2004 CHRYSLER VOYAGER torque

FRONT CROSSMEMBER
MOUNT BUSHINGS
REMOVAL
(1) Using paint or grease pencil, mark outline of
cradle crossmember on frame rails.
(2) Loosen bolts attaching crossmember to frame
rails.
(3) Remove bolt on bushing that requires replace-
ment.
(4) Allow cradle crossmember to drop down enough
to gain clearance for bushing removal.
(5) Remove bushing from vehicle.
INSTALLATION
(1) Apply rubber lubrication or soap to replace-
ment bushing.(2) Insert lower half of bushing into square hole in
cradle crossmember.
(3) Place upper half of bushing on top of cross-
member aligned to receive square tube protruding
upward from lower bushing half.
(4) Squeeze bushing halves together to ensure they
are properly mated.
(5) Lift cradle crossmember upward to close gap
between the bushing and frame.
(6) Verify that lower bushing is fully seated into
cradle crossmember and upper bushing.
(7) Install bolt attaching bushing and crossmember
to frame rail hand tight.
(8) Align cradle crossmember to reference marks
on frame rails.
(9) Tighten cradle crossmember to frame rails
attaching bolts to 163 N´m (120 ft. lbs.) torque.
Fig. 15 CRADLE CROSSMEMBER
1 - ENGINE OIL PAN
2 - TRANSAXLE
3 - LOWER CONTROL ARM4 - FRONT CROSSMEMBER
5 - LIFT DEVICE
6 - SPINDLE
13 - 12 FRAME & BUMPERSRS
FRONT CRADLE CROSSMEMBER (Continued)

FUEL SYSTEM
TABLE OF CONTENTS
page page
FUEL DELIVERY..........................1FUEL INJECTION........................17
FUEL DELIVERY
TABLE OF CONTENTS
page page
FUEL DELIVERY
DESCRIPTION..........................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
SPECIFICATIONS
FUEL SYSTEM PRESSURE..............3
TORQUE.............................3
SPECIAL TOOLS
FUEL................................4
FUEL LEVEL SENDING UNIT / SENSOR
DESCRIPTION..........................5
OPERATION............................5
REMOVAL.............................5
INSTALLATION..........................5
FUEL LINES
DESCRIPTION - FUEL LINES/HOSES AND
CLAMPS.............................6
STANDARD PROCEDURE - HOSES AND
CLAMP..............................7
FUEL PRESSURE REGULATOR
OPERATION............................7
REMOVAL.............................7
INSTALLATION..........................7FUEL PUMP
DESCRIPTION..........................8
OPERATION............................8
FUEL PUMP MODULE
DESCRIPTION..........................8
OPERATION............................8
REMOVAL.............................8
INSTALLATION..........................9
FUEL RAIL
REMOVAL
REMOVAL - 2.4L.......................9
REMOVAL - 3.3/3.8L...................10
INSTALLATION
INSTALLATION - 2.4L..................10
INSTALLATION - 3.3/3.8L................10
FUEL TANK
DESCRIPTION.........................10
OPERATION...........................11
REMOVAL.............................11
INSTALLATION.........................12
FUEL TANK FILLER TUBE
REMOVAL.............................12
INSTALLATION.........................13
INLET FILTER
REMOVAL.............................13
INSTALLATION.........................13
QUICK CONNECT FITTING
STANDARD PROCEDURE - QUICK-CONNECT
FITTINGS...........................14
RSFUEL SYSTEM14-1

NOTE: WRAP SHOP TOWELS AROUND HOSES TO
CATCH ANY GASOLINE SPILLAGE.
(11) Drain fuel tank into holding tank or a prop-
erly labeledGasolinesafety container.
WARNING: GASOLINE OR GASOLINE VAPORS ARE
HIGHLY FLAMMABLE. A FIRE COULD OCCUR IF AN
IGNITION SOURCE IS PRESENT. NEVER DRAIN ORSTORE GASOLINE OR DIESEL FUEL IN AN OPEN
CONTAINER, DUE TO THE POSSIBILITY OF FIRE
OR EXPLOSION. THIS MAY RESULT IN PERSONAL
INJURY OR DEATH.
(12) If fuel pump module removal is necessary,
refer to Fuel Pump Module Removal/Installation in
this section.
SPECIFICATIONS
FUEL SYSTEM PRESSURE
400 kpa  34 kpa (58 psi   5 psi)
TORQUE
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Fuel Filler Neck Clamp 3.3 30
Fuel Rail 2.4L 22 195
Fuel Rail 3.3/3.8L 11.8 105
Fuel Tank Strap 54 40
Fuel Tank T Strap 28.2 250
Fuel Filter Bolt 4.5 40
RSFUEL DELIVERY14-3
FUEL DELIVERY (Continued)

