUNT ASSEMBLY
Fig. 14 LEFT MOUNT TO FRAME BRACKET
1 - FRAME BRACKET
2 - FRAME RAIL - LEFT
3 - BOLT
4 - TRANSAXLE MOUNT
9 - 90 ENGINE 3.3/3.8LRS
ENGINE 3.3/3.8L (Continued)

(47) Connect the radiator upper hose.
(48) Connect the heater hoses. Remove pinch-off
pliers from the rear heater hoses (if equipped).
(49) Install the radiator upper support crossmem-
ber (Refer to 23 - BODY/EXTERIOR/GRILLE OPEN-
ING REINFORCEMENT - INSTALLATION).
(50) Install the wiper module (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
INSTALLATION).
(51) Connect the fuel line to fuel rail (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL LINES -
STANDARD PROCEDURE).
(52) Install the air cleaner and hoses.
(53) Install new oil filter. Fill engine crankcase
with proper oil to correct level.
(54) Connect negative cable to battery.
(55) Fill the cooling system (Refer to 7 - COOLING
- STANDARD PROCEDURE).
(56) Start engine and run until operating temper-
ature is reached.
(57) Adjust transmission linkage, if necessary.
SPECIFICATIONS
3.3/3.8L ENGINE
DESCRIPTION SPECIFICATION
General Specification
Type 60É V-6 Engine
Number of Cylinders 6
Displacement
Ð3.3L 3.3 Liters
(201 cu. in.)
Ð3.8L 3.8 Liters
(231 cu. in.)
Bore
Ð3.3L 93.0 mm
(3.66 in.)
Ð3.8L 96.0 mm
(3.779 in.)
Stroke
Ð3.3L 81.0 mm
(3.188 in.)
Ð3.8L 87.0 mm
(3.425 in.)
Compression Ratio
Ð3.3L 9.35:1
Ð3.8L 9.6:1
DESCRIPTION SPECIFICATION
Firing Order 1-2-3-4-5-6
Cylinder Number (Front
to Rear)
ÐFront Bank 2,4,6
ÐRear Bank 1,3,5
Compression PressureÐ
Minimum689.5 kPa
(100 psi)
Max. Variation Between
Cylinders25%
Cylinder Block
Cylinder Bore Diameter
(Standard)
Ð3.3L 92.993±93.007 mm
(3.661±3.6617 in.)
Ð3.8L 95.993±96.007 mm
(3.7792±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 Diameter 22.980±23.010 mm
(0.905±0.906 in.)
Deck Surface Flatness
(Max.)0.1 mm
(0.004 in.)
Pistons
Piston Diameter
Ð3.3L ÐMeasured 39.8
mm (1.567 in.) from
piston top92.968±92.998 mm
(3.660±3.661 in.)
Ð3.8L ÐMeasured 33.01
mm (1.30 in.) from piston
top95.968±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
Ð3.3L 362  5 grams
(12.77  0.1764 oz.)
Ð3.8L 426  5 grams
(15.03  0.1764 oz.)
Piston Pins
Type Press Fit in Rod
(Serviced as an
Assembly)
RSENGINE 3.3/3.8L9-91
ENGINE 3.3/3.8L (Continued)

DESCRIPTION SPECIFICATION
Valve Margin
Intake 0.825±0.973 mm
(0.032±0.038 in.)
Exhaust 1.565±1.713 mm
(0.061±0.067 in.)
Valve Length (Overall)
Intake 125.84±126.6 mm
(4.95±4.98 in.)
Exhaust 127.2±127.96 mm
(5.00±5.04 in.)
Valve Stem Tip Height
Intake (valve tip to spring
seat washer)48.1±49.7 mm
(1.89±1.95 in.)
Exhaust (valve tip to
spring seat washer)48.53±50.09 mm
(1.91±1.97 in.)
Valve Stem Diameter
Intake (Standard) 6.935±6.953 mm
(0.2730±0.2737 in.)
Exhaust (Standard) 6.906±6.924 mm
(0.2718±0.2725 in.)
Valve Stem to Guide Clearance
Intake 0.025±0.065 mm
(0.001±0.0025 in.)
Max. Allowable (Rocking
Method)0.247 mm
(0.010 in.)
Exhaust 0.059±0.094 mm
(0.002±0.0037 in.)
Max. Allowable (Rocking
Method)0.414 mm
(0.016 in.)
Push Rods
Length 135.438 mm
(5.33 in.)
Valve Springs
Free Length (Approx.) 51.4 mm
(2.02 in.)
Wire Diameter 3.95±4.77 mm
(0.15±0.19 in.)
Number of Coils 7.52DESCRIPTION SPECIFICATION
Spring Tension (Valve
Closed)376.4±424.4 N @ 41.9
mm
(84.6±95.6 lbs. @ 1.65
in.)
Installed Height 41.1±42.7 mm
(1.61±1.68 in.)
Oil Pump
Clearance Over
RotorsÐInner and Outer
(Max.)0.10 mm
(0.004 in.)
Cover Out-of-Flat (Max.) 0.025 mm
(0.001 in.)
Inner Rotor Thickness
(Min.)7.64 mm
(0.301 in.)
Outer Rotor Thickness
(Min.)7.64 mm
(0.301 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
At Curb Idle Speed*
(Minimum with engine at
operating temerature)34.47 kPa
(5 psi)
At 3000 rpm 205±551 kPa
(30±80 psi)
Oil Filter By-pas Valve
Setting62±103 kPa
(9±15 psi)
Oil Pressure Switch
Actuating Pressure14±28 kPa
(2±4 psi)
caution:
*If pressure is ZERO at curb idle, DO NOT run engine
at 3000 rpm.
9 - 94 ENGINE 3.3/3.8LRS
ENGINE 3.3/3.8L (Continued)

