engine CHRYSLER VOYAGER 2005 Service Manual

Fig. 134 Balance Shafts and Carrier Assembly
1 - SPROCKET 7 - GEARS
2 - TENSIONER 8 - GEAR COVER
3 - PLUG 9 - CHAIN COVER
4 - CARRIER 10 - SPROCKET
5 - REAR COVER 11 - GUIDE
6 - BALANCE SHAFTS 12 - CHAIN
Fig. 135 Chain Cover, Guide and Tensioner
1 - STUD
2 - TENSIONER (ADJUSTER)
3 - GEAR COVER
4 - ADJUSTER SCREW
5 - SHOULDERED PIVOT SCREW
6 - CHAIN COVER (CUTAWAY)
7 - GUIDEFig. 136 Drive Chain and Sprockets
1 - NICKEL PLATED LINK AND MARK
2 - GEAR/SPROCKET SCREWS
3 - NICKEL PLATED LINK AND DOT
9 - 72 ENGINE 2.4LRS
BALANCE SHAFTS AND CARRIER ASSEMBLY (Continued)

INSTALLATION
BALANCE SHAFT INSTALLATION/TIMING
Balance shaft and carrier assembly installation is
the reverse of the removal procedure.During instal-
lation crankshaft-to-balance shaft timing must
be established. Refer to Timing procedure in
this section.
(1) With balance shafts installed in carrier (Fig.
134) position carrier on crankcase and install four
attaching bolts and tighten to 54 N´m (40 ft. lbs.).
(2) Turn balance shafts until both shaft key ways
are up, parallel to vertical centerline of engine.
Install short hub drive gear on sprocket driven shaft
and long hub gear on gear driven shaft. After instal-
lation gear and balance shaft keyways must be up
with gear timing marks meshed as shown in (Fig.
139).
(3) Install gear cover and tighten double ended
stud/washer fastener to 12 N´m (105 in. lbs.).
(4) Align flat on balance shaft drive sprocket to the
flat on crankshaft (Fig. 140).
(5) Install balance shaft drive sprocket on crank-
shaft using Special Tool 6052 (Fig. 141).
Fig. 137 Gear Cover and Gears
1 - STUD (DOUBLE ENDED)
2 - DRIVE GEAR
3 - DRIVEN GEAR
4 - CARRIER DOWEL
5 - GEAR(S)
6 - GEAR COVER
Fig. 138 Balance Shaft - Removal/Installation
1 - REAR COVER
2 - CARRIER
3 - BALANCE SHAFT
Fig. 139 Gear Timing
1 - KEY WAYS UP
2 - GEAR ALIGNMENT DOTS
RSENGINE 2.4L9-73
BALANCE SHAFTS AND CARRIER ASSEMBLY (Continued)

(6) Turn crankshaft until number 1 cylinder is at
top dead center (TDC). The timing marks on the
chain sprocket should line up with the parting line
on the left side of number one main bearing cap.
(Fig. 142).(7) Place chain over crankshaft sprocket so that
the plated link of the chain is over the number 1 cyl-
inder timing mark on the balance shaft crankshaft
sprocket (Fig. 142).
(8) Place balance shaft sprocket into the timing
chain (Fig. 142) and align the timing mark on the
sprocket (dot) with the (lower) plated link on the
chain.
NOTE: The lower plated link is 8 links from the
upper link.
(9) With balance shaft keyways pointing up (12
o'clock) slide the balance shaft sprocket onto the nose
of the balance shaft. The balance shaft may have to
be pushed in slightly to allow for clearance.
Fig. 140 Balance Shaft Sprocket Alignment to
Crankshaft
1 - ALIGN FLATS
Fig. 141 Balance Shaft Drive
1 - SPROCKET
2 - SPECIAL TOOL 6052Fig. 142 Balance Shaft Timing
1 - MARK ON SPROCKET
2 - KEYWAYS UP
3 - ALIGN MARKS
4 - PLATED LINK
5 - PARTING LINE (BEDPLATE TO BLOCK)
6 - PLATED LINK
9 - 74 ENGINE 2.4LRS
BALANCE SHAFTS AND CARRIER ASSEMBLY (Continued)