nated fuel in this system. If it is necessary to replace
these lines/tubes/hoses, use new original equipment
lines/tubes/hoses.
If equipped:The hose clamps used to secure rub-
ber hoses on vehicles are of a special rolled edge con-
struction. This construction is used to prevent the
edge of the clamp from cutting into the hose. Only
these rolled edge type clamps may be used in this
system. All other types of clamps may cut into the
hoses and cause leaks.
Use new original equipment type hose clamps.
STANDARD PROCEDURE - HOSES AND CLAMP
Inspect all hose connections (clamps and quick con-
nect fittings) for completeness and leaks. Replace
cracked, scuffed, or swelled hoses. Replace hoses that
rub against other vehicle components or show sign of
wear.
Fuel injected vehicles use specially constructed
hoses. When replacing hoses, only use hoses marked
EFM/EFI.
When installing hoses, ensure that they are routed
away from contact with other vehicle components
that could rub against them and cause failure. Avoid
contact with clamps or other components that cause
abrasions or scuffing. Ensure that rubber hoses are
properly routed and avoid heat sources.
The hose clamps have rolled edges to prevent the
clamp from cutting into the hose. Only use clamps
that are original equipment or equivalent. Other
types of clamps may cut into the hoses and cause
high pressure fuel leaks. Tighten hose clamps to 1
N´m (9 in. lbs.) torque.
Inspect all hose connections such as clamps, cou-
plings and fittings to make sure they are secure and
leaks are not present. The component should be
replaced immediately if there is any evidence of deg-
radation that could result in failure.
Never attempt to repair a plastic fuel line/tube.
Replace as necessary.
Avoid contact of any fuel tubes/hoses with other
vehicle components that could cause abrasions or
scuffing. Be sure that the plastic fuel lines/tubes are
properly routed to prevent pinching and to avoid heat
sources.
FUEL PRESSURE REGULATOR
OPERATION
The fuel system uses a nonadjustable pressure reg-
ulator that maintains fuel system pressure at
approximately 400  34 kPa (58  5 psi). The fuel
pressure regulator contains a diaphragm, calibrated
spring and a fuel return valve. The spring pushes
down on the diaphragm and closes off the fuel returnport. System fuel pressure reflects the amount of fuel
pressure required to open the return port.
The pressure regulator is a mechanical device that
is NOT controlled by the PCM or engine vacuum.
REMOVAL
The fuel pressure regulator is part of the fuel
pump module (Fig. 8). Remove the fuel pump module
from the fuel tank to access the fuel pressure regula-
tor. Refer to the Fuel Pump Module removal in this
section.
(1) Squeeze tangs on pressure regulator retainer
and pull to remove retainer.
(2) Pry fuel pressure regulator out of housing.
(3) Ensure both upper and lower O-rings were
removed with regulator.
INSTALLATION
The fuel pressure regulator is part of the fuel
pump module. Remove the fuel pump module from
the fuel tank to access the fuel pressure regulator.
Refer to the Fuel Pump Module removal in this sec-
tion.
(1) Lightly lubricate the O-rings with clean engine
oil and place them into opening in pump module (Fig.
8).
(2) Push regulator into opening in pump module.
(3) Retaining tabs snap into housing.
Fig. 8 Fuel Pressure Regulator O-rings
1 - UPPER O-RING
2 - LOWER 0-RING
RSFUEL DELIVERY14-7
FUEL LINES (Continued)

