2004 CHRYSLER VOYAGER weight

(3) Verify proper tire inflation.
(4) Clean headlamp lenses.
(5) Verify that luggage area is loaded as the vehi-
cle is routinely used.
(6) Vehicles equipped with automatic load leveling
suspension should be driven normally for approxi-
mately 5 km (3 miles) before attempting a proper
headlamp unit alignment.
(7) Fuel tank should be FULL. Add 2.94 kg (6.5
lbs.) of weight over the fuel tank for each estimated
gallon of missing fuel.
ALIGNMENT SCREEN PREPARATION
(1) Position vehicle on a level surface perpendicu-
lar to a flat wall 10 meters (32.8 ft.) away from front
of headlamp lens (Fig. 15).
(2) If necessary, tape a line on the floor 10 meters
(32.8 ft.) away from and parallel to the wall.
(3) Rock vehicle side-to-side three times and allow
suspension to stabilize.
(4) Jounce front suspension three times by pushing
downward on front bumper and releasing.
(5) Measure the distance from the center of head-
lamp lens to the floor. Transfer measurement to the
alignment screen (with tape). Use this line for
up/down adjustment reference.
HEADLAMP UNIT ADJUSTMENT
The low beam headlamp will project on the screen
upper edge of the beam (cut-off) at the horizontal
lamp cut-off line   20 mm (0.75 in.). The high beam
pattern should be correct when the low beams are
aligned properly (Fig. 15). To adjust headlamp align-
ment, rotate adjustment screws (Fig. 16) to achieve
the specified low beam cut-off location.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the three retaining screws (Fig. 17).
(3) Disconnect the wiring harness from the bulbs
(Fig. 18).
(4) Remove wire harness retainer from back of
headlamp unit.
(5) Remove the headlamp unit.
Fig. 14 HEADLAMP UNIT ADJUSTMENT
1 - ADJUSTMENT LOCATION
2 - HEADLAMP UNIT
RSLAMPS/LIGHTING - EXTERIOR8L-15
HEADLAMP UNIT (Continued)

LOWER DRIVE UNIT TRACK &
RACK
DESCRIPTION
Vehicles equipped with a power sliding side door
utilize a lower drive unit track or door track and
rack assembly. This track provides a mating rack
gear (Fig. 13) for the lower drive unit to engage. The
track also accepts the lower hinge rollers, which
helps support the weight of the side door as well as
providing a smooth surface for the hinge rollers to
move upon.
The lower door track is a replaceable component.
Consult your Mopar parts catalog for specific part
numbers.
OPERATION
With the start of a power door open cycle, the door
motor drives the flex drive assembly. The flex drive
assembly drives the lower drive unit. A metal drive
gear which is part of the lower drive unit, meshes
with the door track rack teeth and moves the door
into the full open position. The same operation
repeats itself, during a power close cycle only the sys-
tem rotates in the opposite direction.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the side door sill plate from the lower
of the door opening. Refer to the Body section for the
procedure.
(3) Remove the hold-open striker. Refer to Body for
the procedure.
(4) Position a floor jack, with a block of wood
under the leading edge of the side door to support it
(Fig. 14).
(5) Remove the lower hinge assembly from the
door. Refer to the Body section of the service manual
for the procedure.
(6) Position the wire harness assembly out of door
opening, this will allow sufficient room to remove the
door track.
(7) Pull back the sealing patches and remove the
lower track retaining nuts (Fig. 15).
(8) Carefully remove the lower door track from the
vehicle.
INSTALLATION
(1) Carefully position the lower door track in the
vehicle.
(2) Install the lower track retaining nuts and
install the sealing patches. Torque the nuts to 70 in.
lbs.
(3) Install the lower hinge assembly on the door.
Refer to the Body section of the service manual for
the procedure.
Fig. 13 Rack Access Hole Locations
1 - Lower Door Track and Rack Assembly
2 - Wire Harness
3 - Rack Access Hole Sealing Patches
4 - Lower Drive Unit Cover
Fig. 14 Supporting Side Door
8N - 34 POWER SLIDING DOOR SYSTEMRS