NOTE: THE TIMING MARK ON THE SPROCKET, THE
(LOWER) NICKEL PLATED LINK, AND THE ARROW
ON THE SIDE OF THE GEAR COVER SHOULD LINE
UP WHEN THE BALANCE SHAFTS ARE TIMED
CORRECTLY.
(10) If the sprockets are timed correctly, install the
balance shaft bolts and tighten to 28 N´m (250 in.
lbs.). A wood block placed between crankcase and
crankshaft counterbalance will prevent crankshaft
and gear rotation.
(11)CHAIN TENSIONING:
(a) Install chain tensioner loosely assembled
withnewshouldered pivot screw and adjuster
screw.
(b) Position guide on double ended stud making
sure tab on the guide fits into slot on the gear
cover. Install and tighten nut/washer assembly to
12 N´m (105 in. lbs.).
(c) Place a shim 1 mm (0.039 in.) thick x 70 mm
(2.75 in.) long between tensioner and chain. Push
tensioner and shim up against the chain.Apply
firm pressure 2.5±3 Kg (5.5±6.6 lbs.) directly
behind the adjustment slot to take up all
slack.Chain must have shoe radius contact as
shown in (Fig. 143).
(d) With the load applied, tighten top tensioner
bolt first, then bottom pivot bolt. Tighten bolts to
12 N´m (105 in. lbs.). Remove shim.
(e) Install carrier covers and tighten screws to
12 N´m (105 in. lbs.).
(12) If removed, install oil pump (Refer to 9 -
ENGINE/LUBRICATION/OIL PUMP - INSTALLA-
TION).(13) Install pick-up tube and oil pan (Refer to 9 -
ENGINE/LUBRICATION/OIL PAN - INSTALLA-
TION).
(14) Fill engine crankcase with proper oil to cor-
rect level.
Fig. 143 Chain Tension Adjustment
1 - 1MM (0.039 IN.) SHIM
2 - TENSIONER (ADJUSTER) BOLT
3 - PIVOT BOLT
RSENGINE 2.4L9-75
BALANCE SHAFTS AND CARRIER ASSEMBLY (Continued)

ENGINE 3.3/3.8L
TABLE OF CONTENTS
page page
ENGINE 3.3/3.8L
DESCRIPTION.........................78
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION...........78
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - PERFORMANCE...........80
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - MECHANICAL.............82
DIAGNOSIS AND TESTING - ENGINE OIL
LEAK INSPECTION....................84
DIAGNOSIS AND TESTING - CYLINDER
COMPRESSION PRESSURE TEST........85
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE
TEST...............................85
STANDARD PROCEDURE
STANDARD PROCEDURE - MEASURING
BEARING CLEARANCE USING
PLASTIGAGE........................86
FORM-IN-PLACE GASKETS AND SEALERS . 86
STANDARD PROCEDURE - ENGINE
GASKET SURFACE PREPARATION........87
HYDROSTATIC LOCKED ENGINE.........87
STANDARD PROCEDURE - REPAIR OF
DAMAGED OR WORN THREADS.........88
STANDARD PROCEDURE - ENGINE CORE
AND OIL GALLERY PLUGS..............88
REMOVAL - ENGINE ASSEMBLY...........88
INSTALLATION - ENGINE ASSEMBLY........91
SPECIFICATIONS
3.3/3.8L ENGINE......................93
SPECIFICATIONS - TORQUE............97
SPECIAL TOOLS
3.3/3.8L ENGINE......................98
AIR CLEANER ELEMENT
REMOVAL............................101
INSTALLATION........................101
AIR CLEANER HOUSING
REMOVAL............................101
INSTALLATION........................102
CYLINDER HEAD
DESCRIPTION........................102
DIAGNOSIS AND TESTINGÐCYLINDER HEAD
GASKET...........................102
REMOVAL - CYLINDER HEAD............103
CLEANING...........................103
INSPECTION.........................104
INSTALLATION - CYLINDER HEAD.........104CYLINDER HEAD COVER(S)
DESCRIPTION........................105
CYLINDER HEAD COVER - RIGHT
REMOVAL............................106
INSTALLATION........................106
CYLINDER HEAD COVER - LEFT
REMOVAL............................107
INSTALLATION........................107
INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION........................107
OPERATION..........................107
STANDARD PROCEDURE - REFACING
VALVESANDVALVESEATS ............107
REMOVAL............................108
CLEANING...........................108
INSPECTION.........................108
INSTALLATION........................109
VALVE SPRINGS
DESCRIPTION........................109
OPERATION..........................109
REMOVAL
REMOVAL - CYLINDER HEAD OFF.......109
REMOVAL - CYLINDER HEAD ON........111
INSPECTION..........................111
INSTALLATION
INSTALLATION - CYLINDER HEAD OFF . . . 111
INSTALLATION - CYLINDER HEAD ON....111
ROCKER ARMS
DESCRIPTION
DESCRIPTION - ROCKER ARMS.........112
DESCRIPTION - PUSHRODS............112
OPERATION
OPERATION - ROCKER ARMS..........112
OPERATION - PUSHRODS.............112
REMOVAL - ROCKER ARMS AND SHAFT....112
DISASSEMBLY - ROCKER ARMS
AND SHAFT.........................113
ASSEMBLY - ROCKER ARMS AND SHAFT . . . 113
INSTALLATION - ROCKER ARMS
AND SHAFT.........................113
VALVE STEM SEALS
DESCRIPTION........................114
REMOVAL............................115
INSTALLATION........................115
ENGINE BLOCK
DESCRIPTION........................115
STANDARD PROCEDURE - CYLINDER BORE
HONING............................115
CLEANING...........................115
9 - 76 ENGINE 3.3/3.8LRS