SPECIFICATIONS - TORQUE
DESCRIPTION N´mFt.
Lbs.In.
Lbs.
Camshaft SprocketÐBolt 54 40 Ð
Camshaft Thrust
PlateÐBolts12 Ð 105
Connecting Rod
CapÐBolts54 +
1¤4
turn40
+1¤4
turnÐ
Crankshaft Main Bearing
CapÐBolts41 +
1¤4
turn30
+1¤4
turnÐ
Crankshaft Main Bearing
Cap Cross Bolts (3.8L)61 45 Ð
Crankshaft Oil Seal
Retainer RearÐBolts12 Ð 105
Crankshaft DamperÐBolt 54 40 Ð
Cylinder Block Drain
Plugs20 15 Ð
Cylinder HeadÐBolts (Refer to 9 - ENGINE/
CYLINDER HEAD -
INSTALLATION)
Cylinder Head CoverÐ
Bolts12 Ð 105
Flex Plate to Crankshaft 95 70 Ð
Engine Mounting (Refer to 9 - ENGINE/
ENGINE MOUNTING)
Exhaust ManifoldÐBolts 23 Ð 200
Exhaust Crossover
PipeÐBolts54 40 Ð
Intake Manifold -
LowerÐBolts23 Ð 200
Intake Manifold - Lower
Gasket RetainerÐBolts12 Ð 105
Intake Manifold
UpperÐBolts12 Ð 105
Lifter Yoke RetainerÐ
Bolts12 Ð 105
Oil Filter Attaching Fitting 54 40 Ð
Oil Cooler Attaching
Fitting27 20 Ð
Oil Filter 20 15 Ð
Oil Filter AdapterÐBolts 28 Ð 250
Oil Gallery Plug 27 20 Ð
Oil PanÐBolts 12 Ð 105
Oil Pan DrainÐPlug 27 20 Ð
Oil Pressure Switch 23 Ð 200
DESCRIPTION N´mFt.
Lbs.In.
Lbs.
Oil Pump Cover
PlateÐScrews12 Ð 105
Oil Pump Pick-up
TubeÐBolt28 Ð 250
Oil Dipstick HousingÐ
Bolts48 35 Ð
Rocker Arm ShaftÐBolts 23 Ð 200
Spark Plug 16 12 Ð
Timing Chain Case Cover
ÐM8 Bolt 27 20 Ð
ÐM10 Bolt 54 40 Ð
Water PumpÐBolts 12 Ð 105
Water Pump PulleyÐ
Bolts28 Ð 250
SPECIAL TOOLS
3.3/3.8L ENGINE
Dolly 6135
Cradle 6710A
RSENGINE 3.3/3.8L9-95
ENGINE 3.3/3.8L (Continued)

Compressor, Valve Spring In-vehicle 8453
Valve Spring Compressor Off-vehicle C-3422-D
Adapter, Valve Spring Compressor Off-vehicle 8464
Remover, Valve Tappet C-4129-A
Remover, Crankshaft Front Seal 6341A
Installer, Crankshaft Front Seal C-4992
Remover and Installer, Crankshaft Main Bearing
C-3059
Rear Crankshaft Oil Seal Installer 6926
Oil Pressure Gauge C-3292
RSENGINE 3.3/3.8L9-97
ENGINE 3.3/3.8L (Continued)

