fuel type CHRYSLER VOYAGER 2001 User Guide

LUBRICATION & MAINTENANCE - RG - 2.5 L TURBO
DIESEL
TABLE OF CONTENTS
page page
LUBRICATION & MAINTENANCE - RG - 2.5 L
TURBO DIESEL
SPECIFICATIONS.........................1
INTERNATIONAL SYMBOLS
DESCRIPTION............................2
FLUID TYPES
DESCRIPTION............................2
FLUID FILL/CHECK LOCATIONS
DESCRIPTION............................5
MAINTENANCE SCHEDULES
DESCRIPTION............................5HOISTING
STANDARD PROCEDURE...................7
HOISTING.............................7
JUMP STARTING
STANDARD PROCEDURE...................8
JUMP STARTING........................8
TOWING
STANDARD PROCEDURE...................8
TOWING RECOMMENDATIONS.............8
LUBRICATION &
MAINTENANCE - RG - 2.5 L
TURBO DIESEL
SPECIFICATIONS
SPECIFICATIONS - FLUID CAPACITIES
DESCRIPTION SPECIFICATION
Fuel Tank 75 L (20 gal.)
Fuel Tank (Diesel) 75 L (20 gal.)
Engine Oil* - 2.4 L 4.7 L (5.0 qts.)
Engine Oil* - 3.3 L 4.0 L (4.5 qts.)
Engine Oil* - 2.5 L 5.22 L (5.52 qts.)
Cooling System** - 2.4 L 10.7 L (11.4 qts.)
Cooling System** - 3.3 L
without Auxiliary Heater12.6 L (13.4 qts.)
Cooling System** - 3.3 L
with Auxiliary Heater15.4 L (16.3 qts.)
Cooling System** - 2.5 L
Turbo Diesel without
Auxiliary Heater13.8 L (14.6 qts.)
DESCRIPTION SPECIFICATION
Cooling System** - 2.5 L
Turbo Diesel with
Auxiliary Heater16.6 L (17.5 qts.)
Automatic Transaxle -
Service Fill3.8 L (4.0 qts.)
Automatic Transaxle -
31TH Overhaul Fill8.6 L (9.1 qts.)
Automatic Transaxle -
41TE Overhaul Fill9.2 L (9.7 qts.)
Manual Transaxle (T850
5-speed)2.4-2.7 L (2.5-2.9 qts.)
AWD Power Transfer Unit 1.15 L (2.4 pts.)
Power Steering 1.2 L (2.5 pts.)
AWD Bi-directional
Overrunning Clutch0.575 L (1.22 pts.)
AWD Rear Carrier 0.7 L (1.48 pts.)
*(includes oil filter)
**(includes heater and recovery/reserve bottle)
RGLUBRICATION & MAINTENANCE - RG - 2.5 L TURBO DIESEL0a-1

INTERNATIONAL SYMBOLS
DESCRIPTION
DaimlerChrysler Corporation uses international
symbols to identify engine compartment lubricant
and fluid check and fill locations (Fig. 1).
FLUID TYPES
DESCRIPTION - ENGINE OIL AND LUBRICANTS
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY. CONTACT YOUR DEALER OR GOVERN-
MENT AGENCY FOR LOCATION OF COLLECTION
CENTER IN YOUR AREA.
When service is required, DaimlerChrysler Corpo-
ration recommends that only Mopartbrand parts,
lubricants and chemicals be used. Mopartprovides
the best engineered products for servicing
DaimlerChrysler Corporation vehicles.
Only lubricants bearing designations defined by
the following organization should be used.
²Society of Automotive Engineers (SAE)
²American Petroleum Institute (API)
²National Lubricating Grease Institute (NLGI)
API SERVICE GRADE CERTIFIED
Use an engine oil that is API Certified. MOPARt
provides engine oils, meeting Material Standard
MS-6395, that meet or exceed this requirement.
SAE VISCOSITY
An SAE viscosity grade is used to specify the vis-
cosity of engine oil. Use only engine oils with multi-
ple viscosities such as 5W-30 or 10W-30. These are
specified with a dual SAE viscosity grade which indi-
cates the cold-to-hot temperature viscosity range.
Select an engine oil that is best suited to your par-
ticular temperature range and variation (Fig. 2).
