2004 CHRYSLER VOYAGER wheel

VIBRATION DAMPER
REMOVAL
(1) Disconnect negative cable from battery.
(2) Raise vehicle on hoist.
(3) Remove the right front wheel and inner splash
shield.
(4) Remove the accessory drive belt. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)
(5) Remove vibration damper bolt.
(6) Insert Special Tool 8450 into crankshaft nose
(Fig. 83).
(7) Position 3-jaw puller Special Tool 1026 on
damper as shown in (Fig. 83). Turn puller forcing
screw until damper releases from crankshaft.
(8) Remove the crankshaft vibration damper.
INSTALLATION
(1) Install crankshaft vibration damper using the
forcing screw, nut, and thrust bearing/washer from
Special Tool 8452 (Fig. 84).NOTE: To minimize friction and prolong tool life,
lubricate the threads on the forcing screw of Spe-
cial Tool 8452.
(2) Position vibration damper on crankshaft.
(3) Screw Special Tool 8452 into crankshaft until
the bolt seats. Turn the nut to install damper until it
seats fully.
(4) Remove Special Tool 8452.
(5) Install vibration damper bolt. Torque bolt to 54
N´m (40 ft. lbs.).
(6) Install the accessory drive belt. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION)
(7) Install inner splash shield and right front
wheel.
(8) Connect negative cable to battery.
Fig. 83 Vibration Damper - Removal
1 - SPECIAL TOOL 8450 - INSERT
2 - SPECIAL TOOL 1026-3JAWPULLER
Fig. 84 Vibration Damper - Installation
1 - FORCING SCREW / NUT FROM SPECIAL TOOL 8452
2 - VIBRATION DAMPER
3 - THRUST BEARING / WASHER
9 - 130 ENGINE 3.3/3.8LRS

LEFT MOUNT
REMOVAL
(1) Raise the vehicle on hoist.
(2) Remove the left front wheel.
(3) Remove the left mount through bolt access
cover.
(4) Support the transaxle with a suitable jack.
(5) Remove the engine front mount through bolt to
allow left mount removal clearance (Fig. 87).
(6) Remove the left mount through frame rail bolt
(Fig. 88).
(7) Lower transaxle for access to horizontal bolts.
(8) Remove the horizontal bolts from the mount to
the transaxle (Fig. 89).
NOTE: To remove mount, additional lowering of
transaxle may be required.
(9) Remove left mount.
INSTALLATION
(1) Install left mount on transaxle (Fig. 89).
(2) Raise transaxle with jack until left mount is in
position.
(3) Install left mount through bolt (Fig. 88).
(4) Install left mount through bolt access cover.
(5) Install front mount through bolt (Fig. 87).
(6) Install left front wheel.
(7) Lower vehicle.
REAR MOUNT
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove the rear mount heat shield (Fig. 90).
(3) Remove the through bolt from the mount and
rear mount bracket (Fig. 91).
(4) Remove the mount bolts (Fig. 91).
(5) Remove the rear mount (Fig. 91).
(6) For rear mount bracket removal, remove the
bolts attaching bracket to transaxle (Fig. 92).
(7) Remove rear mount bracket.
Fig. 88 LEFT MOUNT TO BRACKET
1 - BOLT - BRACKET TO FRAME RAIL 68 N´m (50 ft. lbs.)
2 - BOLT - MOUNT TO RAIL THRU 75 N´m (55 ft. lbs.)
3 - BOLT - LEFT MOUNT TO TRANSAXLE 54 N´m (40 ft. lbs.)
4 - TRANSAXLE
5 - MOUNT - LEFT
6 - BRACKET - LEFT MOUNT
Fig. 89 LEFT MOUNT - 41TE TRANSAXLE
1 - LEFT MOUNT ASSEMBLY
2 - BOLT - 54 N´m (40 ft. lbs.)
3 - TRANSAXLE - 41TE
Fig. 90 REAR MOUNT HEAT SHIELD
1 - BOLT - HEAT SHIELD 11 N´m (100 in. lbs.)
2 - HEAT SHIELD
3 - CLIP
4 - REAR MOUNT
RSENGINE 3.3/3.8L9 - 133

VALVE TIMING
STANDARD PROCEDURE
STANDARD PROCEDURE - VALVE TIMING
VERIFICATION
(1) Remove front cylinder head cover and all 6
spark plugs.
