Chrysler Voyager 2020-present Emissions & Sensor Bolt Torque Specifications
This page provides the torque specifications for all emissions sensor bolts on the 2020-Present Chrysler Voyager, including oxygen sensors, NOx sensors, and related components.
Important Information
Safety guidelines and reference information for proper torque application
Safety First
- Always verify torque specifications with your vehicle's factory service manual
- Use properly calibrated torque wrenches
- Replace all torque-to-yield (TTY) bolts - they are single-use only
- When in doubt, consult a professional mechanic
Quick Reference Guide
Quick Reference Guide
Common Torque Patterns
Star Pattern
Used for wheels and other circular bolt patterns
Cross Pattern
Used for gaskets and cover plates
Sequential Pattern
Used for head bolts and other critical components
Common Mistakes to Avoid
Common Mistakes to Avoid
Over-tightening
Exceeding the specified torque value can stretch or break fasteners, damage threads, or crack components.
Always use a calibrated torque wrench and follow specifications exactly.
Incorrect Torque Sequence
Tightening bolts in the wrong order can cause uneven pressure distribution and potential leaks or damage.
Follow the manufacturer's specified torque sequence pattern.
Dirty Threads
Dirt, rust, or old thread locker can affect torque readings and proper fastener tension.
Clean and inspect all threads before assembly. Use new thread locker if specified.
Reusing TTY Bolts
Torque-to-yield bolts are designed to stretch and must not be reused.
Always replace TTY bolts with new ones. They are single-use only.
Dry vs. Lubricated
Not accounting for whether torque specs are for dry or lubricated fasteners can lead to incorrect tension.
Check if specs are for dry or lubricated threads. Use specified lubricant when required.
Recommended Tools
Recommended Tools
Torque Wrench (1/4" Drive)
Torque Wrench (3/8" Drive)
Torque Wrench (1/2" Drive)
Angle Gauge
Torque Wrench Care
- Calibrate annually or after 5,000 clicks
- Store at lowest setting
- Keep clean and lubricated
Search Specifications
Search by component name, bolt size, or description
Torque Calculator
Convert between different torque units
Exhaust System
Torque specifications for components within the exhaust system, crucial for proper emissions control and sensor readings. These values ensure a leak-free system for accurate sensor measurements and optimal emissions performance.
1 Exhaust Manifold/Headers to Cylinder Head Bolts
M10 x 1.5
Exhaust Manifold/Headers to Cylinder Head Bolts
M10 x 1.5Torque Value
Important Notes
2 Exhaust Pipe to Exhaust Manifold/Headers Bolts
M10 x 1.5
Exhaust Pipe to Exhaust Manifold/Headers Bolts
M10 x 1.5Torque Value
Important Notes
3 Catalytic Converter to Exhaust Pipe Bolts
M10 x 1.5
Catalytic Converter to Exhaust Pipe Bolts
M10 x 1.5Torque Value
Important Notes
4 Muffler to Exhaust Pipe Bolts
M10 x 1.5
Muffler to Exhaust Pipe Bolts
M10 x 1.5Torque Value
Important Notes
5 Oxygen (O2) Sensor
M18 x 1.5
Oxygen (O2) Sensor
M18 x 1.5Torque Value
Important Notes
6 NOx Sensor
M18 x 1.5
NOx Sensor
M18 x 1.5Torque Value
Important Notes
Intake System
Torque specifications for sensors and components within the intake system, which are critical for proper engine management and emissions control. Accurate torque is important to prevent leaks and ensure proper sensor operation.
1 Manifold Absolute Pressure (MAP) Sensor
M6 x 1.0
Manifold Absolute Pressure (MAP) Sensor
M6 x 1.0Torque Value
Important Notes
2 Intake Air Temperature (IAT) Sensor
M6 x 1.0
Intake Air Temperature (IAT) Sensor
M6 x 1.0Torque Value
Important Notes
3 Mass Airflow (MAF) Sensor
M5 x 0.8
Mass Airflow (MAF) Sensor
M5 x 0.8Torque Value
Important Notes
Egr System
Torque specifications for the Exhaust Gas Recirculation (EGR) valve, a critical component for reducing NOx emissions. Proper torque ensures a leak-free seal and optimal EGR operation.
1 EGR Valve Bolts
M8 x 1.25
EGR Valve Bolts
M8 x 1.25Torque Value
Important Notes
Evap System
Torque specifications for components within the Evaporative Emission Control system, vital for preventing fuel vapor leaks into the atmosphere. Correct torque ensures a tight seal and prevents CEL activation related to EVAP system leaks.
