2005 CHRYSLER VOYAGER oil temperature

(1) Before installing the nuts the threads should
be oiled with engine oil.
(2) Install nuts finger tight on each bolt then alter-
nately torque each nut to assemble the cap properly.
(3) Tighten the nuts to 54 N´m PLUS 1/4 turn (40
ft. lbs. PLUS 1/4 turn).
(4) Using a feeler gauge, check connecting rod side
clearance (Fig. 53). Refer to Engine Specifications
(Refer to 9 - ENGINE - SPECIFICATIONS).
STANDARD PROCEDURE - FITTING PISTONS
The piston and cylinder wall must be clean and
dry. Piston diameter should be measured 90 degrees
to piston pin at size location shown in (Fig. 54). Cyl-
inder bores should be measured halfway down the
cylinder bore and transverse to the engine crankshaft
center line shown in (Fig. 55). Refer to Engine Spec-
ifications (Refer to 9 - ENGINE - SPECIFICA-
TIONS).Pistons and cylinder bores should be
measured at normal room temperature, 21ÉC
(70ÉF).
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove the cylinder heads. (Refer to 9 -
ENGINE/CYLINDER HEAD - REMOVAL)
(3) Remove the oil pan. (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL)
(4) Remove the top ridge of cylinder bores with a
reliable ridge reamer, if necessary, before removing
pistons from cylinder block.Be sure to keep tops
of pistons covered during this operation. Pis-
tons and connecting rods must be removed
from top of cylinder block. When removing pis-
ton and connecting rod assemblies from the
engine, rotate crankshaft so that each connect-
ing rod is centered in cylinder bore.
(5) Inspect connecting rods and connecting rod
caps for cylinder identification. Identify them, if nec-
essary (Fig. 56).Fig. 53 Checking Connecting Rod Side Clearance
Fig. 54 Piston Measurement Locations - Typical
1 - 39.8 mm (1.56 in. ) 3.3L ENGINE
2 - 33.0 mm (1.29 in.) 3.8L ENGINE
Fig. 55 Checking Cylinder Bore Size
Fig. 56 Identify Connecting Rod to Cylinder
1 - CYLINDER NUMBER
9 - 120 ENGINE 3.3/3.8LRS
PISTON & CONNECTING ROD (Continued)

(5) Connect the MAP sensor electrical connector.
(6) Connect the brake booster and LDP vacuum
hose to intake manifold (Fig. 117).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
material that causes stripped threads. If threads
become stripped, an oversize repair screw is avail-
able. For more information and procedure (Refer to
9 - ENGINE/MANIFOLDS/INTAKE MANIFOLD - STAN-
DARD PROCEDURE - MANIFOLD STRIPPED
THREAD REPAIR).
(7) Install the power steering reservoir (Fig. 116).
Tighten screws to manifold to 5.6 N´m (50 in. lbs.).
(8) Connect throttle and speed control cables to
throttle body (Refer to 14 - FUEL SYSTEM/FUEL
INJECTION/THROTTLE CONTROL CABLE -
INSTALLATION)
(9) Attach make up air hose clip into the hole in
the throttle cable bracket.
(10) Connect the wiring connectors to the throttle
position sensor (TPS) and Automatic Idle Speed (AIS)
motor.
(11) Install air cleaner and air inlet hose assembly.
(12) Connect the inlet air temperature (IAT) sen-
sor electrical connector.
(13) Connect battery negative cable.
INTAKE MANIFOLD - LOWER
REMOVAL - LOWER INTAKE MANIFOLD
(1) Perform fuel system pressure release procedure
(before attempting any repairs).(Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY - STANDARD
PROCEDURE)
(2) Drain the cooling system. (Refer to 7 - COOL-
ING - STANDARD PROCEDURE)
(3) Remove the upper intake manifold. (Refer to 9
- ENGINE/MANIFOLDS/INTAKE MANIFOLD -
REMOVAL)
(4) Remove the fuel line. (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/FUEL LINES - STANDARD
PROCEDURE) (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY/QUICK CONNECT FITTING - STAN-
DARD PROCEDURE)
(5) Remove ignition coil and bracket (Fig. 120).
(6) Disconnect heater supply hose and engine cool-
ant temperature sensor (Fig. 121).