ENERGY CONSERVING OIL
An Energy Conserving type oil is recommended for
gasoline engines. The designation of ENERGY CON-
SERVING is located on the label of an engine oil con-
tainer.
CONTAINER IDENTIFICATION
Standard engine oil identification notations have
been adopted to aid in the proper selection of engine
oil. The identifying notations are located on the front
label of engine oil plastic bottles and the top of
engine oil cans (Fig. 3).
This symbol means that the oil has been certified
by the American Petroleum Institute (API). Diamler-
Chrysler only recommend API Certified engine oils
that meet the requirements of Material Standard
MS-6395. Use Mopar or an equivalent oil meeting
the specification MS-6395.
GEAR LUBRICANTS
SAE ratings also apply to multigrade gear lubri-
cants. In addition, API classification defines the lubri-
cants usage. Such as API GL-5 and SAE 75W-90.
Fig. 1 International Symbols
Fig. 2 TEMPERATURE/ENGINE OIL VISCOSITY
Fig. 3 API Symbol
0a - 2 LUBRICATION & MAINTENANCE - RG - 2.5 L TURBO DIESELRG

MopartATF+4 (Automatic Transmission Fluid-
Type 9602) 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.A dark brown/black fluid
accompanied with a burnt odor and/or deterioration
in shift quality may indicate fluid deterioration or
transmission component failure.
FLUID ADDITIVES
DaimlerChrysler strongly recommends against the
addition of any fluids to the transmission, other than
those automatic transmission fluids listed above.
Exceptions to this policy are the use of special dyes
to aid in detecting fluid leaks.
Various ªspecialº additives and supplements exist
that claim to improve shift feel and/or quality. These
additives and others also claim to improve converter
clutch operation and inhibit overheating, oxidation,
varnish, and sludge. These claims have not been sup-
ported to the satisfaction of DaimlerChrysler and these
additivesmust not be used.
The use of transmission
ªsealersº should also be avoided, since they may
adversely affect the integrity of transmission seals.
DESCRIPTION - FUEL REQUIREMENTS -
DIESEL ENGINE
WARNING: DO NOT USE ALCOHOL OR GASOLINE
AS A FUEL BLENDING AGENT. THEY CAN BE
UNSTABLE UNDER CERTAIN CONDITIONS AND
HAZARDOUS OR EXPLOSIVE WHEN MIXED WITH
DIESEL FUEL.
Use good quality diesel fuel from a reputable sup-
plier. For most year-round service, number 2 diesel
fuel meeting ASTM specification D-975 will provide
good performance. If the vehicle is exposed to
extreme cold (below -18ÉC/0ÉF) or is required to oper-
ate at colder than normal conditions for prolonged
periods, use climatize No. 2 diesel fuel or dilute the
No. 2 diesel fuel with 50% No. 1 diesel fuel. This will
provide better protection from fuel gelling or wax
plugging of the fuel filters.
Diesel fuel is seldom completely free of water. To
prevent fuel system trouble, including fuel line freez-
ing in winter, drain the accumulated water from the
fuel/water separator using the fuel/water separator
drain provided. If you buy good quality fuel and follow
the cold weather advice above, fuel conditioners should
not be required in your vehicle. If available in your
area, a high cetane ªpremiumº diesel fuel may offer
improved cold starting and warm up performance.
DESCRIPTION - DIESEL ENGINE OIL
API SERVICE GRADE CERTIFIED
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY. CONTACT YOUR DEALER OR GOVERN-
MENT AGENCY FOR LOCATION OF COLLECTION
CENTER IN YOUR AREA.
Standard engine oil identification notations have
been adopted to aid in the proper selection of engine
oil. The identifying notations are located on the label
of engine oil plastic bottles and the top of engine oil
cans.
In diesel engines, use an engine oil that conforms
to API Service Grade CF-4 or CG-4/SH (Fig. 5).
MOPARtprovides an engine oil that conforms to this
particular grade.
SAE VISCOSITY
An SAE viscosity grade is used to specify the vis-
cosity of engine oil. SAE 15W±40 specifies a multiple
viscosity engine oil.
When choosing an engine oil, consider the range of
temperatures the vehicle will be operated in before the
next oil change. Select an engine oil that is best suited
to your area's particular ambient temperature range
and variation. For diesel engines, refer to (Fig. 6).