(2) Rotate engine until the #2 piston is at TDC of
the compression stroke.
(3) Install a degree wheel on the crankshaft pulley.
(4) With proper adaptor, install a dial indicator
into #2 spark plug hole. Using the indicator find TDC
on the compression stroke.
(5) Position the degree wheel to zero.
(6) Remove dial indicator from spark plug hole.
(7) Place a 5.08 mm (0.200 in.) spacer between the
valve stem tip of #2 intake valve and rocker arm pad.
Allow tappet to bleed down to give a solid tappet
effect.
(8) Install a dial indicator so plunger contacts the
#2 intake valve spring retainer as nearly perpendic-
ular as possible. Zero the indicator.
(9) Rotate the engine clockwise until the intake
valve has lifted .254 mm (0.010 in.).
CAUTION: Do not turn crankshaft any further clock-
wise as intake valve might bottom and result in
serious damage.
(10) Degree wheel should read 6 degrees BTDC to
6 degrees ATDC.
STANDARD PROCEDURE - MEASURING
TIMING CHAIN WEAR
NOTE: This procedure must be performed with the
timing chain cover removed (Refer to 9 - ENGINE/
VALVE TIMING/TIMING CHAIN COVER - REMOVAL).
(1) Position a scale next to timing chain so that
any movement of chain may be measured (Fig. 132).
(2) Position a torque wrench and socket on the
camshaft sprocket attaching bolt. Apply force in the
direction of crankshaft rotation to take up slack to
the following torque:
²41 N´m (30 ft. lb.) with cylinder heads installed
²20 N´m (15 ft. lb.) with cylinder heads removed
NOTE: With torque applied to the camshaft
sprocket bolt, crankshaft should not be permitted to
move. It may be necessary to block crankshaft to
prevent rotation.
(3) Holding a measuring scale along edge of chain
links (Fig. 132).(4) Apply force in the reverse direction to the fol-
lowing torque:
²41 N´m (30 ft. lb.) with cylinder heads installed
²20 N´m (15 ft. lb.) with cylinder heads removed
(5) Measure amount of sprocket/chain movement.
(6) Install a new timing chain and sprockets if
movement exceeds 3.175 mm (1/8 in.).
TIMING CHAIN COVER
REMOVAL
(1) Disconnect negative cable from battery.
(2) Drain cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(3) Raise vehicle on hoist.
(4) Drain engine oil.
(5) Remove right wheel and inner splash shield.
(6) Remove oil pan. (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - REMOVAL)
(7) Remove oil pick-up tube (Fig. 133).
(8) Remove accessory drive belt. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)
(9) Remove A/C compressor and set aside.
(10) Remove crankshaft vibration damper. (Refer
to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL)
(11) Remove radiator lower hose.
(12) Remove heater hose from timing chain cover
housing (Fig. 134) or water pump inlet tube (if
engine oil cooler equipped) (Fig. 135).
(13) Remove the right side engine mount. (Refer to
9 - ENGINE/ENGINE MOUNTING/RIGHT MOUNT
- REMOVAL)
(14) Remove idler pulley from engine bracket (Fig.
136).
(15) Remove the engine mount bracket (Fig. 136).
Fig. 132 Measuring Timing Chain Wear
1 - TORQUE WRENCH
RSENGINE 3.3/3.8L9 - 153

(17) Remove the water pump for cover removal
clearance. (Refer to 7 - COOLING/ENGINE/WATER
PUMP - REMOVAL)
(18) Remove the bolt attaching the power steering
pump support strut to the front cover (Fig. 137).
(19) Remove the timing chain cover fasteners.
Remove timing chain cover (Fig. 138).
INSTALLATION
(1) Be sure mating surfaces of chain case cover
and cylinder block are clean and free from burrs.
Crankshaft oil seal must be removed to insure cor-
rect oil pump engagement.
NOTE: DO NOT USE SEALER ON COVER GASKET
(2) Position new gasket on timing cover (Fig. 138).
Adhere new gasket to chain case cover, making sure
that the lower edge of the gasket is flush to 0.5 mm
(0.020 in.) passed the lower edge of the cover.