(18) Remove axle shafts. (Refer to 3 - DIFFEREN-
TIAL & DRIVELINE/HALF SHAFT - REMOVAL)
(19) Drain engine oil and remove oil filter. (Refer
to 9 - ENGINE/LUBRICATION/OIL - STANDARD
PROCEDURE)
(20) Remove crossmember cradle plate (Fig. 6).
(21) Disconnect exhaust pipe from manifold (Fig.
7).
(22) Remove engine front mount and bracket from
engine. (Refer to 9 - ENGINE/ENGINE MOUNTING/
FRONT MOUNT - REMOVAL)(23) Remove structural collar. (Refer to 9 -
ENGINE/ENGINE BLOCK/STRUCTURAL COVER -
REMOVAL)
(24) Remove rear engine mount bracket. (Refer to
9 - ENGINE/ENGINE MOUNTING/REAR MOUNT -
REMOVAL)
(25) Mark flex plate to torque converter and
remove torque converter bolts.
(26) Pinch-off power steering supply hose at pump.
Remove hose from pump.
(27) Remove and set aside the power steering
pump and bracket. Do not disconnect pressure line.
(28) Lower vehicle.
(29) Remove A/C lines at compressor and cap open-
ings.
(30) Remove engine ground straps (strap at engine
right mount and at starter).
(31) Raise vehicle enough to allow engine dolly
Special Tool 6135, cradle Special Tool 6710 with
Posts Special Tool 6848 to be installed under vehicle
(Fig. 8).
(32) Loosen cradle posts to allow movement for
proper positioning. Locate two rear posts (right side
of engine) into the holes on the engine bedplate.
Locate the two front posts (left side of engine) on the
oil pan rails (Fig. 8). Lower vehicle and position cra-
dle mounts until the engine is resting on mounts.
Tighten mounts to cradle frame. This will keep
mounts from moving when removing or installing
engine and transmission.
(33) Install safety straps around the engine to cra-
dle. Tighten straps and lock.
(34) Lower vehicle so the weight ofONLY THE
ENGINE AND TRANSMISSIONare on the cradle.
(35) Remove engine and transmission mount bolts.
(36) Raise vehicle slowly. It may be necessary to
move the engine/transmission assembly with the
dolly to allow for removal around the body.
Fig. 6 Crossmember Cradle Plate
1 - CRADLE PLATE
Fig. 7 Catalytic Converter to Exhaust Manifold
1 - CATALYTIC CONVERTER
2 - BOLT
3 - GASKET
4 - FLAG NUT
9 - 14 ENGINE 2.4LRS
ENGINE 2.4L (Continued)

(33) Start engine and run until operating temper-
ature is reached.
(34) Adjust transmission linkage, if necessary.
SPECIFICATIONS
SPECIFICATIONS - 2.4L ENGINE
DESCRIPTION SPECIFICATION
General Specification
Type In-Line OHV, DOHC
Number of Cylinders 4
Displacement 2.4 Liters
(148 cu. in.)
Bore 87.5 mm
(3.445 in.)
Stroke 101.0 mm
(3.976 in.)
Compression Ratio 9.4:1
Firing Order 1-3-4-2
Compression Pressure 690 kPa (Minimum)
(100 psi Minimum)
Max. Variation Between
Cylinders25%
Cylinder Block
Cylinder Bore Diameter 87.4924±87.5076 mm
(3.4446±3.4452 in.)
Out-of-Round (Max.) 0.051 mm
(0.002 in.)
Taper (Max.) 0.051 mm
(0.002 in.)
Pistons
Piston Diameter 87.463±87.481 mm
(3.4434±3.4441 in.)
Clearance @ 14 mm
(9/16 in.) from bottom of
skirt0.024±0.057 mm
(0.0009±0.0022 in.)
Weight 346±356 grams
(12.20±12.56 oz.)
Land Clearance
(Diametrical)0.614±0.664 mm
(0.024±0.026 in.)
Piston Length 66.25 mm
(2.608 in.)
Piston Ring Groove
Depth No. 14.640±4.784 mm
(0.182±0.188 in.)
DESCRIPTION SPECIFICATION
Piston Ring Groove
Depth No. 24.575±4.719 mm
(0.180±0.185 in.)
Piston Ring Groove
Depth No. 34.097±4.236 mm
(0.161±0.166 in.)
Piston Pins
Clearance in Piston 0.005±0.018 mm
(0.0002±0.0008 in.)
Clearance in Connecting
RodInterference
Diameter 21.998±22.003 mm
(0.8660±0.8662 in.)
End Play None
Length 72.75±73.25 mm
(2.864±2.883 in.)
Piston Rings
Ring GapÐTop
Compression Ring0.25±0.51 mm
(0.0098±0.020 in.)
Wear Limit 0.8 mm
(0.031 in.)
Ring GapÐ2nd
Compression Ring0.23±0.48 mm
(0.009±0.018 in.)
Wear Limit 0.8 mm
(0.031 in.)
Ring GapÐOil Control
Steel Rails0.25±0.64 mm
(0.0098±0.025 in.)
Wear Limit 1.0 mm
(0.039 in.)
Ring Side ClearanceÐ
Compression Rings0.030±0.080 mm
(0.0011±0.0031 in.)
Wear Limit 0.10 mm
(0.004 in.)
Ring Side ClearanceÐOil
Ring Pack0.012±0.178 mm
(0.0004±0.0070 in.)
Ring WidthÐ
Compression Rings1.47±1.50 mm
(0.057±0.059 in.)
Ring WidthÐOil Ring
Pack2.72±2.88 mm
(0.107±0.1133 in.)
Connecting Rod
Bearing Clearance 0.025±0.071 mm
(0.0009±0.0027 in.)
Wear Limit 0.075 mm
(0.003 in.)
RSENGINE 2.4L9-17
ENGINE 2.4L (Continued)

