2005 CHRYSLER VOYAGER oil

OIL COOLER & LINES
DESCRIPTION
An engine oil cooler is used on 3.3/3.8L engines
(Heavy Duty Cooling Only) (Fig. 99). The cooler is a
coolant-to-oil type and mounted between the oil filter
and engine block.
OPERATION
Engine oil travels from the oil filter and into the
oil cooler. Engine oil then exits the cooler into the
main gallery. Engine coolant flows into the cooler
from the heater return tube and exits into the water
pump inlet.
REMOVAL
(1) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE - COOLING SYSTEM
DRAINING).
(2) Disconnect oil cooler inlet and outlet hoses
(Fig. 98).
(3) Remove oil filter.
(4) Remove oil cooler attachment fitting (Fig. 99).
(5) Remove oil cooler.
INSTALLATION
(1) Lubricate seal and position oil cooler to connec-
tor fitting on oil filter adapter (Fig. 99).
NOTE: Position the flat side of oil cooler parallel to
oil pan rail.
(2) Install oil cooler attachment fitting and tighten
to 27 N´m (20 ft. lbs.) (Fig. 99).(3) Install oil filter.
(4) Connect oil cooler inlet and outlet hoses (Fig.
98).
(5) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE - COOLING SYSTEM
FILLING).
OIL FILTER
REMOVAL
CAUTION: When servicing the oil filter avoid
deforming the filter can by installing the remove/in-
stall tool band strap against the can-to-base lock
seam. The lock seam joining the can to the base is
reinforced by the base plate.
(1) Using suitable oil filter wrench, turn filter
counterclockwise to remove from oil filter adapter
(Fig. 100). Properly discard used oil filter.
INSTALLATION
(1) Wipe oil filter adapter base clean and inspect
gasket contact surface.
(2) Lubricate gasket of new filter with clean
engine oil.
(3) Install new filter until gasket contacts base
(Fig. 100). Tighten filter 1 turn or 20 N´m (15 ft.
lbs.). Use filter wrench if necessary.
(4) Start engine and check for leaks.
Fig. 98 Engine Oil Cooler Hoses
1 - OIL COOLER INLET TUBE
2 - INLET HOSE
3 - OIL COOLER OUTLET TUBE
4 - OUTLET HOSE
5 - WATER PUMP INLET TUBE
Fig. 99 Engine Oil Cooler - 3.3/3.8L (Heavy Duty
Cooling)
1 - OIL FILTER ADAPTER
2 - CONNECTOR
3 - ENGINE OIL COOLER
4 - OIL COOLER ATTACHMENT FITTING
5 - OIL FILTER
RSENGINE 3.3/3.8L9 - 141

OIL FILTER ADAPTER
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove the oil filter.
(3) Disconnect oil pressure switch electrical con-
nector.
(4) Remove oil filter adapter attaching bolts (Fig.
100).
(5) Remove oil filter adapter and seal (Fig. 100).
INSTALLATION
(1) Clean oil filter adapter and install new seal.
(2) Position adapter on engine block and install
bolts (Fig. 100).
(3) Tighten adapter bolts to 28 N´m (250 in. lbs.).
(4) Connect oil pressure switch electrical connector
(Fig. 100).
(5) Install the oil filter.
(6) Lower vehicle on hoist.
(7) Start engine and allow to run approximately 2
minutes.
(8) Turn off engine and check oil level. Adjust oil
level as necessary.
OIL PAN
REMOVAL
(1) Disconnect negative cable from battery and
remove engine oil dipstick.
(2) Raise vehicle on hoist and drain engine oil.
(3) Remove drive belt splash shield.
(4) Remove strut to transaxle attaching bolt (Fig.
101). Loosen strut to engine block attaching bolts.
(5) Remove transaxle case cover (Fig. 101).
(6) Remove oil pan fasteners (Fig. 102).
(7) Remove the oil pan and gasket (Fig. 102).
CLEANING
(1) Clean oil pan with solvent and wipe dry with a
clean cloth.
(2) Clean all gasket material from mounting sur-
faces of pan and block.
(3) Clean oil screen and pick-up tube in clean sol-
vent.
Fig. 100 OIL FILTER ADAPTER
1 - SEAL
2 - OIL FILTER ADAPTER
3 - OIL FILTER
4 - BOLT
5 - OIL PRESSURE SWITCH
6 - BOLT
Fig. 101 Powertrain Struts and Transaxle Case
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
9 - 142 ENGINE 3.3/3.8LRS

