2004 CHRYSLER VOYAGER engine

(4) Following the PEP module instruction manual,
connect all required cables to the DRB IIItand PEP
module. Select the available menu options on the
DRBIIItdisplay screen for using the digital pressure
gauge function.
(5) Apply the park brake and start the engine.
(6) With transmission in Park or Neutral, raise
engine speed to 2000 RPM. Monitor the pressure
readings on the DRBIIIt. Back pressure should not
exceed specified limit. Refer to specification in table
below EXHAUST BACK PRESSURE LIMITS .
(7) If pressure exceeds maximum limits, inspect
exhaust system for restricted component. For further
catalytic converter inspection procedures, (Refer to 11
- EXHAUST SYSTEM/CATALYTIC CONVERTER -
INSPECTION). Replace component(s) as necessary.
EXHAUST BACK PRESSURE LIMITS
Exhaust Back Pressure Limit (Max)
Vehicle in Park/Neutral
(no load) @2000 RPM3.45 Kpa (0.5 psi)
INSPECTION
Inspect the exhaust pipes, catalytic converters,
muffler, and resonators for cracked joints, broken
welds and corrosion damage that would result in a
leaking exhaust system. Inspect the clamps, support
brackets, and insulators for cracks and corrosion
damage.
NOTE: Slip joint band clamps are spot welded to
exhaust system. If a band clamp must be replaced,
the spot weld must be ground off.
ADJUSTMENTS
A misaligned exhaust system is usually indicated
by a vibration, rattling noise, or binding of exhaust
system components. These noises are sometimes hard
to distinguish from other chassis noises. Inspect
exhaust system for broken, damaged or loose compo-
nents such as; clamps, heat shields, isolators, and
hanger brackets. Replace or tighten as necessary. It
is important that exhaust system clearances and
alignment be maintained.
Perform the following procedures to align the
exhaust system:
(1) Loosen band clamp at catalytic converter pipe
to muffler/resonator assembly.(2) Align the exhaust system by inserting pipe
inward or outward until specification is achieved as
shown in (Fig. 2).
(3) Tighten band clamp to 54 N´m (40 ft. lbs.).
SPECIFICATIONS
TORQUE
DESCRIPTION N´mFt.
Lbs.In.
Lbs.
Band Clamp 54 40 Ð
Cross-over PipeÐFastener 41 30 Ð
Exhaust Manifold FlangeÐFastener 37 Ð 325
Heat Shield (Muffler)ÐFastener 2.6 Ð 23
Heat Shield (Toe Board)ÐFastener 2.6 Ð 23
Heat Shield (Resonator Pipe)Ð
Fastener2.6 Ð 23
Insulator Mounting BracketÐBolts 28 Ð 250
Fig. 2 Exhaust System Alignment
1 - HANGER BRACKET TO BODY
2 - ISOLATOR
3 - HANGER - MUFFLER/RESONATOR SUPPORT
4-6mm(0.25 in.)
RSEXHAUST SYSTEM11-3
EXHAUST SYSTEM (Continued)

