2004 CHRYSLER VOYAGER oil pressure

ENGINE CONTROL MODULE C1 (DIESEL) - BLACK 81 WAY
CAV CIRCUIT FUNCTION
44 - -
45 - -
46 - -
47 L50 20WT/TN PRIMARY BRAKE SWITCH SIGNAL
48 B29 20DG/WT SECONDARY BRAKE SWITCH SIGNAL
49 T751 20YL FUSED IGNITION SWITCH OUTPUT (START)
50 F855 20PK/YL SENSOR REFERENCE VOLTAGE A
51 - -
52 K121 20DB BOOST PRESSURE SENSOR GROUND
53 - -
54 K957 20BK/OR MASS AIR FLOW SENSOR GROUND
55 N7 20DB/OR VEHICLE SPEED SENSOR SIGNAL
56 C918 20BK/LB A/C PRESSURE SENSOR GROUND
57 - -
58 - -
59 - -
60 K9 20LB FUEL PRESSURE SENSOR 5 VOLT SUPPLY
61 K51 20BR/WT ECM/PCM RELAY CONTROL
62 - -
63 D21 20WT/DG SCI TRANSMIT (ECM)
64 K151 20WT LOW IDLE POSITION SWITCH SENSE
65 - -
66 K936 20BR/YL ENGINE OIL PRESSURE SENSOR GROUND
67 - -
68 - -
69 C13 20LB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL
70 N210 20DB/DG LOW SPEED RADIATOR FAN RELAY CONTROL
71 - -
72 N21 20DB/TN LIFT PUMP RELAY CONTROL
73 - -
74 T752 20DG/OR STARTER MOTOR RELAY CONTROL
75 - -
76 - -
77 K152 20DB/WT GLOW PLUG RELAY CONTROL
78 N122 20DB/YL HIGH SPEED RADIATOR FAN DUAL RELAY CONTROL
79 - -
80 K87 20BR FUEL PRESSURE SOLENOID CONTROL
81 K87 20BR FUEL PRESSURE SOLENOID CONTROL
RS8W-80 CONNECTOR PIN-OUTS8W-80-69

ENGINE COOLANT TEMP SENSOR (DIESEL) - BLUE 2 WAY
CAV CIRCUIT FUNCTION
1 K2 20TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
2 K900 20DB/DG SENSOR GROUND
ENGINE COOLANT TEMP SENSOR (GAS) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 K900 18DB/DG SENSOR GROUND
2 K2 18VT/OR ECT SIGNAL
ENGINE OIL PRESSURE SENSOR (DIESEL) - BLACK 3 WAY
CAV CIRCUIT FUNCTION
1 F855 20PK/YL SENSOR REFERENCE VOLTAGE A
2 G6 20VT/GY ENGINE OIL PRESSURE SENSOR SIGNAL
3 K936 20BR/YL ENGINE OIL PRESSURE SENSOR GROUND
ENGINE OIL PRESSURE SWITCH (GAS) - LT. GREEN 2 WAY
CAV CIRCUIT FUNCTION
1 G6 16VT/GY OIL PRESSURE SIGNAL
2- -
RS8W-80 CONNECTOR PIN-OUTS8W-80-71

INLET AIR TEMPERATURE SENSOR - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 K21 18DB/LG INLET AIR TEMPERATURE SENSOR SIGNAL
2 K900 20DB/DG SENSOR GROUND
INPUT SPEED SENSOR - GRAY 2 WAY
CAV CIRCUIT FUNCTION
1 T13 18DG/VT SPEED SENSOR GROUND
2 T52 18DG/WT INPUT SPEED SENSOR SIGNAL
INSTRUMENT CLUSTER - BLACK 13 WAY
CAV CIRCUIT FUNCTION
1 E13 20OR/WT PANEL LAMPS DRIVER
2 L160 20WT/TN (LOWLINE) RIGHT TURN INDICATOR DRIVER
3 G7 20VT/GY (LHD EXPORT) LOW OIL PRESSURE INDICATOR DRIVER
4 G3 20VT/LB (LHD EXPORT) MALFUNCTION INDICATOR LAMP DRIVER
5 L134 20WT/GY (HIGHLINE) HIGH BEAM INDICATOR DRIVER
6 A701 18BR/RD FUSED B(+) (HAZARD)
7 Z108 18BK/LG GROUND
8 L161 20WT/LG (LOWLINE) LEFT TURN INDICATOR DRIVER
9 D25 20WT/VT PCI BUS
10 B25 16DG/WT (LHD EXCEPT EXPORT) PARK BRAKE SWITCH SENSE
10 B25 18DG/WT (LHD EXPORT) PARK BRAKE SWITCH SENSE
10 B25 20DG/WT (RHD) PARK BRAKE SWITCH SENSE
11 G26 22VT/OR CHIME DRIVER
12 G150 22VT/BR INSTRUMENT CLUSTER WAKE UP SENSE
