2004 CHRYSLER VOYAGER engine

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Page 1438 of 2585

CHRYSLER VOYAGER 2004  Service Manual (7) Lower vehicle and install oil dipstick.
(8) Connect negative cable to battery.
(9) Fill crankcase with oil to proper level.
OIL PRESSURE RELIEF VALVE
REMOVAL
(1) Remove oil pan (Refer to 9 - ENGIN

Page 1439 of 2585

CHRYSLER VOYAGER 2004  Service Manual OIL PUMP
DESCRIPTION
The oil pump is located in the timing chain cover.
It is driven by the crankshaft.
REMOVAL
The oil pump is contained within the timing chain
cover housing (Fig. 105).
(1) Remove o

Page 1440 of 2585

CHRYSLER VOYAGER 2004  Service Manual (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

Page 1441 of 2585

CHRYSLER VOYAGER 2004  Service Manual (3) Install cover and tighten screws to 12 N´m (105
in. lbs.).
(4) If removed, install the oil pressure relief valve.
(Refer to 9 - ENGINE/LUBRICATION/OIL PRES-
SURE RELIEF VALVE - INSTALLATION)
INST

Page 1442 of 2585

CHRYSLER VOYAGER 2004  Service Manual DIAGNOSIS AND TESTING - INTAKE
MANIFOLD LEAKS
An intake manifold air leak is characterized by
lower than normal manifold vacuum. Also, one or
more cylinders may not be functioning.
WARNING: USE EXTREM

Page 1443 of 2585

CHRYSLER VOYAGER 2004  Service Manual (7) Disconnect the manifold absolute pressure
(MAP) sensor electrical connector.
(8) Disconnect the vapor purge vacuum hose from
throttle body.
(9) Disconnect the PCV hose (Fig. 114).
(10) Remove the

Page 1444 of 2585

CHRYSLER VOYAGER 2004  Service Manual ²Mounting surface distortion by using a straight-
edge and thickness gauge.
INSTALLATION - UPPER INTAKE MANIFOLD
(1) If the following components were removed from
manifold, install and tighten to spe

Page 1445 of 2585

CHRYSLER VOYAGER 2004  Service Manual CAUTION: The special screws used for attaching
the EGR tube and power steering reservoir to the
manifold must be installed slowly using hand tools
only. This requirement is to prevent the melting of
m