(7) Disconnect the fuel injector wire harness.
(8) Remove the fuel injectors and rail assembly
(Fig. 120).
(9) Remove radiator upper hose.
(10) Remove the intake manifold bolts.
(11) Remove lower intake manifold (Fig. 122).
Fig. 118 INTAKE MANIFOLD - UPPER
1 - BOLT
2 - MAP SENSOR
3 - SCREW
4 - MANIFOLD - UPPER
5 - WIRE HARNESS
6 - GASKET (3 PER CYL. BANK)
Fig. 119 UPPER MANIFOLD TIGHTENING
SEQUENCE
9 - 150 ENGINE 3.3/3.8LRS
INTAKE MANIFOLD - UPPER (Continued)

WARNING: INTAKE MANIFOLD GASKET IS MADE
OF VERY THIN METAL AND MAY CAUSE PER-
SONAL INJURY, HANDLE WITH CARE.
(12) Remove intake manifold seal retainers screws
(Fig. 122). Remove intake manifold gasket.
(13) Inspect and clean manifold. (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSPECTION) (Refer to 9 - ENGINE/MANIFOLDS/
INTAKE MANIFOLD - CLEANING)
CLEANING
(1) Discard gasket(s).
(2) Clean all sealing surfaces.
INSPECTION
Check for:
²Damage and cracks of each section.
²Clogged water passages in end cross-overs (if
equipped).²Check for cylinder head mounting surface distor-
tion using a straightedge and thickness gauge. (Refer
to 9 - ENGINE/CYLINDER HEAD - INSPECTION)
INSTALLATION - LOWER INTAKE MANIFOLD
(1) Place a bead (approximately 1/4 in. diameter)
of MopartEngine RTV GEN II onto each of thefour
manifold to cylinder head gasket corners (Fig. 123).
(2) Carefully install the new intake manifold gas-
ket (Fig. 122). Tighten end seal retainer screws to 12
N´m (105 in. lbs.).
(3) Install lower intake manifold (Fig. 122). Install
the bolts and torque to 1 N´m (10 in. lbs.). Then
torque bolts to 22 N´m (200 in. lbs.) in sequence
shown in (Fig. 124). Then torque again to 22 N´m
(200 in. lbs.). After intake manifold is in place,
inspect to make sure seals are in place.
(4) Install the fuel injectors and rail assembly.
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/
FUEL RAIL - INSTALLATION)
(5) Connect fuel injector electrical harness.
(6) Connect the engine coolant temperature sensor
(Fig. 121).
(7) Connect the heater supply (Fig. 121) and radi-
ator upper hoses to manifold.
(8) Connect the fuel line. (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/QUICK CONNECT FIT-
TING - STANDARD PROCEDURE)
Fig. 120 FUEL RAIL AND IGNITION COIL &
BRACKET
1 - FUEL RAIL
2 - BOLT - FUEL RAIL
3 - NUT - IGNITION COIL
4 - BOLT - IGNITION COIL
5 - IGNITION COIL
6 - BRACKET - IGNITION COIL
7 - STUD - IGNITION COIL
8 - SEPARATOR - SPARK PLUG CABLE
9 - BRACKET - SPARK PLUG CABLE SEPARATOR
10 - BOLT - SEPARATOR BRACKET
11 - BRACKET - SPARK PLUG CABLE SEPARATOR
Fig. 121 ECT SENSOR & HEATER SUPPLY
1 - ENGINE COOLANT TEMPERATURE SENSOR
2 - CONNECTOR - ENGINE COOLANT SENSOR
3 - FITTING - HEATER SUPPLY
RSENGINE 3.3/3.8L9 - 151
INTAKE MANIFOLD - LOWER (Continued)

HEAT SHIELDS
DESCRIPTION
The exhaust system heat shields (Fig. 7), (Fig. 8),
or (Fig. 9) are attached to the under body of the vehi-
cle. On vehicles equipped with All Wheel Dive
(AWD), an additional heat shield is mounted to the
catalytic converter.
OPERATION
Heat shields are needed to protect both the vehicle
and the environment from the high temperatures
developed near the catalytic converter.Avoid application of rust prevention com-
pounds or undercoating materials to exhaust
system floor pan heat shields on cars so
equipped. Light over spray near the edges is
permitted. Application of coating will greatly
reduce the efficiency of the heat shields result-
ing in excessive floor pan temperatures and
objectionable fumes.