1 EVAP System Purge Valve Mounting Bolts/Screws
M6 x 1.0
EVAP System Purge Valve Mounting Bolts/Screws
M6 x 1.0Torque Value
Important Notes
2 EVAP Canister Mounting Bolts
M8 x 1.25
EVAP Canister Mounting Bolts
M8 x 1.25Torque Value
Important Notes
Troubleshooting Guide
Common issues, diagnostic steps, and prevention guidelines
Common Issues
Bolt stretching, stripped threads, uneven torque patterns
Common Issues
Bolt stretching, stripped threads, uneven torque patterns
Loose Components
Symptoms:
- Rattling or vibration noises
- Visible movement in components
- Uneven panel gaps
Solutions:
- Clean threads and mounting surfaces
- Replace damaged fasteners
- Apply proper torque in sequence
- Use thread locker if specified
Stripped Fasteners
Symptoms:
- Unable to achieve proper torque
- Fastener spins freely
- Visible thread damage
Solutions:
- Use thread repair kit if appropriate
- Install thread insert (HeliCoil)
- Replace component if threaded hole is damaged
- Upgrade to higher grade fastener if recommended
Overtightened Components
Symptoms:
- Cracked or deformed parts
- Broken fasteners
- Compressed gaskets or seals
Solutions:
- Replace damaged components
- Use new fasteners
- Follow proper torque sequence
- Verify correct torque specifications
Diagnostic Steps
Visual inspection, torque verification, thread assessment
Diagnostic Steps
Visual inspection, torque verification, thread assessment
Visual Inspection
Inspect the affected area for any visible signs of damage or wear
- Check for cracks or deformation
- Look for signs of excessive wear
- Verify proper fastener installation
Torque Verification
Verify the torque applied to the fasteners
- Check the torque wrench calibration
- Verify the torque specification
- Compare the applied torque to the specification
Thread Assessment
Assess the condition of the threads
- Check for signs of thread damage
- Verify the thread type and size
- Check for proper thread engagement
Prevention Guidelines
Best practices, maintenance tips, tool care
Prevention Guidelines
Best practices, maintenance tips, tool care
Best Practices
- Always follow the recommended torque specification
- Use the correct type and size of fasteners
- Verify the torque wrench calibration regularly
Maintenance Tips
- Regularly inspect the affected area for signs of wear or damage
- Replace damaged or worn-out components promptly
- Keep the work area clean and organized
Tool Care
- Regularly clean and maintain the torque wrench
- Store the torque wrench in a dry and secure location
- Verify the torque wrench calibration before each use
Frequently Asked Questions
Find answers to common questions about torque specifications
Q1 Why is using the correct torque specification important for emissions sensors?
Why is using the correct torque specification important for emissions sensors?
Using the correct torque specification is crucial for proper sensor function and preventing damage. Over-tightening can crush the sensor housing or damage internal components, leading to inaccurate readings or failure. Under-tightening can lead to leaks, vibrations, and sensor malfunction. For example, an overtightened oxygen sensor can crack, causing a false reading and potentially triggering the check engine light.
Q2 What happens if I don't have a torque wrench?
What happens if I don't have a torque wrench?
While a torque wrench is highly recommended for accurate tightening, if one is unavailable, tighten the bolt snugly by hand, then turn approximately 1/8th of a turn further. However, this is a less accurate method, and the risk of over or under tightening is greater. It is best practice to acquire and use a proper torque wrench when dealing with critical components like emissions sensors.
Q3 How often should I inspect the emissions sensors on my 2020-Present Chrysler Voyager?
How often should I inspect the emissions sensors on my 2020-Present Chrysler Voyager?
Emissions sensors typically don't require routine inspection unless you suspect a malfunction (check engine light). However, during other routine maintenance (e.g., oil change or tire rotation), visually check for any signs of damage, cracks, or loose wiring. If you notice a check engine light, it's crucial to diagnose the specific sensor malfunction promptly. Neglecting a faulty sensor can impact fuel efficiency and emissions.
Q4 Can I reuse the gaskets or seals on the emissions sensors?
Can I reuse the gaskets or seals on the emissions sensors?
It's generally recommended to replace gaskets and seals anytime an emissions sensor is removed. These components are designed to provide a proper seal and prevent leaks. Reusing old gaskets/seals can lead to leaks or poor sensor performance. For instance, reusing a gasket on an exhaust gas temperature sensor can cause exhaust gases to leak, triggering an error code.
Q5 What kind of damage can occur to emissions sensors if not properly torqued?
What kind of damage can occur to emissions sensors if not properly torqued?
Improper torque can result in a variety of issues. Over-tightening can crack the sensor housing, shear mounting studs or damage the sensor's internal components. Under-tightening can cause leaks, vibration, sensor movement, or loosen the sensor altogether. All these scenarios will likely impact the sensor's ability to function properly. For example, a loose NOx sensor could give inaccurate readings, causing the engine to perform poorly.