(3) Rotate crankshaft so that the oil pump drive
flats are in the vertical position.
(4) Position oil pump inner rotor so the mating
flats are in the same position as the crankshaft drive
flats (Fig. 138).
CAUTION: Make sure the oil pump is engaged on
the crankshaft correctly or severe damage may
result.
(5) Install timing cover (Fig. 138).
(6) Install timing chain cover bolts. Tighten M8
bolts to 27 N´m (20 ft. lbs.) and M10 bolts to 54 N´m
(40 ft. lbs.) (Fig. 139).
(7) Install crankshaft front oil seal. (Refer to 9 -
ENGINE/ENGINE BLOCK/CRANKSHAFT OIL
SEAL - FRONT - INSTALLATION)
(8) Install water pump and pulley. (Refer to 7 -
COOLING/ENGINE/WATER PUMP - INSTALLA-
TION)(9) Install crankshaft vibration damper. (Refer to 9
- ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
INSTALLATION)
(10) Install engine mount bracket (Fig. 136) and
tighten M10 to 54 N´m (40 ft. lbs.), M8 bolt to 28
N´m (21 ft. lb. lbs.).
(11) Install idler pulley on engine mount bracket
(Fig. 136).
(12) Install right side engine mount. (Refer to 9 -
ENGINE/ENGINE MOUNTING/RIGHT MOUNT -
INSTALLATION)
(13) Install camshaft position sensor (Refer to 8 -
ELECTRICAL/IGNITION CONTROL/CAMSHAFT
POSITION SENSOR - INSTALLATION).
(14) Connect the heater return hose at rear of tim-
ing chain cover (Fig. 134) or at water pump inlet
tube (if engine oil cooler equipped) (Fig. 135).
(15) Connect the radiator lower hose.
(16) Install A/C compressor.
(17) Install accessory drive belt. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION)
(18) Install oil pump pick-up tube with new
O-ring. Tighten attaching bolt to 28 N´m (250 in.
lbs.).
(19) Install oil pan. (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION)
(20) Install inner splash shield and right front
wheel.
(21) Fill crankcase with engine oil to proper level.
(22) Fill cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(23) Connect negative cable to battery.
Fig. 137 Power Steering Pump Strut
1 - BOLT - LOWER
2 - STRUT - P/S PUMP
3 - BOLT - UPPER
Fig. 138 Timing Chain Cover and Gasket
1 - GASKET
2 - TIMING CHAIN COVER
RSENGINE 3.3/3.8L9 - 155
TIMING CHAIN COVER (Continued)

CAUTION: Use extreme care when handling crank-
shaft. Tone wheel damage can occur if crankshaft is
mis-handled.
(22) Lift out crankshaft from cylinder block. Do
not damage the main bearings or journals when
removing the crankshaft.
(23) Remove the target ring mounting screws and
discard.
(24) Remove the target ring from the crankshaft.
INSPECTION
For crankshaft specifications (Refer to 9 - ENGINE
- SPECIFICATIONS).
The crankshaft journals should be checked for
excessive wear, taper and scoring (Fig. 4). Limits of
taper or out of round on any crankshaft journals
should be held to 0.025 mm (0.001 in.). Journal
grinding should not exceed 0.305 mm (0.012 in.)
under the standard journal diameter. DO NOT grind
thrust faces of No. 3 main bearing. DO NOT nick
crank pin or bearing fillets. After grinding, remove
rough edges from crankshaft oil holes and clean out
all passages.
CAUTION: With the nodular cast iron crankshafts, it
is important that the final paper or cloth polish be
in the same direction as normal rotation in the
engine.
INSTALLATION - CRANKSHAFT
CRANKSHAFT MAIN BEARING LOCATION
The crankshaft is supported in five main bearings.
All upper bearing shells in the crankcase have oil
grooves and holes. All lower bearing shellsexcept
for the thrust bearing half have oil grooves and holes
(Fig. 5). Crankshaft end play is controlled by a
flanged bearing on the number three main bearing
journal.