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove fasteners attaching applicable heat
shield (Fig. 7), (Fig. 8), or (Fig. 9).
(3) Remove heat shield(s).
INSTALLATION
(1) Position heat shield(s) to underbody.
(2) Install heat shield fasteners and tighten to 2.6
N´m (23 in. lbs.) (Fig. 7), (Fig. 8), or (Fig. 9).
(3) Lower vehicle.
(4) Start the engine and inspect for exhaust leaks.
Repair exhaust leaks as necessary.
(5) Check the exhaust system for contact with the
body panels. Make the necessary adjustments, if
needed.
MUFFLER
REMOVAL
(1) Raise vehicle on a body contact type hoist.
NOTE: To provide removal clearance between muf-
fler/resonator pipe and rear axle parts, the rear sus-
pension must be relieved of all body weight.
(2) Apply a penetrating oil to clamp nuts of com-
ponent requiring removal.
Fig. 7 CATALYTIC CONVERTER HEAT SHIELD
1 - HEAT SHIELD - CATALYTIC CONVERTER
2 - SCREW (QTY. 4)
Fig. 8 MUFFLER HEAT SHIELD
1 - HEAT SHIELD - MUFFLER
2 - SCREW (QTY. 6)
Fig. 9 RESONATOR PIPE HEAT SHIELD
1 - SCREW (QTY. 3)
2 - HEAT SHIELD - RESONATOR PIPE
3 - MUFFLER
RSEXHAUST SYSTEM11-7

1 second. Therefore, battery voltage is not supplied to
the fuel pump, ignition coil, fuel injectors and heated
oxygen sensors.
ENGINE START-UP MODE
This is an OPEN LOOP mode. If the vehicle is in
park or neutral (automatic transaxles) or the clutch
pedal is depressed (manual transaxles) the ignition
switch energizes the starter relay when the engine is
not running. The following actions occur when the
starter motor is engaged.
²If the PCM receives the camshaft position sensor
and crankshaft position sensor signals, it energizes
the Auto Shutdown (ASD) relay and fuel pump relay.
If the PCM does not receive both signals within
approximately one second, it will not energize the
ASD relay and fuel pump relay. The ASD and fuel
pump relays supply battery voltage to the fuel pump,
fuel injectors, ignition coil, (EGR solenoid and PCV
heater if equipped) and heated oxygen sensors.
²The PCM energizes the injectors (on the 69É
degree falling edge) for a calculated pulse width until
it determines crankshaft position from the camshaft
position sensor and crankshaft position sensor sig-
nals. The PCM determines crankshaft position within
1 engine revolution.
²After determining crankshaft position, the PCM
begins energizing the injectors in sequence. It adjusts
injector pulse width and controls injector synchroni-
zation by turning the individual ground paths to the
injectors On and Off.
²When the engine idles within  64 RPM of its
target RPM, the PCM compares current MAP sensor
value with the atmospheric pressure value received
during the Ignition Switch On (zero RPM) mode.
Once the ASD and fuel pump relays have been
energized, the PCM determines injector pulse width
based on the following:
²MAP
²Engine RPM
²Battery voltage
²Engine coolant temperature
²Inlet/Intake air temperature (IAT)
²Throttle position
²The number of engine revolutions since cranking
was initiated
During Start-up the PCM maintains ignition tim-
ing at 9É BTDC.
ENGINE WARM-UP MODE
This is an OPEN LOOP mode. The following inputs
are received by the PCM:
²Manifold Absolute Pressure (MAP)
²Crankshaft position (engine speed)
²Engine coolant temperature
²Inlet/Intake air temperature (IAT)²Camshaft position
²Knock sensor
²Throttle position
²A/C switch status
²Battery voltage
²Vehicle speed
²Speed control
²O2 sensors
The PCM adjusts injector pulse width and controls
injector synchronization by turning the individual
ground paths to the injectors On and Off.
The PCM adjusts ignition timing and engine idle
speed. Engine idle speed is adjusted through the idle
air control motor.