Environmental Considerations
Temperature, humidity, and seasonal effects on torque specifications
Temperature Effects
Includes: High Heat, Cold Weather, Thermal Cycling
Temperature Effects
Includes: High Heat, Cold Weather, Thermal Cycling
Temperature can significantly impact torque values and fastener behavior
Cold Weather
Effects:
- Increased material brittleness
- Higher torque required due to thread contraction
- Reduced thread lubricant effectiveness
Recommendations:
- Allow components to warm to room temperature when possible
- Consider using winter-grade thread lubricants
- Check torque values more frequently during winter months
Hot Weather
Effects:
- Thermal expansion of components
- Decreased friction in threads
- Accelerated lubricant breakdown
Recommendations:
- Check torque when components are at normal operating temperature
- Use temperature-resistant thread lockers
- Consider re-torquing after heat cycles
Humidity and Corrosion
Covers: Rust Prevention, Salt Exposure, Moisture Control
Humidity and Corrosion
Covers: Rust Prevention, Salt Exposure, Moisture Control
Moisture and corrosion can affect fastener integrity and torque values
High Humidity
Effects:
- Accelerated corrosion formation
- Reduced friction coefficient
- Potential thread seizing
Prevention:
- Use corrosion-resistant fasteners
- Apply appropriate anti-seize compounds
- Maintain proper protective coatings
Salt Exposure
Effects:
- Rapid corrosion development
- Thread damage
- Seized fasteners
Prevention:
- Regular underbody washing
- Use of sacrificial anodes where appropriate
- Application of protective coatings
Seasonal Maintenance
Spring, Summer, Fall, and Winter maintenance schedules
Seasonal Maintenance
Spring, Summer, Fall, and Winter maintenance schedules
Spring
- Inspect for winter damage
- Clean and protect exposed fasteners
- Check torque on critical components
Summer
- Monitor heat-affected components
- Check expansion-related loosening
- Inspect cooling system mounts
Fall
- Prepare for winter conditions
- Apply corrosion protection
- Verify all fasteners are properly torqued
Winter
- More frequent inspection of critical fasteners
- Check for salt damage
- Monitor suspension component torque
Related Resources
Tools, service procedures, and technical bulletins
Recommended Tools
Torque Wrench (1/4" Drive)
A calibrated torque wrench for accurately tightening bolts to the specified torque.
- 1/4 inch drive for smaller bolts
- Adjustable torque settings
- Click-type mechanism for accurate torque application
Torx Socket Set
A set of various Torx sockets, which are commonly used for emissions sensor bolts.
- Various sizes to fit different bolts
- Durable construction
- Clearly marked sizes
Extension Bars
Extension bars of various lengths to access sensors in tight locations.
- Various lengths for extended reach
- Secure connection with sockets
- Durable construction
Service Procedures
Emissions Sensor Removal and Installation
This procedure outlines the steps for removing and installing emissions sensors, ensuring correct torque specifications are met.
- Disconnect the negative battery cable.
- Locate the specific emissions sensor (e.g., O2 sensor, NOx sensor).
- Disconnect the electrical connector from the sensor.
- Using the appropriate Torx socket, loosen and remove the sensor mounting bolts.
- Carefully remove the old sensor.
- Install the new sensor, ensuring the mating surfaces are clean.
- Install and hand-tighten the mounting bolts.
- Using a calibrated 1/4" drive torque wrench, tighten the mounting bolts to the specified torque for the specific sensor (Refer to service manual).
- Reconnect the electrical connector.
- Reconnect the negative battery cable.
- Clear any diagnostic trouble codes.
- Verify proper sensor operation by monitoring readings with a scan tool.
Verifying Emissions Sensor Torque
This procedure guides you in ensuring that the emissions sensors are correctly torqued, preventing leaks or sensor damage.
- Locate the emissions sensors.
- Using a calibrated 1/4" drive torque wrench, verify the torque of each sensor mounting bolt.
- If any bolt is below the specified torque, loosen and re-torque to specification (Refer to service manual).
- If any bolt is over the specified torque, loosen and re-torque to specification (Refer to service manual).
- Check sensor functionality using a scan tool to ensure proper operation after torque adjustment.
Technical Service Bulletins
Erroneous O2 Sensor Readings Due to Improper Torque
2021-05-15Some 2020-2021 Voyager models have reported inaccurate O2 sensor readings. Investigation shows that this is sometimes caused by improper torque of the mounting bolts affecting the sensor's internal components and seal.
Resolution: Ensure all O2 sensor mounting bolts are tightened to 89 in-lbs (10 N-m). If error readings persist, replace the sensor after verifying the torque.
NOx Sensor Mounting Bolt Corrosion Issue
2022-11-20Some 2020-2022 Voyager models in regions with high salt exposure are experiencing corrosion on the NOx sensor mounting bolts, which can affect torque application and sensor grounding.
Resolution: Inspect the NOx sensor mounting bolts for corrosion. If corrosion is present, replace the bolts and apply anti-seize compound to threads. Re-install to the specified 18 ft-lbs (24 N-m) torque.
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Technical Information
- All specifications, including torque values, fluid capacities, and maintenance procedures, should be verified against your vehicle's factory service manual.
- Vehicle specifications and procedures may vary by model year, trim level, and region.
- Always follow the manufacturer's recommended procedures and safety precautions.
- Working on vehicles can be dangerous. Always take proper safety precautions and use appropriate safety equipment.
- If you're unsure about any procedure, consult a qualified professional mechanic.