Fig. 3 Bed Plate Bolt Removal Sequence
Fig. 4 Crankshaft Journal Measurements - Typical
Fig. 5 Main Bearing Identification
1 - OIL GROOVE
2 - MAIN BEARINGS
3 - OIL HOLE
4 - LOWER THRUST BEARING PLAIN (NO OIL HOLE OR
GROOVE)
RSENGINE 2.4L SUPPLEMENT9s-7
CRANKSHAFT (Continued)

(1) Install the main bearing upper shells with the
lubrication groove and oil hole in the engine block
(Fig. 6).
(2) Make certain oil holes in block line up with oil
hole in bearings and bearing tabs seat in the block
tab slots.
NOTE: If the crankshaft is sent out for machine
work, it must be balenced as an assembly with the
target ring installed.
(3) Clean crankshaft and target ring with
MOPARtbrake parts cleaner and dry with com-
pressed air to ensure that the crankshaft mating sur-
face and target ring mounting holes are free from oil
and lock patch debris.
NOTE: Always use NEW mounting screws whether
installing original or new target ring.
(4) InstallNEWmounting screws finger tight
starting with the #1 location. (Fig. 7) Make sure
engagment occurs with the shoulder of the screw and
mounting hole before starting all other screws.
(5) Torque all mounting screws with T30 torx bit
to 13 Nm (110 in-lbs) following the torque sequence.
CAUTION: Use extreme care when handling crank-
shaft. Tone wheel damage can occur if crankshaft is
mis-handled.
CAUTION: Do not get oil on the bed plate mating
surface. It will affect the ability of the sealer to seal
the bed plate to cylinder block.(6) Oil the bearings and journals. Install crank-
shaft in the engine block.
CAUTION: Use only MoparTBed Plate Sealant on
the bed plate or damage may occur to the engine.
(7) Install lower main bearings into main bearing
cap/bed plate. Make certain the bearing tabs are
seated into the bed plate slots and apply oil.
(8) Apply 1.5 to 2.0 mm (0.059 to 0.078 in.) bead of
MopartBed Plate Sealant to bed plate as shown in
(Fig. 8).
Fig. 6 Installing Main Bearing Upper Shell
1 - LUBRICATION GROOVES
2 - OIL HOLESFig. 7 Target Ring Torque Sequence
Fig. 8 Bed Plate Sealing
9s - 8 ENGINE 2.4L SUPPLEMENTRS
CRANKSHAFT (Continued)

Visually inspect the catalytic converter element by
using a borescope or equivalent. Remove oxygen sen-
sor(s) and insert borescope. If borescope is not avail-
able, remove converter and inspect element using a
flashlight. Inspect element for cracked or melted sub-
strate.
NOTE: Before replacing a catalytic converter, deter-
mine the root cause of failure. Most catalytic con-
verter failures are caused by air, fuel or ignition
problems. (Refer to Appropriate Diagnostic Informa-
tion) for test procedures.
INSTALLATION
(1) Position new gasket onto the manifold flange
and install catalytic converter (Fig. 5). Tighten fas-
teners to 37 N´m (325 in. lbs.).
NOTE: Be careful not to twist or kink the oxygen
sensor wires.
(2) Install (if removed) and connect the down-
stream oxygen sensor (Fig. 4).
(3) Install the muffler/resonator assembly. (Refer
to 11 - EXHAUST SYSTEM/MUFFLER - INSTALLA-
TION)
CROSS-OVER PIPE - 3.3/3.8L
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove the fasteners attaching the left bank
manifold connection to cross-over pipe (Fig. 6).
(3) Raise vehicle and remove the left front wheel.
(4) Access the lower right bank pipe connection
fastener through the left front wheel opening using a
long ratchet extension. Loosen and remove the lower
fastener.
(5) Remove the upper right bank pipe connection
fastener by accessing though the catalytic converter
floor pan tunnel.
(6) Lower the vehicle.
(7) Remove the cross-over pipe (Fig. 6).
(8) Remove gaskets and discard (Fig. 6).
INSTALLATION
(1) Position cross-over pipe to the manifold connec-
tions (Fig. 6).
(2) Position new gasket on left bank (front) pipe
connection and loosely install fasteners (Fig. 6).
(3) Raise the vehicle.
(4) Position new gasket on the right bank pipe con-
nection and install fasteners.
