2004 CHRYSLER VOYAGER length

(4) Place a piece of Plastigage across the entire
width of the bearing shell in the cap approximately
6.35 mm (1/4 in.) off center and away from the oil
holes (Fig. 69). (In addition, suspected areas can be
checked by placing the Plastigage in the suspected
area). Torque the bearing cap bolts of the bearing
being checked to the proper specifications.
(5) Remove the bearing cap and compare the width
of the flattened Plastigage (Fig. 70) with the scale
provided on the package. Locate the band closest to
the same width. This band shows the amount of
clearance in thousandths. Differences in readings
between the ends indicate the amount of taper
present. Record all readings taken. (Refer to 9 -
ENGINE - SPECIFICATIONS)Plastigage gener-
ally is accompanied by two scales. One scale is
in inches, the other is a metric scale.
NOTE: Plastigage is available in a variety of clear-
ance ranges. Use the most appropriate range for
the specifications you are checking.
PLASTIGAGE METHODÐENGINE OUT-OF-VEHICLE
(1) With engine in the inverted position (crank-
shaft up) and mounted on a repair stand, remove
main journal cap.
(2) Remove oil from journal and bearing shell.
(3) Cut Plastigage to same length as width of the
bearing and place it in parallel with the journal axis
(Fig. 69).(4) Carefully install the main bearing cap and
tighten the bolts to specified torque.
CAUTION: Do not rotate crankshaft or the Plasti-
gage will be smeared.
(5) Carefully remove the bearing cap and measure
the width of the Plastigage at the widest part using
the scale on the Plastigage package (Fig. 70). Refer
to Engine Specifications for proper clearances (Refer
to 9 - ENGINE - SPECIFICATIONS). If the clearance
exceeds the specified limits, replace the main bear-
ing(s) with the appropriate size, and if necessary,
have the crankshaft machined to next undersize.
REMOVAL - CRANKSHAFT MAIN BEARINGS
(1) Remove the oil pan. (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL)
(2) Identify main bearing caps before removal.
(3) Remove bearing caps one at a time. Remove
upper half of bearing by inserting Special Main Bear-
ing Tool C-3059 (Fig. 71) into the oil hole of crank-
shaft.
(4) Slowly rotate crankshaft clockwise, forcing out
upper half of bearing shell.
INSTALLATION - CRANKSHAFT MAIN
BEARINGS
NOTE: One main bearing should be selectively fit-
ted while all other main bearing caps are properly
tightened.
Fig. 69 Plastigage Placed in Lower
1 - PLASTIGAGE
Fig. 70 Clearance Measurement
Fig. 71 Upper Main Bearing Removing/Installing
With Special Tool C-3059
1 - SPECIAL TOOL C-3059
2 - BEARING
3 - SPECIAL TOOL C-3059
4 - BEARING
9 - 124 ENGINE 3.3/3.8LRS
CRANKSHAFT MAIN BEARINGS (Continued)

(5) Install outer rotor into chain case cover. Press
rotor to one side with fingers and measure clearance
between rotor and chain case cover (Fig. 109). If mea-
surement is 0.39 mm (0.015 in.) or more, replace
chain case cover, only if outer rotor is in specification.
(6) Install inner rotor into chain case cover. If
clearance between inner and outer rotors (Fig. 110) is
0.203 mm (0.008 in.) or more, replace both rotors.
(7) Place a straightedge across the face of the
chain case cover, between bolt holes. If a feeler gauge
of 0.10 mm (0.004 in.) or more can be inserted
between rotors and the straightedge, replace pump
assembly (Fig. 111).ONLYif rotors are in specs.
(8) Remove oil pressure relief valve. (Refer to 9 -
ENGINE/LUBRICATION/OIL PRESSURE RELIEF
VALVE - REMOVAL)
(9) Inspect oil pressure relief valve and bore.
Inspect for scoring, pitting and free valve operationin bore (Fig. 112). Small marks may be removed with
400-grit wet or dry sandpaper.
(10) The relief valve spring has a free length of
approximately 49.5 mm (1.95 inches) it should test
between 19.5 and 20.5 pounds when compressed to
34 mm (1-11/32 inches). Replace spring that fails to
meet specifications.
(11) If oil pressure is low and pump is within spec-
ifications, inspect for worn engine bearings or other
reasons for oil pressure loss.
ASSEMBLY
(1) Assemble pump, using new parts as required.
Install the inner rotor with chamfer facing the
cast iron oil pump cover.
(2) Prime oil pump before installation by filling
rotor cavity with engine oil.
Fig. 106 Checking Oil Pump Cover Flatness
1 - FEELER GAUGE
2 - OIL PUMP COVER
3 - STRAIGHT EDGE
Fig. 107 Measuring Outer Rotor Thickness
Fig. 108 Measuring Inner Rotor Thickness
Fig. 109 Measuring Outer Rotor Clearance in
Housing
1 - FEELER GAUGE
2 - OUTER ROTOR
RSENGINE 3.3/3.8L9 - 143
OIL PUMP (Continued)