Fig. 5 API Service Grade Certification LabelÐDiesel
Engine Oil
0a - 4 LUBRICATION & MAINTENANCE - RG - 2.5 L TURBO DIESELRG
FLUID TYPES (Continued)

FLUID FILL/CHECK
LOCATIONS
DESCRIPTION
The fluid check/fill points and lubrication locations
are located in each applicable service manual section.
MAINTENANCE SCHEDULES
MAINTENANCE SCHEDULES - DIESEL ENGINE
There are two maintenance schedules that show
proper service for the vehicle.
First is ScheduleªAº. It lists all the scheduled
maintenance to be performed under ªnormalº operat-
ing conditions.
Second is ScheduleªBº. It is a schedule for vehi-
cles that are operated under the conditions listed at
the beginning of the schedule.
Use the schedule that best describes the driving
conditions.
Where time and mileage are listed, follow the
interval that occurs first.
At Each Stop for Fuel
²Check the engine oil level, add as required.
²Check the windshield washer solvent and add if
required.
Once a Month
²Check the tire pressure and look for unusual
wear or damage.
²Inspect the battery and clean and tighten termi-
nals as required.
²Check the fluid levels of coolant reservoir, brake
master cylinder, power steering and transaxle and
add as needed.
²Check all lights and all other electrical items for
correct operation.
²Check the rubber seals on each side of the radi-
ator for proper fit.
At Each Oil Change
²Replace the engine oil filter at each oil change.
²Inspect exhaust system.
²Inspect brake hoses
²Inspect the CV joints and front suspension com-
ponents
²Rotate the tires at each oil change interval
shown on schedule ªAº 20 000 km or every other
interval shown on schedule ªBº 20 000 km.
²Check the coolant level, hoses, and clamps.
²Inspect brake linings, hoses and calipers.
²Inspect engine accessory drive belts.
²Inspect for presence of water in fuel filter/water
separator, drain if necessary.
SCHEDULE ªAº
20 000 km (12 000 miles)
²Change engine oil. (1)
²Replace engine oil filter.
²Inspect air filter element. Replace as necessary.
40 000 km (24 000 Miles)
²Change engine oil. (1)
²Replace engine oil filter.
²Replace air filter element.
²Replace fuel filter/water separator element. (2)
²Check alignment.
60 000 km (37 000 Miles)
²Change engine oil. (1)
²Replace engine oil filter.
²Inspect air filter element. Replace as necessary.
80 000 km (49 000 Miles)
²Change engine oil. (1)
²Replace engine oil filter.
²Replace air filter element.
²Replace fuel filter/water separator element. (2)
²Check alignment.
100 000 km (62 000 Miles)
²Change engine oil. (1)
²Replace engine oil filter.
²Inspect air filter element. Replace as necessary.
120 000 km (75 000 Miles)
²Change engine oil. (1)
²Replace engine oil filter.
²Replace air filter element.
²Replace fuel filter/water separator element. (2)
²Check alignment.
140 000 km (86 000 miles)
²Change engine oil. (1)
²Replace engine oil filter.
²Inspect air filter element. Replace as necessary.
Fig. 6 Engine Oil Viscosity Recommendation ±
Diesel Engines
RGLUBRICATION & MAINTENANCE - RG - 2.5 L TURBO DIESEL0a-5
FLUID TYPES (Continued)

(3) Remove overrunning clutch housing drain plug
and drain fluid (Fig. 43).
(4) Install the drain plug and torque to 30 N´m (22
ft. lbs.).
(5) Re-position the drain pan under the overrun-
ning clutch housing fill plug.
(6) Remove fill plug (Fig. 44).
(7) Using a suction gun (Fig. 45), add 0.58 L (1.22
pts.) of MopartATF+4 (Automatic Transmission Flu-
idÐType 9602).
(8)
Install fill plug and torque to 30 N´m (22 ft. lbs.).
VISCOUS COUPLER
DESCRIPTION
The heart of the all-wheel drive system is the inter-
axle viscous coupling and bi-directional overrunning
clutch. Under normal driving the vehicle retains pre-
dominantly front wheel drive characteristics. The all-
wheel drive takes effect when the front wheels start to
slip. Under normal level road, straight line driving,
100% of the torque is allocated to the front wheels.
The viscous coupler allows more torque to the rear
wheels in accordance with the amount of slippage at
the front wheels. The variable torque distribution is
automatic with no driver inputs required.