INSPECTION
(1) Inspect oil drain plug and plug hole for
stripped or damaged threads and repair as necessary.
Install a new drain plug gasket. Tighten to 27 N´m
(20 ft. lbs.).
(2) Inspect oil pan mounting flange for bends or
distortion. Straighten flange if necessary.
(3) Inspect condition of oil screen and pick-up tube.
INSTALLATION
(1) Clean sealing surfaces and apply a 1/8 inch
bead of MopartEngine RTV GEN II at the parting
line of the chain case cover and the rear seal retainer
(Fig. 103).
(2) Position a new pan gasket on oil pan (Fig. 102).
(3) Install oil pan and tighten fasteners to 12 N´m
(105 in. lbs.) (Fig. 102).
(4) Install cover to transaxle case (Fig. 101).
(5) Install the strut bolt to transaxle housing (Fig.
101). Tighten all bending brace bolts.
(6) Install the drive belt splash shield.
(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 - ENGINE/LUBRI-
CATION/OIL PAN - REMOVAL).
(2) Drill a 3.175 mm (1/8 in.) hole in the center of
the retainer cap (Fig. 104). Insert a self-threading
sheet metal screw into the cap.
(3) Using suitable pliers, remove cap and discard.
(4) Remove spring and relief valve (Fig. 104).
Fig. 102 OIL PAN
1 - GASKET
2 - BOLT
3 - OIL PAN
4 - NUT
Fig. 103 Oil Pan Sealing
1 - SEALER LOCATIONS
Fig. 104 Oil Pressure Relief Valve
1 - RELIEF VALVE
2 - SPRING
3 - RETAINER CAP
RSENGINE 3.3/3.8L9 - 143
OIL PAN (Continued)

INSTALLATION
(1) Clean relief valve, spring and bore.
NOTE: Lubricate relief valve with clean engine oil
before installing.
(2) Install relief valve and spring into housing.
(3) Install new retainer cap until flush with seal-
ing surface.
(4) Install oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION).
(5) Fill crankcase with proper oil to correct level.
OIL PRESSURE SWITCH
DESCRIPTION
The engine oil pressure switch is located on the
lower left front side of the engine. It screws into the
oil filter adapter. The normally closed switch provides
an input through a single wire to the low pressure
indicator light on the instrument cluster.
OPERATION
The oil pressure switch provides a ground for the
instrument cluster low oil pressure indicator light.
The switch receives oil pressure input from the
engine main oil gallery. When engine oil pressure is
greater than 27.5 Kpa (4 psi), the switch contacts
open, providing a open circuit to the low pressure
indicator light. For wiring circuits and diagnostic
information, (Refer to Appropriate Wiring/Diagnostic
Information).
REMOVAL
(1) Raise vehicle on hoist.
(2) Disconnect electrical connector from switch.
(3) Remove oil pressure switch (Fig. 105).
INSTALLATION
(1) Install oil pressure switch. Torque oil pressure
switch to 23 N´m (200 in. lbs.) (Fig. 105).
(2) Connect electrical connector to switch.
(3) Lower the vehicle.
(4) Start engine and check for leaks.
(5) Check engine oil level. Adjust as necessary.
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. 106).
(1) Remove oil pan. (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - REMOVAL)
(2) Remove the timing chain cover. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL)
(3) Disassemble oil pump from timing chain cover.
(Refer to 9 - ENGINE/LUBRICATION/OIL PUMP -
DISASSEMBLY)
(4) Clean and Inspect oil pump components. (Refer
to 9 - ENGINE/LUBRICATION/OIL PUMP - CLEAN-
ING) (Refer to 9 - ENGINE/LUBRICATION/OIL
PUMP - INSPECTION)
Fig. 105 OIL FILTER ADAPTER
1 - SEAL
2 - OIL FILTER ADAPTER
3 - OIL FILTER
4 - BOLT
5 - OIL PRESSURE SWITCH
6 - BOLT
9 - 144 ENGINE 3.3/3.8LRS
OIL PRESSURE RELIEF VALVE (Continued)