ROCKER ARMS
DESCRIPTION
DESCRIPTION - ROCKER ARMS
The rocker arms are installed on the rocker arm
shaft. The rocker arms and shaft assembly is
attached to the cylinder head with seven bolts and
retainers. The rocker arms are made of stamped
steel.
DESCRIPTION - PUSHRODS
The pushrods are made of steel and are a hollow
design. The pushrods are positioned between the
hydraulic lifter and the rocker arm.
OPERATION
OPERATION - ROCKER ARMS
The rocker arm pivots on the rocker shaft. Rocker
arms are used to translate up and down motions pro-
vided by the camshaft, hydraulic lifter, and pushrod
on one end, into a down and up motions on the valve
stem on the opposing end.
OPERATION - PUSHRODS
The pushrod is a solid link between the hydraulic
lifter and the rocker arm. Also, the pushrod supplies
engine oil from the hydraulic lifter to the rocker arm.
REMOVAL - ROCKER ARMS AND SHAFT
(1) Remove the cylinder head cover(s). (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL)
NOTE: Rocker arm shaft bolts are captured to the
shaft.
(2) Loosen the rocker shaft bolts (Fig. 39), rotating
one turn each, until all valve spring pressure is
relieved.
(3) Remove the rocker arms and shaft assembly
(Fig. 39).
(4) For rocker arm disassembly procedures, (Refer
to 9 - ENGINE/CYLINDER HEAD/ROCKER ARMS -
DISASSEMBLY).
DISASSEMBLY - ROCKER ARMS AND SHAFT
CAUTION: Do not attempt to drive the bolt from the
rocker shaft. This can damage the retainer and bolt
assembly.
(1) Remove the rocker arm retainer and bolt by
performing the following procedure:
(a) Using adjustable pliers, grip the edges of the
retainer (Fig. 40).
(b) Apply an upward force with a slight rocking
motion until the retainer disengages from shaft
(Fig. 40).
(2) Remove rocker arms (Fig. 41). Identify the
component locations for reassembly in original loca-
tions.
ASSEMBLY - ROCKER ARMS AND SHAFT
(1) Install rocker arms on the shaft (Fig. 41).
Install in the orginal positions if re-used.Ensurethe
rocker shaft, all the retainers and washers are prop-
erly positioned and installed in the correct locations
(Fig. 41).
(2) Install rocker arms and shaft to the cylinder
head. (Refer to 9 - ENGINE/CYLINDER HEAD/
ROCKER ARMS - INSTALLATION)
Fig. 39 ROCKER ARMS AND SHAFT
1 - ROCKER ARMS AND SHAFT ASSEMBLY
2 - ROCKER SHAFT BOLTS
RSENGINE 3.3/3.8L9 - 109

CYLINDER BORE
NOTE: The cylinder bores should be measured at
normal room temperature, 21ÉC (70ÉF).
The cylinder walls should be checked for out-of-
round and taper with Tool C119 or equivalent (Fig.
45) (Refer to 9 - ENGINE - SPECIFICATIONS). If
the cylinder walls are badly scuffed or scored, the
cylinder block should be replaced, and new pistons
and rings fitted.
Measure the cylinder bore at three levels in direc-
tions A and B (Fig. 45). Top measurement should be
10 mm (3/8 in.) down and bottom measurement
should be 10 mm (3/8 in.) up from bottom of bore.
(Refer to 9 - ENGINE - SPECIFICATIONS).
HYDRAULIC LIFTERS (CAM IN
BLOCK)
DESCRIPTION
The hydraulic lifters are a roller type design and
are positioned in the cylinder block. The lifters are
aligned and retained by a yoke and a retainer (Fig.
47).Lifter alignment is maintained by machined flats
on lifter body. Lifters are fitted in pairs into six
aligning yokes. The aligning yokes are secured by a
yoke retainer (Fig. 47).
DIAGNOSIS AND TESTING - HYDRAULIC
LIFTERS
HYDRAULIC LIFTERS DIAGNOSIS - PRELIMINARY
STEP
Before disassembling any part of the engine to cor-
rect lifter noise, check the engine oil pressure. (Refer
to 9 - ENGINE/LUBRICATION - DIAGNOSIS AND
TESTING)
Check engine oil level. The oil level in the pan
should never be above the MAX mark on dipstick, or
below the MIN mark. Either of these two conditions
could cause noisy lifters.
OIL LEVEL TOO HIGH
If oil level is above the MAX mark on dipstick, it is
possible for the connecting rods to dip into the oil
while engine is running and create foaming. Foam in
oil pan would be fed to the hydraulic lifters by the oil
pump causing them to become soft and allow valves
to seat noisily.
OIL LEVEL TOO LOW
Low oil level may allow pump to take in air which
when fed to the lifters it causes them to become soft
and allows valves to seat noisily. Any leaks on intake
side of pump, through which air can be drawn, will
create the same lifter noise. Check the lubrication
system from the intake strainer to the oil pump
cover, including the relief valve retainer cap. When
lifter noise is due to aeration, it may be intermittent
or constant, and usually more than one lifter will be
noisy. When oil level and leaks have been corrected,
the engine should be operated at fast idle to allow all
of the air inside of the lifters to be bled out.
VALVE TRAIN NOISE
To determine source of valve train noise, operate
engine at idle with cylinder head covers removed and
listen for source of the noise.
NOTE: Worn valve guides or cocked springs are
sometimes mistaken for noisy lifters. If such is the
case, noise may be dampened by applying side
thrust on the valve spring. If noise is not apprecia-
bly reduced, it can be assumed the noise is in the
tappet. Inspect the rocker arm push rod sockets
and push rod ends for wear.
Fig. 45 Checking Cylinder Bore Size
RSENGINE 3.3/3.8L9 - 113
ENGINE BLOCK (Continued)