The combustion reaction caused by the catalyst
releases additional heat in the exhaust system, caus-
ing temperature increases in the area of the reactor
under severe operating conditions. Such conditions
can exist when the engine misfires or otherwise does
not operate at peak efficiency.Do notremove spark
plug wires from plugs or by any other means short
out cylinders, if exhaust system is equipped with a
catalytic converter. Failure of the catalytic converter
can occur due to temperature increases caused by
unburned fuel passing through the converter. This
deterioration of the catalyst core can result in exces-
sively high emission levels, noise complaints, and
exhaust restrictions.
Unleaded gasoline must be used to avoid ruining
the catalyst core. Do not allow engine to operate
above 1200 RPM in neutral for extended periods over
5 minutes. This condition may result in excessive
exhaust system/floor pan temperatures because of no
air movement under the vehicle.
The flex joint allows flexing as the engine moves,
preventing breakage that could occur from the back-
and-forth motion of a transverse mounted engine.
CAUTION: Due to exterior physical similarities of
some catalytic converters with pipe assemblies,
extreme care should be taken with replacement
parts. There are internal converter differences
required in some parts of the country (particularly
vehicles built for States with strict emission
requirements) and between model years.
REMOVAL
(1) Loosen clamp and disconnect the muffler/reso-
nator assembly from catalytic converter pipe.
(2) Disconnect downstream oxygen sensor electri-
cal connector (Fig. 4). For removal of downstream
oxygen sensor, (Refer to 14 - FUEL SYSTEM/FUEL
INJECTION/O2 SENSOR - REMOVAL).
(3) Remove catalytic converter to exhaust manifold
attaching fasteners (Fig. 5).
(4) Remove catalytic converter and gasket (Fig. 5).
INSPECTION
WARNING: THE NORMAL OPERATING TEMPERA-
TURE OF THE EXHAUST SYSTEM IS VERY HIGH.
THEREFORE, NEVER ATTEMPT TO SERVICE ANY
PART OF THE EXHAUST SYSTEM UNTIL IT IS
COOLED. SPECIAL CARE SHOULD BE TAKEN
WHEN WORKING NEAR THE CATALYTIC CON-
VERTER. THE TEMPERATURE OF THE CONVERTER
RISES TO A HIGH LEVEL AFTER A SHORT PERIOD
OF ENGINE OPERATION TIME.Check catalytic converter for a flow restriction.
(Refer to 11 - EXHAUST SYSTEM - DIAGNOSIS
AND TESTING) Exhaust System Restriction Check
for procedure.
Fig. 4 Downstream Oxygen Sensor
1 - OXYGEN SENSOR CONNECTOR
2 - CATALYTIC CONVERTER
3 - DOWNSTREAM OXYGEN SENSOR
4 - ENGINE HARNESS CONNECTOR
Fig. 5 Catalytic Converter to Exhaust Manifold
1 - FLAG NUT
2 - GASKET
3 - BOLT
4 - CATALYTIC CONVERTER
RSEXHAUST SYSTEM11-5
CATALYTIC CONVERTER (Continued)

NOTE: If the rear fascia is to not to be removed for
other service issues use the step below.
(3) Using a trim stick, pry up the rear edge of the
scuff pad to release tabs from the rear bumper fascia
and pull scuff pad to release the forward tabs (Fig.
5).
INSTALLATION
(1) Verify that there are fifteen slots in the fascia.
(2) Place scuff pad in position (Fig. 5).(3) Align and insert the center forward tab.
(4) Align the remaining tabs and press into the
slots, starting in the center and working outboard.
(5) Assure all tabs are fully engaged into the fas-
cia.
(6) If rear bumper fascia has been removed install.
(Refer to 13 - FRAME & BUMPERS/BUMPERS/
REAR FASCIA - INSTALLATION).
FRAME
SPECIFICATIONS
FRAME DIMENSIONS
Frame dimensions are listed in metric scale. All
dimensions are from center to center of Principal
Locating Point (PLP), or from center to center of PLP
and fastener location.
VEHICLE PREPARATION
Position the vehicle on a frame alignment rack,
refer to instructions provided with equipment being
used. Adjust the vehicle PLP heights to the specified
dimension above the work surface (datum line). Ver-
tical dimensions can be taken from the datum line to
the locations indicated were applicable.
INDEX
DESCRIPTION FIGURE
CROSSMEMBER DIMENSIONS 6
ENGINE BOX - TOP VIEW 7
ENGINE COMPARTMENT AND FRAME RAIL - SIDE VIEW 8
FULL VEHICLE - BOTTOM VIEW 9
Fig. 5 SCUFF PAD
1 - SCUFF PAD
2 - TABS
13 - 4 FRAME & BUMPERSRS
REAR FASCIA - SCUFF PAD (Continued)

Fig. 7 ENGINE BOX - TOP VIEW
13 - 6 FRAME & BUMPERSRS
FRAME (Continued)

Fig. 8 ENGINE COMPARTMENT AND FRAME RAIL - SIDE VIEW
RSFRAME & BUMPERS13-7
FRAME (Continued)