(5) Tighten right bank upper fastener to 41 N´m
(30 ft. lbs.).(6) Tighten right bank lower fastener to 41 N´m
(30 ft. lbs.) using a long ratchet extension accessing
through the left wheel opening.
(7) Install the left front wheel and lower vehicle.
(8) Tighten the left bank pipe connection fasteners
to 41 N´m (30 ft. lbs.) (Fig. 6).
HEAT SHIELDS
DESCRIPTION
The exhaust system heat shields (Fig. 7), (Fig. 8),
or (Fig. 9) are attached to the under body of the vehi-
cle. On vehicles equipped with All Wheel Dive
(AWD), an additional heat shield is mounted to the
catalytic converter.
Fig. 6 CROSS-OVER PIPE
1 - CROSS-OVER PIPE
2 - BOLT
3 - GASKET
4 - FLAG NUT
Fig. 7 CATALYTIC CONVERTER HEAT SHIELD
1 - HEAT SHIELD - CATALYTIC CONVERTER
2 - SCREW (QTY. 4)
11 - 6 EXHAUST SYSTEMRS
CATALYTIC CONVERTER (Continued)

FRAME & BUMPERS
TABLE OF CONTENTS
page page
BUMPERS
SPECIFICATIONS - TORQUE...............1
FRONT FASCIA
REMOVAL.............................1
INSTALLATION..........................1
FRONT BUMPER REINFORCEMENT
REMOVAL.............................2
INSTALLATION..........................2
REAR FASCIA
REMOVAL.............................2
INSTALLATION..........................2
REAR BUMPER REINFORCEMENT
REMOVAL.............................3
INSTALLATION..........................3
REAR FASCIA - SCUFF PAD
REMOVAL.............................3INSTALLATION..........................4
FRAME
SPECIFICATIONS
FRAME DIMENSIONS...................4
SPECIFICATIONS - TORQUE.............9
FRONT CRADLE CROSSMEMBER
DESCRIPTION
DESCRIPTION - FRONT CRADLE
CROSSMEMBER.......................9
DESCRIPTION - FRONT CRADLE
CROSSMEMBER THREAD REPAIR.........9
REMOVAL.............................10
INSTALLATION.........................11
FRONT CROSSMEMBER MOUNT BUSHINGS
REMOVAL.............................12
INSTALLATION.........................12
BUMPERS
SPECIFICATIONS - TORQUE
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Front bumper reinforcement attaching nut 54 40 Ð
Rear bumper reinforcement attaching nut 27 20 Ð
FRONT FASCIA
REMOVAL
(1) Release hood latch and open hood.
(2) Remove the headlamp assemblies (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
HEADLAMP - REMOVAL).
(3) Hoist vehicle and support with safety stands.
(4) Remove the five bolts attaching bottom of fas-
cia/air dam to radiator closure panel.
(5) Remove front wheels.
(6) Remove front wheelhouse splash shields fasten-
ers as necessary to gain access to bolts attaching
front fascia to fender. (Refer to 23 - BODY/EXTERI-
OR/ WHEELHOUSE SPLASH SHIELD -
REMOVAL).
(7) Remove the two bolts and two nuts attaching
fascia to the front fenders (Fig. 1).
(8) Disconnect fog lamp wire connectors, if neces-
sary.
(9) Lower vehicle.(10) Remove two bolts attaching the upper grille
support to the headlamp mounting panel at each side
of the grille.
(11) Remove bumper fascia from vehicle.
INSTALLATION
(1) Position front bumper fascia on vehicle.
(2) Install the two bolts attaching fascia to head-
lamp mounting panel at each side of grille.
(3) Hoist vehicle and support with safety stands.
(4) Install the two bolts and two nuts attaching
fascia to the front fenders (Fig. 1). The fascia should
be flush to fender.
(5) Install front wheelhouse splash shields fasten-
ers. (Refer to 23 - BODY/EXTERIOR/ WHEEL-
HOUSE SPLASH SHIELD - INSTALLATION).
(6) Install front wheels.
(7) Connect fog lamp wire connectors, if necessary.
(8) Install the five bolts attaching bottom of fascia
to radiator closure panel.
(9) Lower the vehicle.
RSFRAME & BUMPERS13-1