CRUISE OR IDLE MODE
When the engine is at operating temperature this
is a CLOSED LOOP mode. During cruising or idle
the following inputs are received by the PCM:
²Manifold absolute pressure
²Crankshaft position (engine speed)
²Inlet/Intake air temperature
²Engine coolant temperature
²Camshaft position
²Knock sensor
²Throttle position
²Exhaust gas oxygen content (O2 sensors)
²A/C switch status
²Battery voltage
²Vehicle speed
The PCM adjusts injector pulse width and controls
injector synchronization by turning the individual
ground paths to the injectors On and Off.
The PCM adjusts engine idle speed and ignition
timing. The PCM adjusts the air/fuel ratio according
to the oxygen content in the exhaust gas (measured
by the upstream and downstream heated oxygen sen-
sor).
The PCM monitors for engine misfire. During
active misfire and depending on the severity, the
PCM either continuously illuminates or flashes the
malfunction indicator lamp (Check Engine light on
instrument panel). Also, the PCM stores an engine
misfire DTC in memory, if 2nd trip with fault.
The PCM performs several diagnostic routines.
They include:
²Oxygen sensor monitor
²Downstream heated oxygen sensor diagnostics
during open loop operation (except for shorted)
²Fuel system monitor
²EGR monitor (if equipped)
²Purge system monitor
²Catalyst efficiency monitor
²All inputs monitored for proper voltage range,
rationality.
RSFUEL INJECTION14-23
FUEL INJECTION (Continued)

IDLE AIR CONTROL MOTOR
DESCRIPTION
The idle air control valve is mounted on the throt-
tle body. The PCM operates the idle air control valve
(Fig. 15) or (Fig. 16).
OPERATION
The PCM adjusts engine idle speed through the
idle air control valve to compensate for engine load,
coolant temperature or barometric pressure changes.The throttle body has an air bypass passage that
provides air for the engine during closed throttle idle.
The idle air control valve regulates air flow through
the bypass passage.
The PCM controls engine idle speed by adjusting
the position of the idle air control valve. The adjust-
ments are based on inputs the PCM receives. The
inputs are from the throttle position sensor, crank-
shaft position sensor, coolant temperature sensor,
MAP sensor, vehicle speed sensor and various switch
operations (brake, park/neutral, air conditioning).
When engine rpm is above idle speed, the IAC is
used for the following functions:
²Off-idle dashpot
²Deceleration air flow control
²A/C compressor load control (also opens the pas-
sage slightly before the compressor is engaged so
that the engine rpm does not dip down when the
compressor engages)
Target Idle
Target idle is determined by the following inputs:
²Gear position
²ECT Sensor
²Battery voltage
²Ambient/Battery Temperature Sensor
²VSS
²TPS
²MAP Sensor
REMOVAL
When servicing throttle body components, always
reassemble components with new O-rings and seals
where applicable. If assembly of component is diffi-
cult, a light coat of engine oil may be applied to the
O-RINGS ONLY to aid assembly. Use care when
removing hoses to prevent damage to hose or hose
nipple.
(1) Disconnect negative cable from battery.
(2) Remove electrical connector from idle air con-
trol valve (Fig. 17).
(3) Remove idle air control valve mounting screw.
(4) Remove valve from throttle body. Ensure the
O-rings is removed with the valve.
INSTALLATION
When servicing throttle body components, always
reassemble components with new O-rings and seals
where applicable. If assembly of component is diffi-
cult,a light coat of engine oil may be applied to
the O-RINGS ONLY (Fig. 18)to aid assembly. Use
care when removing hoses to prevent damage to hose
or hose nipple.
(1) Carefully place idle air control motor into
throttle body.
Fig. 15 TPS/IAC 2.4L
1 - Idle Air Control Valve
2 - Throttle Position Sensor
Fig. 16 TPS/IAC 3.3/3.8L
1 - Idle Air Control Valve
2 - Throttle Position Sensor
RSFUEL INJECTION14-33

FLUID
STANDARD PROCEDURE
FLUID LEVEL AND CONDITION CHECK
NOTE: Only transmission fluid of the type labeled
Mopar ATF+4 (Automatic Transmission Fluid)
should be used in this transaxle.
FLUID LEVEL CHECK
The transmission sump has a fluid level indicator
(dipstick) to check oil similar to most automatic
transmissions. It is located on the left side of the
engine. Be sure to wipe all dirt from dipstick handle
before removing.