SPECIFICATIONS - TORQUE
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Front Cradle Crossmember to Fram Rail Attaching Bolts (4) 163 120 Ð
Reinforcement Plate to Crossmember Attaching Bolt Size M14 (9) 153 113 Ð
Reinforcement Plate to Crossmember Attaching Bolt Size M12 (1) 106 78 Ð
Reinforcement Plate to Crossmember Attaching Bolt Size M10 (4) 61 45 Ð
Rear Engine Mount to Crossmember Attaching Through Bolt 68 50 Ð
Radiator Support Crossmember Attaching Bolts 51 38 Ð
FRONT CRADLE
CROSSMEMBER
DESCRIPTION
DESCRIPTION - FRONT CRADLE
CROSSMEMBER
This vehicle uses a one piece cast aluminum cradle
for the front cradle crossmember. The cradle cross-
member is used as the attaching points for the lower
control arms, stabilizer bar and steering gear. The
cradle also has the power steering hoses and the
chassis brake tubes attached to it.
WARNING: If a threaded hole in the suspension cra-
dle needs to be repaired, only use the type of
thread insert and installation procedure specified
for this application.
The threaded holes in the front cradle crossmem-
ber that are used for attachment of the lower control
arm rear bushing retainer, power steering hose and
chassis brake tubes can be repaired. The repair is
done by the installation of a Heli-Coiltthread insert
which has been specifically developed for this appli-
cation. Refer to the Mopar Parts Catalog for the spec-
ified Heli-Coiltthread insert to be used for this
application. The procedure for installing the Heli-
Coiltthread insert is detailed in the Service Proce-
dures section in this group of the service manual.
DESCRIPTION - FRONT CRADLE
CROSSMEMBER THREAD REPAIR
WARNING: When performing this procedure use
only the thread inserts which are specified in the
Mopar Parts Catalog for this repair procedure.
These thread inserts have been specifically devel-
oped for this application and use of other types of
thread inserts can result in an inferior long term
repair.The threaded holes in the front cradle crossmem-
ber, if damaged, can repaired by installing a Heli-
Coiltthread insert.
The threaded holes that are repairable using the
thread insert, are the lower control arm rear bushing
retainer mounting bolt holes, routing bracket attach-
ing locations for the power steering hoses, and brake
hose attachment holes.
This repair procedure now allows the threaded
holes in the cradle crossmember to be repaired, elim-
inating the need to replace the cradle crossmember if
damage occurs to one of the threaded holes.
The thread inserts for this application are specified
by part number in the Mopar Parts Catalog.Do not
use a substitute thread insert.
The specific tools and equipment required to install
the thread insert are listed below. Refer to the
instructions included with the thread insert for the
detailed procedure used for the installation of the
thread insert.
NOTE: The thread inserts for this application are for
the repair of M8x1.25 and M10x1.5 threads. Be sure
the correct tools are used for the required thread
insert size.
TOOL REQUIREMENT FOR M8x1.25 Thread
²8.3mm (5/16 in.) Drill Bit
²120É Countersink
²Heli-CoiltTap #4863-8
²Heli-CoiltGage #4624-8
²Heli-CoiltHand Inserting Tool 7751-8
²Needle Nose Pliers ± For Removal Of Thread
Insert Driving Tang
TOOL REQUIREMENT FOR M10x1.5 Thread
²10.5mm (25/64 in.) Drill Bit
²120É Countersink
²Heli-CoiltTap #4863-10
²Heli-CoiltGage #4624-10
²Heli-CoiltHand Inserting Tool 7751-10
²Needle Nose Pliers ± For Removal Of Thread
Insert Driving Tang
RSFRAME & BUMPERS13-9
FRAME (Continued)