13 Z18 18BK/LB GROUND
INSTRUMENT PANEL SWITCH BANK (EXCEPT HEATED SEATS)-6WAY
CAV CIRCUIT FUNCTION
1 E14 20OR/TN PANEL LAMPS DRIVER
2- -
3 F201 20PK/OR ORC RUN-START DRIVER
4 L91 22WT/DB HAZARD SWITCH SENSE
5- -
6 Z406 20BK/BR GROUND
RS8W-80 CONNECTOR PIN-OUTS8W-80-81

MEMORY SET SWITCH - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 G200 20VT/BR MEMORY SELECT SWITCH MUX
2 G920 20VT/YL MEMORY SELECT SWITCH RETURN
MESSAGE CENTER (HIGHLINE) - WHITE 14 WAY
CAV CIRCUIT FUNCTION
1 L160 20WT/TN (LHD) RIGHT TURN INDICATOR DRIVER
2 G3 20VT/LB (LHD EXPORT) MALFUNCTION INDICATOR LAMP DRIVER
3 L134 20WT/GY (RHD) HIGH BEAM INDICATOR DRIVER
4 L160 20WT/TN (RHD) RIGHT TURN INDICATOR DRIVER
5- -
6 G7 20VT/GY (LHD EXPORT) LOW OIL PRESSURE INDICATOR DRIVER
7 A701 18BR/RD (LHD) FUSED B(+) (HAZARD)
8 A701 18BR/RD (RHD) FUSED B(+) (HAZARD)
9 G7 20VT/GY (RHD) LOW OIL PRESSURE INDICATOR DRIVER
10 - -
11 L161 20WT/LG (LHD) LEFT TURN INDICATOR DRIVER
12 L134 20WT/GY (LHD) HIGH BEAM INDICATOR DRIVER
13 G3 20VT/LB (RHD) MALFUNCTION INDICATOR LAMP DRIVER
14 L161 20WT/LG (RHD) LEFT TURN INDICATOR DRIVER
MODE DOOR ACTUATOR - GRAY 2 WAY
CAV CIRCUIT FUNCTION
1 C135 20DB/GY (ATC) MODE DOOR DRIVER (B)
1 C34 20DB/LB (MTC) COMMON DOOR DRIVER (B)
2 C35 20LB/OR MODE DOOR DRIVER (A)
MULTI-FUNCTION SWITCH - BLACK 4 WAY
CAV CIRCUIT FUNCTION
1 W52 22BR/YL FRONT WIPER SWITCH MUX
2 G902 22VT/LB MULTI-FUNCTION SWITCH MUX RETURN
3 L305 20WT/LB TURN SIGNAL SWITCH MUX
4 G194 22VT/LG HIGH BEAM/FRONT WASHER SWITCH MUX
RS8W-80 CONNECTOR PIN-OUTS8W - 80 - 101

POWER WINDOW SWITCH (LHD LOWLINE) - BLACK 8 WAY
CAV CIRCUIT FUNCTION
1 F304 16WT/PK FUSED WINDOW CIRCUIT BREAKER OUTPUT
2 Z421 12BK/BR GROUND
3 Z421 12BK/BR GROUND
4- -
5 Q26 12OR/GY MASTER WINDOW SWITCH PASSENGER (DOWN)
6 F304 16WT/PK FUSED WINDOW CIRCUIT BREAKER OUTPUT
7 Z421 20BK/BR GROUND
8 Q16 12OR/TN MASTER WINDOW SWITCH PASSENGER (UP)
POWERTRAIN CONTROL MODULE C1 - BLACK 38 WAY
CAV CIRCUIT FUNCTION
1- -
2- -
3- -
4- -
5- -
6- -
7- -
8- -
9 Z130 18BK/BR GROUND
10 - -
11 F202 20PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START)
12 F1 18PK/WT (EATX) FCM OUTPUT (UNLOCK-RUN-START)
13 N7 18DB/OR (MTX) VEHICLE SPEED SIGNAL
14 - -
15 - -
16 - -
17 - -
18 Z131 18BK/DG GROUND
19 - -
20 G6 16VT/GY OIL PRESSURE SIGNAL
21 - -
22 G31 18VT/LG AAT SIGNAL
23 - -
24 - -
25 D20 20WT/LG SCI RECEIVE (PCM)
26 D123 20WT/BR (2.4L EATX) FLASH PROGRAM ENABLE
26 D123 20WT/OR (3.3L/3.8L) FLASH PROGRAM ENABLE
27 - -
28 - -
29 A109 18OR/RD FUSED B(+)
30 T751 18YL FUSED IGNITION SWITCH OUTPUT (START)
31 K141 18DB/YL O2 1/2 SIGNAL
32 K904 18DB/DG (2.4L) O2 RETURN (DOWN)
32 K904 18BR/DG (3.3L/3.8L) O2 RETURN (DOWN)
33 - -
34 - -
35 - -
36 D21 20WT/DG (2.4L) SCI TRANSMIT (PCM)
36 D21 20WT/BR (3.3L/3.8L) SCI TRANSMIT (PCM)