DESCRIPTION SPECIFICATION
Bore DiameterÐPiston
Pin20.96±20.98 mm
(0.8252±0.8260 in.)
Bore DiameterÐ
Crankshaft End53.007±52.993 mm
(2.0868±2.0863 in.)
Side Clearance 0.13±0.38 mm
(0.005±0.015 in.)
Wear Limit 0.40 mm
(0.016 in.)
WeightÐTotal (Less
Bearing)565.8 grams
(19.96 oz.)
Crankshaft
Connecting Rod Journal
Diameter49.984±50.000 mm
(1.968±1.9685 in.)
Main Bearing Journal
Diameter59.992±60.008 mm
(2.362±2.3625 in.)
Journal Out-of-Round
(Max.)0.0035 mm
(0.0003 in.)
Journal Taper (Max.) 0.007 mm
(0.0001 in.)
End Play 0.09±0.24 mm
(0.0035±0.0094 in.)
Wear Limit 0.38 mm
(0.015 in.)
Main Bearing Diametrical
Clearance0.018±0.062 mm
(0.0007±0.0024 in.)
Hydraulic Lash Adjuster
Body Diameter 15.901±15.913 mm
(0.626±0.6264 in.)
Plunger Travel Minimum
(Dry)3.0 mm
(0.118 in.)
Cylinder Head Camshaft Bearing Bore Diameter
Journals No.1±6 26.020±26.041 mm
(1.024±1.025 in.)
Camshaft
Journal Diameter No. 1±6 25.951±25.970 mm
(1.021±1.022 in.)
Bearing ClearanceÐ
Diametrical0.069±0.071 mm
(0.0027±0.003 in.)
End Play 0.05±0.17 mm
(0.0019±0.0066 in.)
Lift (Zero Lash)
Intake 8.25 mm
(0.324 in.)DESCRIPTION SPECIFICATION
Exhaust 6.60 mm
(0.259 in.)
Intake Valve Timing*
Closes (ABDC) 51É
Opens (BTDC) 1É
Duration 232É
Exhaust Valve Timing*
Closes (ATDC) 7É
Opens (BBDC) 47É
Duration 234É
Valve Overlap 8É
*All readings in crankshaft degrees. Timing points @
4É from top of Ramps.
Cylinder Head
Material Cast Aluminum
Gasket Thickness
(Compressed)0.71 mm
(0.028 in.)
Valve Seat
Angle 44.5±45É
Seat DiameterÐIntake 34.37±34.63 mm
(1.353±1.363 in.)
Seat DiameterÐExhaust 27.06±27.32 mm
(1.065±1.075 in.)
Runout (Max.) 0.05 mm
(0.002 in.)
Valve Seat WidthÐIntake
and Exhaust0.9±1.3 mm
(0.035±0.051 in.)
Service LimitÐIntake 2.0 mm
(0.079 in.)
Service LimitÐExhaust 2.5 mm
(0.098 in.)
Valve Guide
Diameter I.D. 5.975±6.000 mm
(0.235±0.236 in.)
Guide Bore Diameter 11.0±11.02 mm
(0.4330±0.4338 in.)
Guide Height (spring seat
to guide tip)13.25±13.75 mm
(0.521±0.541 in.)
Valves
Face AngleÐIntake and
Exhaust44.5Ð45É
Head DiameterÐIntake 34.67±34.93 mm
1.364±1.375 in.)
9 - 18 ENGINE 2.4LRS
ENGINE 2.4L (Continued)