The torque converter fills in both the P Park and N
Neutral positions. Place the selector lever in P Park
to be sure that the fluid level check is accurate.The
engine should be running at idle speed for at
least one minute, with the vehicle on level
ground.At normal operating temperature 82É C
(180É F), the fluid level is correct if it is in the HOT
region on the oil level indicator (Fig. 187). The fluid
level should be within the COLD region of the dip-
stick at 27É C (80É F) fluid temperature.
FLUID LEVEL CHECK USING DRB
NOTE: Engine and Transaxle should be at normal
operating temperature before performing this proce-
dure.
(1) Start engine and apply parking brake.
(2) Hook up DRB scan tool and select transmis-
sion.(3) Select sensors.
(4) Read the transmission temperature value.
(5) Compare the fluid temperature value with the
fluid temperature chart (Fig. 188).
(6) Adjust transmission fluid level shown on the
indicator according to the chart.
(7) Check transmission for leaks.
Low fluid level can cause a variety of conditions
because it allows the pump to take in air along with
the fluid. As in any hydraulic system, air bubbles
make the fluid spongy, therefore, pressures will be
low and build up slowly.
Improper filling can also raise the fluid level too
high. When the transaxle has too much fluid, the
gears churn up foam and cause the same conditions
which occur with a low fluid level.
In either case, air bubbles can cause overheating
and/or fluid oxidation, and varnishing. This can
interfere with normal valve, clutch, and accumulator
operation. Foaming can also result in fluid escaping
from the transaxle vent where it may be mistaken
for a leak.
FLUID CONDITION
Along with fluid level, it is important to check the
condition of the fluid. When the fluid smells burned,
and is contaminated with metal or friction material
particles, a complete transaxle recondition is proba-
bly required. Be sure to examine the fluid on the dip-
stick closely. If there is any doubt about its condition,
drain out a sample for a double check.
MopartATF+4 (Automatic Transmission Fluid)
when new is red in color. The ATF is dyed red so it
can be identified from other fluids used in the vehicle
such as engine oil or antifreeze. The red color is not
permanent and is not an indicator of fluid condition.
As the vehicle is driven, the ATF will begin to look
darker in color and may eventually become brown.
This is normal.ATF+4 also has a unique odor that
may change with age. Consequently,odor and color
cannot be used to indicate the fluid condition
or the need for a fluid change.
After the fluid has been checked, seat the dipstick
fully to seal out water and dirt.
STANDARD PROCEDURE - FLUID AND FILTER
SERVICE
NOTE: Refer to the maintenance schedules in
LUBRICATION and MAINTENANCE, or the vehicle
owner's manual, for the recommended maintenance
(fluid/filter change) intervals for this transaxle.
Fig. 187 Fluid Level Indicator
1 - FLUID LEVEL INDICATOR
21 - 82 40TE AUTOMATIC TRANSAXLERS

NOTE: Only fluids of the type labeled MoparTATF+4
(Automatic Transmission Fluid) should be used. A
filter change should be made at the time of the
transmission oil change. The magnet (on the inside
of the oil pan) should also be cleaned with a clean,
dry cloth.
NOTE: If the transaxle is disassembled for any rea-
son, the fluid and filter should be changed.
FLUID/FILTER SERVICE (RECOMMENDED)
(1) Raise vehicle on a hoist. Refer to LUBRICA-
TION and MAINTENANCE for proper procedures.
Place a drain container with a large opening, under
transaxle oil pan.
(2) Loosen pan bolts and tap the pan at one corner
to break it loose allowing fluid to drain, then remove
the oil pan.
(3) Install a new filter and o-ring on bottom of the
valve body (Fig. 189).
(4) Clean the oil pan and magnet. Reinstall pan
using new Mopar Silicone Adhesive sealant. Tighten
oil pan bolts to 19 N´m (165 in. lbs.).(5) Pour four quarts of MopartATF+4 (Automatic
Transmission Fluid) through the dipstick opening.
Fig. 188 Transmission Fluid Temperature Chart
1 - MAX. LEVEL2 - MIN. LEVEL
Fig. 189 Filter and O-Ring
1 - OIL FILTER
2 - O-RING
RS40TE AUTOMATIC TRANSAXLE21-83
FLUID (Continued)