INSPECTION..........................115
HYDRAULIC LIFTERS (CAM IN BLOCK)
DESCRIPTION........................116
DIAGNOSIS AND TESTING - HYDRAULIC
LIFTERS...........................116
REMOVAL............................117
INSTALLATION........................117
CAMSHAFT & BEARINGS (IN BLOCK)
DESCRIPTION........................118
OPERATION..........................118
REMOVAL............................118
INSPECTION..........................118
INSTALLATION........................118
PISTON & CONNECTING ROD
DESCRIPTION........................119
STANDARD PROCEDURE
STANDARD PROCEDURE - FITTING
CONNECTING RODS..................119
STANDARD PROCEDURE - FITTING
PISTONS...........................120
REMOVAL............................120
INSTALLATION........................121
CONNECTING ROD BEARINGS
STANDARD PROCEDURE - MEASURING
CONNECTING ROD BEARING
CLEARANCE........................123
PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING............................124
REMOVAL............................124
INSTALLATION........................124
CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDURE - MAIN BEARING
FITTING............................125
REMOVAL - CRANKSHAFT MAIN BEARINGS . 127
INSTALLATION - CRANKSHAFT MAIN
BEARINGS..........................127
CRANKSHAFT
DESCRIPTION
DESCRIPTION - 3.3L..................128
DESCRIPTION - 3.8L..................128
STANDARD PROCEDURE - MEASURING
CRANKSHAFT END PLAY..............128
REMOVAL............................128
INSTALLATION........................129
CRANKSHAFT OIL SEAL - FRONT
REMOVAL............................130
INSTALLATION........................130
CRANKSHAFT OIL SEAL - REAR
REMOVAL............................131
INSTALLATION........................131
CRANKSHAFT REAR OIL SEAL RETAINER
REMOVAL............................132
INSTALLATION........................132
VIBRATION DAMPER
REMOVAL............................132
INSTALLATION........................132FLEX PLATE
REMOVAL............................133
INSTALLATION........................133
ENGINE MOUNTING
DESCRIPTION........................134
FRONT MOUNT
REMOVAL............................134
INSTALLATION........................134
LEFT MOUNT
REMOVAL............................136
INSTALLATION........................136
REAR MOUNT
REMOVAL............................136
INSTALLATION........................137
RIGHT MOUNT
REMOVAL............................138
INSTALLATION........................138
LUBRICATION
DESCRIPTION........................138
OPERATION..........................138
DIAGNOSIS AND TESTING - ENGINE OIL
PRESSURE.........................138
OIL
STANDARD PROCEDURE
STANDARD PROCEDURE - ENGINE OIL
AND FILTER CHANGE.................139
STANDARD PROCEDURE - ENGINE OIL
LEVEL CHECK.......................140
OIL COOLER & LINES
DESCRIPTION........................141
OPERATION..........................141
REMOVAL............................141
INSTALLATION........................141
OIL FILTER
REMOVAL............................141
INSTALLATION........................141
OIL FILTER ADAPTER
REMOVAL............................142
INSTALLATION........................142
OIL PAN
REMOVAL............................142
CLEANING...........................142
INSPECTION.........................143
INSTALLATION........................143
OIL PRESSURE RELIEF VALVE
REMOVAL............................143
INSTALLATION........................144
OIL PRESSURE SWITCH
DESCRIPTION........................144
OPERATION..........................144
REMOVAL............................144
INSTALLATION........................144
OIL PUMP
DESCRIPTION........................144
REMOVAL............................144
DISASSEMBLY........................145
CLEANING...........................145
RSENGINE 3.3/3.8L9-77