PISTONS
DESCRIPTION SPECIFICATION
Metric Standard
Piston Diameter 87.463 - 87.481
mm3.4434 -3.4441
in.
Clearance @ 14
mm (0.551 in.)
from bottom of
skirt0.024 - 0.057
mm0.0009 - 0.0022
in.
Weight 331 - 339
grams11.67- 11.95 oz.
Land Clearance
(Diametrical)0.614 - 0.664
mm0.024 - 0.026 in.
Piston Length 66.25 mm 2.608 in.
Piston Ring
Groove Depth
No. 14.640 - 4.784
mm0.182 - 0.188 in.
Piston Ring
Groove Depth
No. 24.575 - 4.719
mm(0.180 - 0.185
in.)
Piston Ring
Groove Depth
No. 34.097 - 4.236
mm0.161 - 0.166 in.
PISTON PINS
DESCRIPTION SPECIFICATION
Metric Standard
Clearance in
Piston0.005 - 0.018
mm0.0002 - 0.0008
in.
Clearance in
Connecting RodInterference
Diameter 21.998 - 22.003
mm0.8660 - 0.8662
in.
End Play None
Length 72.75 - 73.25
mm2.864 - 2.883 in.
PISTON RINGS
DESCRIPTION SPECIFICATION
Metric Standard
Ring Gap
To p
Compression
Ring0.25 - 0.51 mm 0.0098 - 0.020
in.
Wear Limit 0.8 mm 0.031 in.
2nd
Compression
Ring0.23 - 0.48 mm 0.009 - 0.018 in.
Wear Limit 0.8 mm 0.031 in.
Oil Control Steel
Rails0.25 - 0.64 mm 0.0098 - 0.025
in.
Wear Limit 1.00 mm 0.039 in.
Compression
Rings0.030 - 0.080
mm0.0011 - 0.0031
in.
Wear Limit 0.10 mm 0.004 in.
Ring Side
Clearance - Oil
Ring Pack0.012 - 0.178
mm0.0004 - 0.0070
in.
Ring Width -
Compression
Rings1.47 - 1.50 mm 0.057 - 0.059 in.
Ring Width - Oil
Ring Pack2.72 - 2.88 mm 0.107 - 0.1133
in.
CONNECTING ROD
DESCRIPTION SPECIFICATION
Metric Standard
Bearing
Clearance0.025 - 0.071
mm0.0009 - 0.0027
in.
Wear Limit 0.075 mm 0.003 in.
Bore Diameter -
Piston Pin20.96 - 20.98
mm0.8252 - 0.8260
in.
Bore Diameter -
Crankshaft End53.007 - 52.993
mm2.0868 - 2.0863
in.
Side Clearance 0.13 - 0.38 mm 0.005 - 0.015 in.
Wear Limit 0.40 mm 0.016 in.
Weight - Total
(Less Bearing)565.8 grams 19.96 oz.
9s - 2 ENGINE 2.4L SUPPLEMENTRS
ENGINE 2.4L SUPPLEMENT (Continued)

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)

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)

VALVE STEM TO GUIDE CLEARANCE
DESCRIPTION SPECIFICATION
Metric Standard
Intake 0.025-0.065
mm0.001-0.0025 in.
Exhaust 0.059-0.094
mm0.002-0.0037 in.
Max Allowable-
Intake (Rocking
Method)0.247 mm 0.010 in.
Max Allowable-
Exhaust
(Rocking
Method)0.414 mm 0.016 in.
PUSH RODS
DESCRIPTION SPECIFICATION
Metric Standard
Length 135.438 mm 5.33 in.
VALVE SPRING
DESCRIPTION SPECIFICATION
Metric Standard
Free Length-
Type A51.4 mm 2.02 in.
Free Length-
Type B53.4 mm 2.10 in.
Wire Diameter
Type A3.95-4.77 mm 0.15-0.19 in.
Wire Diameter
Type B4.19-4.29 mm 0.16-0.17 in.
Number of Coils
Type A7.52
Number of Coils
Type B7.25
Spring Tension
(Valve Closed)
Type A376.4-424.4 N
@ 41.9 mm84.6-95.6 lbs. @
1.65 in.
Spring Tension
(Valve Open)
Type A863.9-959.9 N
@ 41.9 mm194.2-215.8 lbs.
@ 1.65 in.
Spring Tension
(Valve Closed)
Type B377-423 N @
41.9 mm84.8-95.2 lbs. @
1.65 in.
Spring Tension
(Valve Open)
Type B880-962 N @
30.91 mm197.9-216.3 lbs.
@ 122 in.
Installed Height 41.1-42.7 mm 1.61-1.68 in
LUBRICATION
DESCRIPTION SPECIFICATION
Metric Standard
At Curb Idle
Speed*
(Minimum with
engine at
operating
temperature)34.47 kPa 5 psi
At 3000 RPM 205-551 kPa 30-80 psi
Oil Filter
By-Pass 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.
OIL PUMP
DESCRIPTION SPECIFICATION
Metric Standard
Clearance Over
rotors-Inner and
Outer0.10 mm 0.004 in.
Cover
Out-Of-Flat
(Max.)0.025 mm 0.001 in.
Inner Rotor
Thickness7.64 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.
RSENGINE 3.3/3.8L SUPPLEMENT9s-15
ENGINE 3.3/3.8L SUPPLEMENT (Continued)