DISASSEMBLY
(1) Remove oil pump cover screws, and lift off
cover (Fig. 106).
(2) Remove oil pump rotors (Fig. 106).
(3) Clean and inspect oil pump components. (Refer
to 9 - ENGINE/LUBRICATION/OIL PUMP - CLEAN-
ING) (Refer to 9 - ENGINE/LUBRICATION/OIL
PUMP - INSPECTION)
CLEANING
(1) Clean all parts thoroughly in a suitable sol-
vent.
INSPECTION
(1) Inspect mating surface of the chain case cover.
Surface should be smooth. Replace cover if scratched
or grooved.
(2) Lay a straightedge across the pump cover sur-
face (Fig. 107). If a 0.025 mm (0.001 in.) feeler gauge
can be inserted between cover and straight edge,
cover should be replaced.
(3) Measure thickness and diameter of outer rotor.
If outer rotor thickness measures 7.64 mm (0.301 in.)
or less (Fig. 108), or if the diameter is 79.95 mm
(3.148 in.) or less, replace outer rotor.(4) If inner rotor thickness measures 7.64 mm
(0.301 in.) or less, replace inner rotor (Fig. 109).
(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. 110). 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. 111) 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. 112).ONLYif rotors are in specs.
Fig. 106 OIL PUMP
1 - TIMING CHAIN COVER
2 - SCREWS
3 - INNER ROTOR
4 - OUTER ROTOR
5 - COVER
Fig. 107 Checking Oil Pump Cover Flatness
1 - FEELER GAUGE
2 - OIL PUMP COVER
3 - STRAIGHT EDGE
Fig. 108 Measuring Outer Rotor Thickness
RSENGINE 3.3/3.8L9 - 145
OIL PUMP (Continued)

(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 operation
in bore (Fig. 113). 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.
(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)
INSTALLATION
(1) Install oil pump. (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PUMP - ASSEMBLY)
Fig. 109 Measuring Inner Rotor Thickness
Fig. 110 Measuring Outer Rotor Clearance in
Housing
1 - FEELER GAUGE
2 - OUTER ROTOR
Fig. 111 Measuring Clearance Between Rotors
1 - FEELER GAUGE
2 - INNER ROTOR
3 - OUTER ROTOR
Fig. 112 Measuring Clearance Over Rotors
1 - FEELER GAUGE
2 - STRAIGHT EDGE
9 - 146 ENGINE 3.3/3.8LRS
OIL PUMP (Continued)