INSPECTION.........................145
ASSEMBLY...........................146
INSTALLATION........................146
INTAKE MANIFOLD
DESCRIPTION........................147
DIAGNOSIS AND TESTING - INTAKE
MANIFOLD LEAKS....................147
INTAKE MANIFOLD - UPPER
STANDARD PROCEDURE
STANDARD PROCEDURE - MANIFOLD
STRIPPED THREAD REPAIR............147
STANDARD PROCEDURE - INTAKE
MANIFOLD VACUUM PORT REPAIR......148
REMOVAL - UPPER INTAKE MANIFOLD.....148
CLEANING...........................148
INSPECTION.........................149
INSTALLATION - UPPER INTAKE MANIFOLD . 149
INTAKE MANIFOLD - LOWER
REMOVAL - LOWER INTAKE MANIFOLD....150
CLEANING...........................151
INSPECTION.........................151
INSTALLATION - LOWER INTAKE MANIFOLD . 151
EXHAUST MANIFOLD - RIGHT
REMOVAL............................152
CLEANING...........................153
INSPECTION.........................153INSTALLATION........................153
EXHAUST MANIFOLD - LEFT
REMOVAL............................154
CLEANING...........................154
INSPECTION.........................155
INSTALLATION........................155
VALVE TIMING
STANDARD PROCEDURE
STANDARD PROCEDURE - VALVE TIMING
VERIFICATION.......................155
STANDARD PROCEDURE - MEASURING
TIMING CHAIN WEAR.................155
TIMING CHAIN COVER
REMOVAL............................156
INSTALLATION........................157
TIMING CHAIN AND SPROCKETS
REMOVAL
REMOVAL - TIMING CHAIN AND
CAMSHAFT SPROCKET...............159
REMOVAL - CRANKSHAFT SPROCKET . . . 159
INSTALLATION
INSTALLATION - CRANKSHAFT
SPROCKET.........................160
INSTALLATION - TIMING CHAIN AND
CAMSHAFT SPROCKET...............160
ENGINE 3.3/3.8L
DESCRIPTION
The 3.3 Liter (201 cu. in.) and 3.8 Liter (231 cu.
in.) engines are 60É V-6 engines with cast iron cylin-
der blocks and aluminum cylinder heads (Fig. 1). The
engine uses a single, block mounted camshaft with
pushrods to actuate the valves. These engines do not
have provisions for a free wheeling valve train.
The firing order is 1±2±3±4±5±6. The cylinders are
numbered from the front of the engine to the rear.
The front cylinder bank is numbered 2, 4, and 6. The
rear cylinder bank is numbered 1, 3, and 5.
The engine identification number is located on the
rear of the cylinder block just below the cylinder
head (Fig. 2).
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION
Engine diagnosis is helpful in determining the
causes of malfunctions not detected and remedied by
routine maintenance.These malfunctions may be classified as either
mechanical (e.g., a strange noise), or performance
(e.g., engine idles rough and stalls).
Refer to the Engine Mechanical and the Engine
Performance diagnostic charts, for possible causes
and corrections of malfunctions (Refer to 9 - ENGINE
- DIAGNOSIS AND TESTING - MECHANICAL)
(Refer to 9 - ENGINE - DIAGNOSIS AND TESTING
- PERFORMANCE).
For fuel system diagnosis, (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY - DIAGNOSIS AND
TESTING).
Additional tests and diagnostic procedures may be
necessary for specific engine malfunctions that can-
not be isolated with the Service Diagnosis charts.
Information concerning additional tests and diagno-
sis is provided within the following:
²Cylinder Compression Pressure Test
²Cylinder Combustion Pressure Leakage Test
²Engine Cylinder Head Gasket Failure Diagnosis
²Intake Manifold Leakage Diagnosis
²Hydraulic Lash Adjuster Noise Diagnosis
²Engine Oil Leak Inspection
9 - 78 ENGINE 3.3/3.8LRS