(1) Install the main bearing upper shells with the
lubrication groove and oil hole in the engine block
(Fig. 49).
(2) Make certain oil holes in block line up with oil
hole in bearings and bearing tabs seat in the block
tab slots.
CAUTION: Do not get oil on the bedplate mating
surface. It will affect the sealer ability to seal the
bedplate to cylinder block.
(3) Oil the bearings and journals. Install crank-
shaft.
CAUTION: Use only the specified anaerobic sealer
on the bedplate or damage may occur to the
engine.
(4) Apply 1.5 to 2.0 mm (0.059 to 0.078 in.) bead of
MopartBed Plate Sealant to cylinder block as shown
in (Fig. 50).(5) Install lower main bearings into main bearing
cap/bedplate. Make certain the bearing tabs are
seated into the bedplate slots. Install the main bear-
ing/bedplate into engine block.
(6) Before installing the bolts the threads should
be oiled with clean engine oil, wipe off any excess oil.
(7) Install main bearing bedplate to engine block
bolts 11, 17, and 20 finger tight. Tighten these bolts
down together until the bedplate contacts the cylin-
der block.
(8) To ensure correct thrust bearing alignment,
perform the following steps:
²Step 1: Rotate crankshaft until number 4 piston
is at TDC.
²Step 2: Move crankshaft rearward to limits of
travel.
²Step 3: Then, move crankshaft forward to limits
of travel.
²Step 4: Wedge an appropriate tool between the
rear of the cylinder block(NOT BED PLATE)and
the rear crankshaft counterweight. This will hold the
crankshaft in it's furthest forward position.
²Step 5: Install and tighten bolts (1±10) in
sequence shown in (Fig. 51) to 41 N´m (30 ft. lbs.).
²Step 6: Remove wedge tool used to hold crank-
shaft.
(9) Tighten bolts (1±10) again to 41 N´m (30 ft.
lbs.) in sequence shown in (Fig. 51).
CAUTION: Do Not use a torque wrench for the fol-
lowing step.
(10) Turn bolts (1±10) an additional 1/4 turn in
sequence shown in (Fig. 51).
(11) Install main bearing bedplate to engine block
bolts (11±20), and torque each bolt to 28 N´m (250 in.
lbs.) in sequence shown in (Fig. 51).
(12) Tighten bolts (11±20) again to 28 N´m (250 in.
lbs.) in sequence shown in (Fig. 51).
Fig. 49 Installing Main Bearing Upper Shell
1 - LUBRICATION GROOVES
2 - OIL HOLES
Fig. 50 Bedplate Sealing
Fig. 51 Bedplate Bolt Torque Sequence
RSENGINE 2.4L9-39
CRANKSHAFT (Continued)

(41) Disconnect the knock sensor electrical connec-
tor (3.8L only).
(42) Disconnect the engine block heater electrical
connector (if equipped).
(43) Remove the accessory belt splash shield.
(44) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(45) Disconnect the radiator lower hose.
(46) Remove air conditioning compressor from
engine.
(47) Remove the generator (Refer to 8 - ELECTRI-
CAL/CHARGING/GENERATOR - REMOVAL).
(48)
Remove the water pump pulley attaching bolts
and position pulley between pump hub and housing.
(49) Disconnect the oil pressure switch electrical
connector.
(50) Disconnect wiring harness support clip from
engine oil dipstick tube.
(51) Install Special Tools 6912 and 8444 Adapters
on the right side (rear) of engine block (Fig. 9).
(52) Lower the vehicle.
(53) Remove the power steering pump and set
aside.
(54) Raise vehicle enough to allow engine dolly
Special Tool 6135 and cradle Special Tool 6710 withpost Special Tool 6848 and adaptor Special Tool 6909
to be installed under vehicle (Fig. 12).
(55) Loosen cradle/post mounts to allow movement
for positioning posts into locating holes on the engine
(Fig. 10) and (Fig. 11). Slowly lower vehicle and posi-
tion cradle/post mounts until the engine is resting on
posts. Tighten all cradle/post mounts to cradle frame.
This will keep mounts from moving when removing
or installing engine and transmission.
(56) Lower vehicle so the weight ofONLY THE
ENGINE AND TRANSMISSIONis on the cradle.
(57) Install and secure the safety straps to the cra-
dle fixture and around the engine (Fig. 12).
(58) Remove the engine right side mount to engine
attaching bolts (Fig. 13).
(59) Remove the left mount through bolt (Fig. 14).
(60) Raise vehicle slowly. It is necessary to move
the engine/transmission assembly with the dolly to
allow for removal around body flanges.
Fig. 8 POWERTRAIN SUPPORTS AND DUST COVER
1 - BRACKET - ENGINE REAR MOUNT
2 - BOLT - TRANSAXLE CASE COVER
3 - STRUT - TRANSAXLE TO ENGINE HORIZONTAL
4 - BOLT - HORIZONTAL STRUT
5 - BOLT - STRUT TO TRANSAXLE
6 - COVER - TRANSAXLE CASE LOWER
7 - STRUT - TRANSAXLE TO ENGINE
8 - BOLT - STRUT TO ENGINE
9 - BOLT - ENGINE REAR MOUNT BRACKET
Fig. 9 ADAPTER TOOLS MOUNTED ON BLOCK
1 - SPECIAL TOOL 6912
2 - SPECIAL TOOL 8444
Fig. 10 Positioning Special Tool 6848 for use with
Adapters 8444 & 6912
1 - SLOTS
2 - SPECIAL TOOLS 6848
9 - 88 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)