2004 CHRYSLER VOYAGER Power system

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Page 1296 of 2585

CHRYSLER VOYAGER 2004  Service Manual REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Look inside and note position of the retaining
bosses (Fig. 4).
(3) Using external snap ring pliers with 90 degree
tips. Insert plier

Page 1302 of 2585

CHRYSLER VOYAGER 2004  Service Manual CONDITION POSSIBLE CAUSE CORRECTION
ENGINE LOSS OF POWER 1. Dirty or incorrectly gapped plugs. 1. Clean plugs and set gap.
2. Contamination in fuel system. 2. Clean system and replace fuel
filter.
3.

Page 1313 of 2585

CHRYSLER VOYAGER 2004  Service Manual INSTALLATION - ENGINE ASSEMBLY
(1) Position engine and transmission assembly
under vehicle and slowly lower the vehicle over the
engine and transmission.
(2) Align engine and transmission mounts to
at

Page 1322 of 2585

CHRYSLER VOYAGER 2004  Service Manual ²Excessive steam (white smoke) emitting from
exhaust
²Coolant foaming
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determine if an engine cylinder head gasket is
leaking between adjacent cylinders, follow t

Page 1324 of 2585

CHRYSLER VOYAGER 2004  Service Manual (2) Position cylinder head gasket on engine block
(Fig. 18).
(3) Install cylinder head on engine block.
(4) Tighten the cylinder head bolts in the sequence
shown in (Fig. 19). Using the 4 step torque

Page 1345 of 2585

CHRYSLER VOYAGER 2004  Service Manual INSTALLATION
CAUTION: Torque procedure for the structural collar
must be followed or damage could occur to oil pan
and collar.
(1) Perform the following steps for installing struc-
tural collar. Refer

Page 1356 of 2585

CHRYSLER VOYAGER 2004  Service Manual (9) Disconnect throttle and speed control (if
equipped) cables from throttle lever and bracket.
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
THROTTLE CONTROL CABLE - REMOVAL)
(10) Remove the EGR tube. (

Page 1357 of 2585

CHRYSLER VOYAGER 2004  Service Manual INTAKE MANIFOLD - LOWER
REMOVAL
(1) Perform fuel system pressure release proce-
durebefore attempting any repairs.(Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY - STANDARD
PROCEDURE)
(2) Remove upper intake