(2) Install timing chain cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION) and oil pan (Refer to 9
- ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
INTAKE MANIFOLD
DESCRIPTION
The intake system is made up of an upper and
lower intake manifold. The upper intake manifold is
made of a composite for both the 3.3L engine and for
the 3.8L engine (Fig. 118). The lower intake manifold
is common between the two engines (Fig. 122). It also
provides coolant crossover between cylinder heads
and houses the coolant thermostat (Fig. 122).
The intake manifold utilizes a compact design with
very low restriction and outstanding flow balance.
This design allows the engine to perform with a wide
torque curve while increasing higher rpm horse-
power.
If, for some reason, the molded-in vacuum ports
break, the composite manifold can be salvaged. The
vacuum ports are designed to break at the shoulder,
if overloaded. Additional material in the shoulder
area provides sufficient stock to repair. For more
information and procedure, (Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD - STANDARD
PROCEDURE). Also, if the special screws that attach
the MAP sensor, power steering reservoir, throttle
cable bracket, and the EGR tube become stripped, an
oversized screw is available to repair the stripped-out
condition. For more information and procedure,
(Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANI-
FOLD - STANDARD PROCEDURE)
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 EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
(1) Start the engine.
(2) Spray a small stream of water (Spray Bottle) at
the suspected leak area.
(3) If engine RPM'S change, the area of the sus-
pected leak has been found.
(4) Repair as required.
INTAKE MANIFOLD - UPPER
STANDARD PROCEDURE
STANDARD PROCEDURE - MANIFOLD
STRIPPED THREAD REPAIR
The composite upper intake manifold thread
bosses, if stripped out, can be repaired by utilizing a
repair screw available through Mopartparts. Repair
screws are available for the following manifold
attached components:
²MAP sensor
²Power steering reservoir
²EGR tube
²Throttle cable bracket
The repair screws require a unique tightening
torque specification from the original screw. Refer to
the following chart for specification.
DESCRIPTION TORQUE*
STRIP-OUT REPAIR SCREWS ONLY
MAP Sensor Repair
Screw4 N´m (35 in. lbs.)
Power Steering Reservoir
Repair Screw9 N´m (80 in. lbs.)
EGR Tube Attaching
Repair Screw9 N´m (80 in. lbs.)
Throttle Cable Bracket
Repair Screw9 N´m (80 in. lbs.)
*Install Slowly Using Hand Tools Only
Fig. 113 Oil Pressure Relief Valve
1 - RELIEF VALVE
2 - SPRING
3 - RETAINER CAP
RSENGINE 3.3/3.8L9 - 147
OIL PUMP (Continued)

INSPECTION
Check manifold for:
²Damage and cracks.
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 specifications:
CAUTION: The special screws used for the compos-
ite manifold attached components must be installed
slowly using hand tools only. This requirement is to
prevent the melting of material that causes stripped
threads. If threads become stripped, an oversize
repair screw is available. For more information and
procedure (Refer to 9 - ENGINE/MANIFOLDS/IN-
TAKE MANIFOLD - STANDARD PROCEDURE - MAN-
IFOLD STRIPPED THREAD REPAIR).
²MAP sensor - 1.7 N´m (15 in. lbs.)
²Throttle cable bracket - 5.6 N´m (50 in. lbs.)
(2) Remove covering on lower intake manifold and
clean surfaces.
(3) Inspect manifold gasket condition. Gaskets can
be re-used, if not damaged. To replace, remove gasket
from upper manifold (Fig. 118). Position new gasket
in seal channel and press lightly in-place. Repeat
procedure for each gasket position.
(4) Position upper manifold on lower manifold (Fig.
118). Apply MopartLock & Seal Adhesive (Medium
Strength Threadlocker) to each upper intake mani-
fold bolt. Install and tighten bolts to 12 N´m (105 in.
lbs.) following torque sequence in (Fig. 119).
Fig. 115 PCV & HOSE
1 - HOSE - PCV
2 - P C V VA LV E
Fig. 116 POWER STEERING FLUID RESERVOIR
1 - POWER STEERING RESERVOIR
2 - BOLT - RESERVOIR TO MANIFOLD
3 - NUT - RESERVOIR TO COIL BRACKET
Fig. 117 BRAKE BOOSTER & LDP VACUUM HOSES
1 - LDP & SPEED CONTROL VACUUM HOSE
2 - BRAKE BOOSTER VACUUM HOSE
3 - MAP SENSOR
RSENGINE 3.3/3.8L9 - 149
INTAKE MANIFOLD - UPPER (Continued)