37 D15 18DG/YL (EATX) SCI TRANSMIT (TCM)
38 D25 18WT/VT PCI BUS
8W - 80 - 110 8W-80 CONNECTOR PIN-OUTSRS

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Engine Control Module C2
(Diesel)BK Right Side of Engine N/S
Engine Coolant Temp Sensor
(Gas)BK On Cylinder Block N/S
Engine Coolant Temp Sensor
(Diesel)BL On Cylinder Block 15
Engine Oil Pressure Sensor
(Diesel)BK Rear of Engine 16
Engine Oil Pressure Switch (Gas) LTGN On Cylinder Block 12, 18
EVAP/Purge Solenoid (Gas) BK Right Motor Mount 10, 17
Evaporator Temperature Sensor BK Right Side of HVAC N/S
Floor Console Lamp BK At Lamp N/S
Floor Console Power Outlet RD At Front Console N/S
Front Blower Module C1 (ATC) BK On HVAC N/S
Front Blower Module C2 (ATC) BK On HVAC N/S
Front Cigar Lighter RD/NAT Rear of Lighter 20, 23, 25
Front Control Module BK In Integrated Power Module N/S
Front Intrusion Sensor (United
Kingdom)BK At Sensor N/S
Front Reading Lamps/Switch BK At Switch N/S
Fuel Heater (Diesel) BK Left Rear Engine Compartment N/S
Fuel Injector No.1 BK At Fuel Injector N/S
Fuel Injector No.1 (Diesel) BK At Fuel Injector 15
Fuel Injector No.2 BK At Fuel Injector N/S
Fuel Injector No.2 (Diesel) BK At Fuel Injector 15
Fuel Injector No.3 BK At Fuel Injector N/S
Fuel Injector No.3 (Diesel) BK At Fuel Injector 15
Fuel Injector No.4 BK At Fuel Injector N/S
Fuel Injector No.4 (Diesel) BK At Fuel Injector 15
Fuel Injector No.5 BK At Fuel Injector N/S
Fuel Injector No.6 BK At Fuel Injector N/S
Fuel Pressure Sensor (Diesel) BK Top Left of Engine 15
Fuel Pressure Solenoid (Diesel) Right Front Engine 15
Fuel Pump Module LTGY Side of Fuel Tank 34
Generator BK Rear of Generator 11, 15, 17, 18
Glow Plug Relay (Diesel) BK Near Transmission 15, 16
Headlamp Switch BK Rear of Switch 20, 21, 30
Headlamp Washer Pump Motor
(Export)BK At Motor 3
High Note Horn BK Left Frame Rail 5
High Pressure Fuel Pump
(Diesel)Rear of Pump 15
Hood Ajar Switch (Export) BK Left Fender 6
Idle Air Control Motor (Gas) BK On Throttle Body 10, 11 17
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-5
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

ENGINE
TABLE OF CONTENTS
page page
ENGINE 2.4L.............................. 1ENGINE 3.3/3.8L......................... 74
ENGINE 2.4L
TABLE OF CONTENTS
page page
ENGINE 2.4L
DESCRIPTION..........................3
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION............3
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - PERFORMANCE............4
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - MECHANICAL..............6
DIAGNOSIS AND TESTING - ENGINE OIL
LEAK INSPECTION.....................8
DIAGNOSIS AND TESTING - CYLINDER
COMPRESSION PRESSURE TEST.........9
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE
TEST................................9
STANDARD PROCEDURE