REMOVAL
The front cradle crossmember must be installed in
the design location to achieve proper front end sus-
pension alignment. If the cradle crossmember is
removed without applying reference marks on the
frame rails, align the cradle crossmember according
to the dimensions provided in this group.
NOTE: If the caged nuts in the frame rails become
damaged and cannot be reused, a replacement nut
can be obtained through MoparT(Fig. 10).
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove steering column lower cover from
instrument panel (Refer to 23 - BODY/INSTRU-
MENT PANEL/STEERING COLUMN OPENING
COVER - REMOVAL).
(3) Remove steering column cover backing plate
(Refer to 23 - BODY/INSTRUMENT PANEL/STEER-
ING COLUMN COVER BACKING PLATE -
REMOVAL).
(4) Position steering so front wheels are straight
ahead.
CAUTION: Do not rotate steering wheel after disen-
gaging lower coupling from steering gear, damage
to air bag clock spring can result.
(5) Remove clinch bolt attaching steering column
coupling to steering gear shaft (Fig. 11).
(6) Remove steering column coupling from tele-
scoping steering gear shaft.(7) Hoist vehicle and support on safety stands.
(8) Position a drain pan under power steering
pump and oil return hose coupling.
(9) Using a hose pinch-off pliers (C-4390), pinch
power steering oil return hose off between the cross-
member coupling and the pump.
(10) Loosen hose clamp at the cradle crossmember
coupling.
(11) Disconnect return hose from metal tube.
(12) While holding pressure relief valve nut on
back of power steering pump, Remove flare nut
attaching high pressure hose to back of pump.
(13) Remove high pressure hose from pump.
(14) Allow power steering fluid to drain into pan.
(15) Remove bolts attaching anti-lock brake sensor
leads to cradle crossmember.
(16) Position anti-lock brake leads out of the way.
(17) Disconnect stabilizer bar links from ends of
stabilizer bar.
(18) Disconnect lower ball joints from lower steer-
ing knuckles (Refer to 2 - SUSPENSION/FRONT/
LOWER BALL JOINT - REMOVAL).
(19) Remove the rear engine mount heat shield
(Fig. 12).
(20) Remove through bolt attaching rear engine
mount to cradle crossmember (Fig. 13).
(21) Using paint or grease pencil, mark outline of
cradle crossmember on frame rails to aid installation.
(22) Support cradle crossmember on suitable lift-
ing device (Fig. 15).
(23) Remove bolts attaching crossmember to front
frame rails (Fig. 14).
(24) Remove cradle crossmember from vehicle (Fig.
15).
Fig. 10 FRONT CRADLE CROSSMEMBER CAGED
NUT
1 - BRACKET
2 - CAGED NUT
Fig. 11 STEERING COUPLING
1 - STEERING SHAFT BOOT
2 - STEERING SHAFT
3 - CROSSMEMBER
4 - STEERING GEAR
5 - MOUNT
6 - TRANSAXLE
13 - 10 FRAME & BUMPERSRS
FRONT CRADLE CROSSMEMBER (Continued)

INSTALLATION
NOTE: If cradle crossmember requires replacement.
Refer to Group 2, Suspension, to transfer suspen-
sion components and Group 19, Steering, to trans-
fer steering components.
(1) Support crossmember on suitable lifting device
(Fig. 15).
(2) Position crossmember to vehicle.
(3) Loosely install bolts attaching cradle cross-
member to front frame rails.
(4) Align crossmember to previously made marks
on frame rails.(5) Tighten bolts attaching cradle crossmember to
frame rails.
(6) Install through bolt attaching rear engine
mount to cradle crossmember (Fig. 13) and tighten to
68 N´m (50 ft. lbs.) torque.
(7) Install the rear mount heat shield (Fig. 12).
(8) Connect lower ball joints to steering knuckles
(Refer to 2 - SUSPENSION/FRONT/LOWER BALL
JOINT - INSTALLATION)
(9) Connect stabilizer bar links to ends of stabi-
lizer bar.
(10) Install bolts attaching anti-lock brake sensor
leads to cradle crossmember.
(11) Install high pressure hose to pump.
(12) Connect return hose to metal tube.
(13) Tighten hose clamp at the cradle crossmember
coupling.
(14) Remove pinch-off pliers.
(15) Position steering so front wheels are straight
ahead.
(16) Install steering column coupling to telescoping
steering gear shaft.
(17) Install clinch bolt attaching steering column
coupling to steering gear shaft.
(18) Install steering column cover backing plate
(Refer to 23 - BODY/INSTRUMENT PANEL/STEER-
ING COLUMN COVER BACKING PLATE -
INSTALLATION)
(19) Install steering column lower cover from
instrument panel (Refer to 23 - BODY/INSTRU-
MENT PANEL/STEERING COLUMN OPENING
COVER - INSTALLATION).
(20) Connect battery negative cable.
Fig. 12 REAR MOUNT HEAT SHIELD
1 - BOLT
2 - HEAT SHIELD
3 - CLIP
4 - REAR ENGINE MOUNT
Fig. 13 REAR MOUNT
1 - BOLT
2 - REAR MOUNT BRACKET
3 - THROUGH BOLT
4 - REAR MOUNT
Fig. 14 CRADLE CROSSMEMBER MOUNT
1 - CROSSMEMBER MOUNT
2 - BRAKE HOSE MOUNT
3 - STEERING TIE ROD
4 - FRONT CROSSMEMBER
5 - FRAME RAIL
RSFRAME & BUMPERS13-11
FRONT CRADLE CROSSMEMBER (Continued)