OPERATION
The viscous coupler (Fig. 46) is a housing nearly
filled with a high viscosity silicone liquid and thin
metal plates alternately splined to an inner and
outer drum. The viscous coupler provides torque in
the following modes:
²Shear mode (normal operation)
²Hump mode (locked mode)
The inner plates are slotted around the radius and
the outer plates have holes in them. In the shear
mode (normal operation), the plates are evenly
spaced and the torque is created by the shearing of
the plates through the fluid and 90-100% of the
torque is applied to the rear axle. During the shear
mode, a fluid flow pattern is created from this design
(holes and slots). This fluid flow causes high pressure
on each side of each pair of plates and low pressure
between each pair of plates.
Fig. 43 Overrunning Clutch Case Drain Plug
1 - OVERRUNNING CLUTCH HOUSING DRAIN PLUG
Fig. 44 Overrunning Clutch Housing Fill Plug
1 - OVERRUNNING CLUTCH HOUSING FILL PLUG
2 - FUEL TANK
Fig. 45 Filling Overrunning Clutch Case
1 - OVERRUNNING CLUTCH HOUSING FILL HOLE
2 - SUCTION GUN
RSREAR DRIVELINE MODULE3-45
FLUID (Continued)

(3) Remove ignition coil and bracket (Fig. 5).
(4) Disconnect coolant sensor electrical connector
(Fig. 6).
(5) Remove coolant sensor (Fig. 6).
INSTALLATION
(1) Install engine coolant temperature sensor (Fig.
6). Tighten sensor to 7 N´m (60 in. lbs.).
(2) Connect electrical connector to sensor (Fig. 6).
(3) Install ignition coil bracket (Fig. 5).
(4) Install ignition coil (Fig. 5).
(5) Install power steering reservoir (Fig. 4).
(6) Fill cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
ENGINE COOLANT
THERMOSTAT
DESCRIPTION
The engine cooling thermostats are a wax pellet
driven, reverse poppet choke type. The thermostat is
mounted in a housing on the coolant outlet of the
engine (Fig. 8) or (Fig. 10).
OPERATION
The engine cooling thermostat is a wax pellet
driven, reverse poppet choke type. The thermostat is
designed to provide the fastest warm up possible by
preventing leakage through it and to guarantee a
minimum engine operating temperature of 88 to
93ÉC (192 to 199ÉF). The thermostat also will auto-
matically reach wide open so it will not restrict flow
to the radiator as temperature of the coolant rises in
hot weather to around 104ÉC (220ÉF). Above this
temperature the coolant temperature is controlled by
the radiator, fan, and ambient temperature, not the
thermostat.
The thermostat is operated by a wax filled con-
tainer (pellet) which is sealed. When heated coolant
reaches a predetermined temperature, the wax
expands enough to overcome the closing spring and
water pump pressure, which forces the valve to open.
Fig. 5 Fuel Rail, Ignition Coil and 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. 6 Engine Coolant Temperature Sensor
1 - ENGINE COOLANT TEMPERATURE SENSOR
2 - CONNECTOR - ENGINE COOLANT SENSOR
3 - FITTING - HEATER SUPPLY
RSENGINE7-21
ENGINE COOLANT TEMP SENSOR - 3.3/3.8L (Continued)

INSTRUMENT CLUSTER
TABLE OF CONTENTS
page page
INSTRUMENT CLUSTER
DESCRIPTION............................1OPERATION.............................1
INSTRUMENT CLUSTER
DESCRIPTION
WATER IN FUEL LAMP
The Water In Fuel Lamp is located in the instru-
ment cluster. When moisture is found within the fuel
system, the sensor sends a message via the PCI data
bus to the instrument cluster. The sensor is located
underneath the vehicle, directly above the rear axle.
The sensor is housed within the fuel filter/water sep-
arator assembly cover. The sensor is not serviced sep-
arately. If found defective, the entire assembly cover
must be replaced.
OPERATION
WATER IN FUEL LAMP
The Water In Fuel Sensor is a resistive type
switch. It is calibrated to sense the different resis-
tance between diesel fuel and water. When water
enters the fuel system, it is caught in the bottom of
the fuel filter/water separator assembly, where the
sensor is located. Water has less resistance than die-
sel fuel. The sensor then sends a PCI data bus mes-
sage to the instrument cluster to illuminate the
lamp.