(6) Remove harness from vehicle.
(7) Remove fuel hose quick connect fitting from the
chassis tube.Refer to Fuel Hoses, Clamps and
Quick Connect Fittings in this Section.Place a
shop towel under the connections to absorb any fuel
spilled from the fitting.
WARNING: WRAP A SHOP TOWEL AROUND HOSES
TO CATCH ANY GASOLINE SPILLAGE.
(8) Remove fuel rail attaching bolts.
(9) Remove fuel rail. Be careful not to damage the
injector O-rings upon removal from their ports.
REMOVAL - 3.3/3.8L
(1) Perform fuel system pressure release procedure
before servicing or starting repairs.Refer to
Fuel System Pressure Release Procedure in this sec-
tion.
(2) Disconnect negative cable from battery.
(3) Remove upper intake manifold, refer to the
Engine/Manifolds/Upper Intake for more informa-
tion..
(4) Cover intake manifold with suitable cover
when servicing.
(5) Remove the fuel hose quick connect fitting from
the chassis tube.Refer to Fuel Hoses, Clamps
and Quick Connect Fittings in this Section.
WARNING: WRAP A SHOP TOWEL AROUND HOSES
TO CATCH ANY GASOLINE SPILLAGE.
(6) Remove the fuel rail attaching bolts (Fig. 13).
(7) Remove fuel rail. Be careful not to damage the
injector O-rings upon removal from their ports.
INSTALLATION
INSTALLATION - 2.4L
(1) Ensure injector holes are clean. Replace
O-rings if damaged.
(2) Lubricate injector O-rings with a drop of clean
engine oil to ease installation.
(3) Put the tip of each injector into their ports.
Push the assembly into place until the injectors are
seated in the ports.
(4) Install the fuel rail mounting bolts. Tighten
bolts to 22 N´m (200 in. lbs.) torque.
(5) Connect the connectors to the fuel injectors.
(6) Install wiring harness to brackets.
(7) Connect the wiring connectors to fuel injectors
harness (Fig. 12).
(8) Connect negative battery cable.
(9) Use the DRBIIItscan tool to pressurize the
fuel system. Check for leaks.
INSTALLATION - 3.3/3.8L
(1) Ensure injector holes are clean. Replace
O-rings if damaged.
(2) Lubricate injector O-rings with a drop of clean
engine oil to ease installation.
(3) Put the tip of each injector into their ports.
Push the assembly into place until the injectors are
seated in the ports.
(4) Install the fuel rail mounting bolts. Tighten
bolts to 22 N´m (200 in. lbs.) torque.
(5) Remove covering on lower intake manifold and
clean surface.
(6) Install the Upper Intake Manifold, refer to
Engine/Manifolds/Upper Intake for more information.
(7) Install fuel hose quick connector fitting to chas-
sis tubes.Refer to Fuel Hoses, Clamps and
Quick Connect Fittings in this Section.Push the
fitting onto the chassis tube until it clicks into place.
Pull on the fitting to ensure complete insertion.
(8) Connect negative cable to battery.
(9) Use the DRBIIItscan tool to pressurize the
fuel system. Check for leaks.
FUEL TANK
DESCRIPTION
The fuel tank is constructed of a plastic material.
Its main functions are for fuel storage and for place-
ment of the fuel pump module. The tank is made
from High density Polyethylene (HDPE) material.If
equipped with ORVR (Onboard Refueling Vapor
Recovery) it has been added to the fuel tank to con-
trol refueling vapor emissions.
Fig. 13 FUEL INJECTORS 3.3/3.8L
14 - 10 FUEL DELIVERYRS
FUEL RAIL (Continued)

INSTALLATION
(1) Position fuel tank on transmission jack. Con-
nect check valve hose. Connect fuel filler tube vent
hose to fuel filler tube.
(2) Feed filler vent line thru frame rail.
(3) Raise tank into position and carefully work fuel
filler metal tube into the rubber hose on fuel tank. A
light coating of clean engine oil on the tube end may
be used to aid assembly.
(4) Tighten strap bolts to 54 N´m (40 ft. lbs.)
torque. Tighten T strap bolt to 28.2 N´m (250 in.
lbs.). Remove transmission jack.
(5) Tighten filler hose clamp to 3.3 N´m (30 in.
lbs.).CAUTION: Ensure straps are not twisted or bent
before or after tightening strap screws.
(6) Connect fuel pump/module electrical connector.
Place retainer in locked position.
(7) Lubricate the fuel supply line with clean 30
weight engine oil, install the quick connect fuel fit-
ting. Refer to Tube/Fitting Assembly in the Fuel
Delivery section of this section.
(8) Connect the control vapor lines at front of
tank.
(9) Pull-pull-push on all connections to make sure
of connection.
(10) Fill fuel tank, replace cap, and connect bat-
tery negative cable.
(11) Use the DRBIIItscan tool to pressurize the
fuel system. Check for leaks.
FUEL TANK FILLER TUBE
REMOVAL
(1) Disconnect the negative battery cable.
(2) Remove the 3 screws at the filler door.
(3) Raise and support vehicle
(4) Remove the left rear tire.
(5) Remove the splash shield (Fig. 19) or (Fig. 18).
(6)For RGRemove the canister from filler tube
(Fig. 20).
(7)For RGDisconnect the vent at the top of the
filler tube.
(8) Remove the ground strap.
(9) Remove filler tube at tank.
Fig. 16 Pump Module Connector Retainer and Lock
1 - PUSH DOWN ON RETAINER
2 - CONNECTOR LOCK
Fig. 17 VENT HOSE
Fig. 18 FUEL FILLER TUBE (RS)
14 - 12 FUEL DELIVERYRS
FUEL TANK (Continued)