STANDARD PROCEDURE - ENGINE CORE
AND OIL GALLERY PLUGS..............10
STANDARD PROCEDURE - REPAIR OF
DAMAGED OR WORN THREADS.........10
STANDARD PROCEDURE - HYDROSTATIC
LOCKED ENGINE.....................10
STANDARD PROCEDURE - FORM-IN-
PLACE GASKETS AND SEALERS.........11
STANDARD PROCEDURE - ENGINE
GASKET SURFACE PREPARATION........11
STANDARD PROCEDURE - MEASURING
BEARING CLEARANCE USING
PLASTIGAGE........................12
REMOVAL - ENGINE ASSEMBLY...........13
INSTALLATION - ENGINE ASSEMBLY........16
SPECIFICATIONS
SPECIFICATIONS - 2.4L ENGINE.........17
SPECIFICATIONS - TORQUE............20
SPECIAL TOOLS
2.4L ENGINE.........................21AIR CLEANER ELEMENT
REMOVAL.............................24
INSTALLATION.........................24
AIR CLEANER HOUSING
REMOVAL.............................24
INSTALLATION.........................24
CYLINDER HEAD
DESCRIPTION.........................24
DIAGNOSIS AND TESTINGÐCYLINDER HEAD
GASKET............................24
REMOVAL - CYLINDER HEAD.............25
CLEANING............................26
INSPECTION..........................26
INSTALLATION - CYLINDER HEAD..........26
CAMSHAFT OIL SEAL(S)
REMOVAL.............................27
INSTALLATION.........................28
CAMSHAFT(S)
DESCRIPTION.........................28
OPERATION...........................28
STANDARD PROCEDURE - MEASURING
CAMSHAFT END PLAY.................29
REMOVAL.............................29
CLEANING............................29
INSPECTION..........................30
INSTALLATION.........................30
CYLINDER HEAD COVER
REMOVAL.............................31
CLEANING............................31
INSPECTION..........................31
INSTALLATION.........................31
INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION.........................32
CLEANING............................32
VALVE SPRINGS & SEALS
REMOVAL
REMOVAL - CYLINDER HEAD ON.........32
RSENGINE9-1

REMOVAL - CYLINDER HEAD OFF........32
INSPECTION..........................32
INSTALLATION
INSTALLATION - CYLINDER HEAD ON.....33
INSTALLATION - CYLINDER HEAD OFF....33
HYDRAULIC LASH ADJUSTERS
DIAGNOSIS AND TESTING - HYDRAULIC
LASH ADJUSTER NOISE DIAGNOSIS......34
REMOVAL.............................34
INSTALLATION.........................34
ROCKER ARMS
REMOVAL.............................34
INSPECTION..........................35
INSTALLATION.........................35
ENGINE BLOCK
DESCRIPTION.........................35
STANDARD PROCEDURE - CYLINDER BORE
HONING............................35
CLEANING............................36
INSPECTION..........................36
CRANKSHAFT
STANDARD PROCEDURE - CRANKSHAFT
ENDPLAY ...........................36
REMOVAL - CRANKSHAFT................37
INSPECTION..........................37
INSTALLATION - CRANKSHAFT............38