Fig. 1 3.3/3.8L V-6 Engines
Fig. 2 Engine Identification
RSENGINE 3.3/3.8L9-79
ENGINE 3.3/3.8L (Continued)

DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE
CONDITION POSSIBLE CAUSE CORRECTION
ENGINE WILL NOT START 1. Weak battery. 1. Test battery. Charge or replace
as necessary. (Refer to 8 -
ELECTRICAL/BATTERY SYSTEM -
DIAGNOSIS AND TESTING)
2. Corroded or loose battery
connections.2. Clean and tighten battery
connections. Apply a coat of light
mineral grease to terminals.
3. Faulty starter. 3. Test starting system. (Refer to 8 -
ELECTRICAL/STARTING -
DIAGNOSIS AND TESTING)
4. Faulty coil(s) or control unit. 4. Test and replace as needed.
(Refer to Appropriate Diagnostic
Information)
5. Incorrect spark plug gap. 5. Set gap. (Refer to 8 -
ELECTRICAL/IGNITION CONTROL
- SPECIFICATIONS)
6. Contamination in fuel system. 6. Clean system and replace fuel
filter.
7. Faulty fuel pump. 7. Test fuel pump and replace as
needed. (Refer to Appropriate
Diagnostic Information)
8. Incorrect engine timing. 8. Check for a skipped timing
belt/chain.
ENGINE STALLS OR IDLES
ROUGH1. Idle speed too low. 1. Test minimum air flow. (Refer to
Appropriate Diagnostic Information)
2. Incorrect fuel mixture. 2. (Refer to Appropriate Diagnostic
Information)
3. Intake manifold leakage. 3. Inspect intake manifold, manifold
gasket, and vacuum hoses.
4. Faulty ignition coil(s). 4. Test and replace as necessary.
(Refer to Appropriate Diagnostic
Information)
9 - 80 ENGINE 3.3/3.8LRS
ENGINE 3.3/3.8L (Continued)

CONDITION POSSIBLE CAUSE CORRECTION
ENGINE LOSS OF POWER 1. Dirty or incorrectly gapped plugs. 1. Clean plugs and set gap.
2. Contamination in fuel system. 2. Clean system and replace fuel
filter.
3. Faulty fuel pump. 3. Test and replace as necessary.
(Refer to Appropriate Diagnostic
Information)
4. Incorrect valve timing. 4. Correct valve timing.
5. Leaking cylinder head gasket. 5. Replace cylinder head gasket.
6. Low compression. 6. Test compression of each
cylinder.
7. Burned, warped, or pitted valves. 7. Replace valves.
8. Plugged or restricted exhaust
system.8. Perform exhaust restriction test.
(Refer to 11 - EXHAUST SYSTEM -
DIAGNOSIS AND TESTING) Install
new parts, as necessary.
9. Faulty ignition coil(s). 9. Test and replace as necessary.
(Refer to Appropriate Diagnostic
Information)
ENGINE MISSES ON
ACCELERATION1. Dirty or incorrectly gapped spark
plugs.1. Clean spark plugs and set gap.
2. Contamination in Fuel System. 2. Clean fuel system and replace
fuel filter.
3. Burned, warped, or pitted valves. 3. Replace valves.
4. Faulty ignition coil(s). 4. Test and replace as necessary.
(Refer to Appropriate Diagnostic
Information)
ENGINE MISSES AT HIGH SPEED 1. Dirty or incorrect spark plug gap. 1. Clean spark plugs and set gap.
2. Faulty ignition coil(s). 2. Test and replace as necessary.
(Refer to Appropriate Diagnostic
Information)
3. Dirty fuel injector(s). 3. Test and replace as necessary.
(Refer to Appropriate Diagnostic
Information)
4. Contamination in fuel system. 4. Clean system and replace fuel
filter.
RSENGINE 3.3/3.8L9-81
ENGINE 3.3/3.8L (Continued)