FUEL INJECTION
TABLE OF CONTENTS
page page
FUEL INJECTION
OPERATION
OPERATION - INJECTION SYSTEM.......18
OPERATION - MODES OF OPERATION....18
FUEL CORRECTION or ADAPTIVE
MEMORIES..........................20
PROGRAMMABLE COMMUNICATIONS
INTERFACE (PCI) BUS.................21
SYSTEM DIAGNOSIS..................22
SPECIFICATIONS
TORQUE............................22
SPECIAL TOOLS
FUEL...............................23
ACCELERATOR PEDAL
REMOVAL.............................24
INSTALLATION.........................24
CRANKSHAFT POSITION SENSOR
DESCRIPTION.........................25
OPERATION...........................25
REMOVAL.............................25
INSTALLATION - 2.4L....................26
ENGINE SPEED SENSOR
DESCRIPTION.........................26
OPERATION...........................26
FUEL INJECTOR
DESCRIPTION.........................26
OPERATION...........................26
REMOVAL
REMOVAL - 2.4L......................27
REMOVAL - 3.3/3.8L...................27
INSTALLATION
INSTALLATION - 2.4L..................28
INSTALLATION - 3.3/3.8L................28
FUEL PUMP RELAY
DESCRIPTION.........................28
OPERATION...........................28
IDLE AIR CONTROL MOTOR
DESCRIPTION.........................28
OPERATION...........................28REMOVAL.............................29
INSTALLATION.........................29
INLET AIR TEMPERATURE SENSOR
DESCRIPTION.........................30
MAP SENSOR
DESCRIPTION.........................30
OPERATION...........................30
REMOVAL
REMOVAL - 2.4L......................31
REMOVAL - 3.3/3.8L...................31
INSTALLATION
INSTALLATION - 2.4L..................31
INSTALLATION - 3.3/3.8L................31
O2 SENSOR
DESCRIPTION.........................32
OPERATION...........................32
REMOVAL
REMOVAL - UPSTREAM 1/1 - 2.4L........33
REMOVAL - UPSTREAM 1/1 - 3.3/3.8L.....33
REMOVAL - DOWNSTREAM 1/2 - 2.4/3.3/
3.8L................................34
INSTALLATION
INSTALLATION - UPSTREAM 1/1 - 2.4L.....34
INSTALLATION - UPSTREAM 1/1 - 3.3/3.8L . . 34
INSTALLATION DOWNSTREAM 2/1 -
2.4/3.3/3.8L..........................34
THROTTLE BODY
DESCRIPTION.........................35
OPERATION...........................35
REMOVAL.............................35
INSTALLATION.........................35
THROTTLE CONTROL CABLE
REMOVAL.............................35
INSTALLATION.........................36
THROTTLE POSITION SENSOR
DESCRIPTION.........................36
OPERATION...........................36
REMOVAL - 3.3/3.8L.....................36
INSTALLATION - 3.3/3.8L.................37
RSFUEL INJECTION14-17

²Instrument Panel
²Body Control Module
²Air Bag System Diagnostic Module
²Full ATC Display Head (if equipped)
²ABS Module
²Transmission Control Module
²Powertrain Control Module
²Travel Module
²SKIMSYSTEM DIAGNOSIS
OPERATION
The PCM can test many of its own input and out-
put circuits. If the PCM senses a fault in a major
system, the PCM stores a Diagnostic Trouble Code
(DTC) in memory.
For DTC information see On-Board Diagnostics
(Refer to 8 - ELECTRICAL/ELECTRONIC CON-
TROL MODULES/POWERTRAIN CONTROL MOD-
ULE - DESCRIPTION) .
SPECIFICATIONS
TORQUE
DESCRIPTION N´m Ft. Lbs. In. Lbs.
MAP SENSOR PLASTIC
MANIFOLD1.7 15
MAP SENSOR
ALUMINUM MANIFOLD3.3 30
POWER STEERING
RESERVOIR PLASTIC
MANIFOLD5.7 50
POWER STEERING
RESERVOIR ALUMINUM
MANIFOLD11.9 105
THROTTLE CABLE
BRACKET PLASTIC
MANIFOLD5.7 50
THROTTLE CABLE
BRACKET ALUMINUM
MANIFOLD11.9 105
EGR TUBE PLASTIC
MANIFOLD5.7 50
EGR TUBE ALUMINUM
MANIFOLD11.9 105
THROTTLE BODY BOLTS
2.4L28 20.65 250  50
THROTTLE BODY BOLTS
3.3/3.8L11.8 8.7 105  20
O2 Sensors 27 20
The composite manifolds uses special Plastic screws. The factory installed Plastic screws can be removed and
installed up to 5 times. Do not exceed the specified torque. These screws must be installed slowly (less than 600
rpms) to avoid melting the parent material. There are service repair screws avialable for repair. They require a
higher torque than the original screws..
14 - 22 FUEL INJECTIONRS
FUEL INJECTION (Continued)