CRANKSHAFT OIL SEAL - FRONT
REMOVAL.............................40
INSTALLATION.........................40
CRANKSHAFT OIL SEAL - REAR
REMOVAL.............................41
INSTALLATION.........................42
PISTON & CONNECTING ROD
DESCRIPTION.........................42
STANDARD PROCEDURE - PISTON TO
CYLINDER BORE FITTING..............42
REMOVAL.............................43
INSTALLATION.........................44
CONNECTING ROD BEARINGS
STANDARD PROCEDURE
CONNECTING ROD - FITTING...........45
PISTON RINGS
STANDARD PROCEDURE
PISTON RING - FITTING................45
REMOVAL.............................46
INSTALLATION.........................46
VIBRATION DAMPER
REMOVAL.............................47
INSTALLATION.........................47
STRUCTURAL COLLAR
REMOVAL.............................47
INSTALLATION.........................48
ENGINE MOUNTING
DESCRIPTION.........................48
FRONT MOUNT
REMOVAL.............................49
INSTALLATION.........................49LEFT MOUNT
REMOVAL.............................49
INSTALLATION.........................50
REAR MOUNT
REMOVAL.............................50
INSTALLATION.........................50
RIGHT MOUNT
REMOVAL.............................51
INSTALLATION.........................51
LUBRICATION
DESCRIPTION.........................52
OPERATION...........................52
DIAGNOSIS AND TESTING - CHECKING
ENGINE OIL PRESSURE................52
OIL
STANDARD PROCEDURE
ENGINE OIL LEVEL CHECK.............53
STANDARD PROCEDURE - ENGINE OIL
AND FILTER CHANGE..................53
OIL FILTER
DESCRIPTION.........................53
REMOVAL.............................53
INSTALLATION.........................53
OIL PAN
REMOVAL.............................54
INSTALLATION.........................54
OIL PRESSURE SWITCH
REMOVAL.............................54
INSTALLATION.........................54
OIL PUMP
REMOVAL.............................55
DISASSEMBLY.........................55
CLEANING............................56
INSPECTION..........................56
ASSEMBLY............................56
INSTALLATION.........................57
INTAKE MANIFOLD
DESCRIPTION.........................58
DIAGNOSIS AND TESTING - INTAKE
MANIFOLD LEAKS.....................58
INTAKE MANIFOLD - UPPER
REMOVAL.............................58
INSPECTION..........................59
INSTALLATION.........................59
INTAKE MANIFOLD - LOWER
REMOVAL.............................60
INSPECTION..........................60
INSTALLATION.........................60
EXHAUST MANIFOLD
REMOVAL.............................61
CLEANING............................61
INSPECTION..........................61
INSTALLATION.........................61
TIMING BELT COVER(S)
REMOVAL.............................61
INSTALLATION.........................62
9 - 2 ENGINE 2.4LRS