If the lamp is inoperative, perform the self diag-
nostic test on the instrument cluster to check the
lamp operation before continuing diagnosis.
RGINSTRUMENT CLUSTER8Ja-1

(1) Inspect air cleaner, induction system and
intake manifold to insure system is dry and clear of
foreign material.
(2) Remove negative battery cable.
(3) Place a shop towel around the spark plugs
when removing them from the engine. This will catch
any fluid that may possibly be in the cylinder under
pressure.
(4) With all spark plugs removed, rotate engine
crankshaft using a breaker bar and socket.
(5) Identify the fluid in the cylinder(s) (i.e., cool-
ant, fuel, oil or other).
(6) Make sure all fluid has been removed from the
cylinders. Inspect engine for damage (i.e., connecting
rods, pistons, valves, etc.)
(7) Repair engine or components as necessary to
prevent this problem from re-occurring.
CAUTION: Squirt approximately one teaspoon of oil
into the cylinders, rotate engine to lubricate the cyl-
inder walls to prevent damage on restart.
(8) Install new spark plugs.
(9) Drain engine oil and remove oil filter.
(10) Install a new oil filter.
(11) Fill engine with specified amount of approved
oil.
(12) Connect negative battery cable.
(13) Start engine and check for any leaks.
STANDARD PROCEDURE - FORM-IN-PLACE
GASKETS AND SEALERS
There are numerous places where form-in-place
gaskets are used on the engine. Care must be taken
when applying form-in-place gaskets to assure
obtaining the desired results.Do not use form-in-
place gasket material unless specified.Bead size,
continuity, and location are of great importance. Too
thin a bead can result in leakage while too much can
result in spill-over which can break off and obstruct
fluid feed lines. A continuous bead of the proper
width is essential to obtain a leak-free gasket.
There are numerous types of form-in-place gasket
materials that are used in the engine area. Mopart
Engine RTV GEN II, MopartATF-RTV, and Mopart
Gasket Maker gasket materials, each have different
properties and can not be used in place of the other.
MOPARtENGINE RTV GEN IIis used to seal
components exposed to engine oil. This material is a
specially designed black silicone rubber RTV that
retains adhesion and sealing properties when
exposed to engine oil. Moisture in the air causes the
material to cure. This material is available in three
ounce tubes and has a shelf life of one year. After one
year this material will not properly cure. Alwaysinspect the package for the expiration date before
use.
MOPARtATF RTVis a specifically designed
black silicone rubber RTV that retains adhesion and
sealing properties to seal components exposed to
automatic transmission fluid, engine coolants, and
moisture. This material is available in three ounce
tubes and has a shelf life of one year. After one year
this material will not properly cure. Always inspect
the package for the expiration date before use.
MOPARtGASKET MAKERis an anaerobic type
gasket material. The material cures in the absence of
air when squeezed between two metallic surfaces. It
will not cure if left in the uncovered tube. The
anaerobic material is for use between two machined
surfaces. Do not use on flexible metal flanges.
MOPARtBED PLATE SEALANTis a unique
(green-in-color) anaerobic type gasket material that
is specially made to seal the area between the bed-
plate and cylinder block without disturbing the bear-
ing clearance or alignment of these components. The
material cures slowly in the absence of air when
torqued between two metallic surfaces, and will rap-
idly cure when heat is applied.
MOPARtGASKET SEALANTis a slow drying,
permanently soft sealer. This material is recom-
mended for sealing threaded fittings and gaskets
against leakage of oil and coolant. Can be used on
threaded and machined parts under all tempera-
tures. This material is used on engines with multi-
layer steel (MLS) cylinder head gaskets. This
material also will prevent corrosion. MopartGasket
Sealant is available in a 13 oz. aerosol can or 4oz./16
oz. can w/applicator.
SEALER APPLICATION
MopartGasket Maker material should be applied
sparingly 1 mm (0.040 in.) diameter or less of sealant
to one gasket surface. Be certain the material sur-
rounds each mounting hole. Excess material can eas-
ily be wiped off. Components should be torqued in
place within 15 minutes. The use of a locating dowel
is recommended during assembly to prevent smear-
ing material off the location.
MopartEngine RTV GEN II or ATF RTV gasket
material should be applied in a continuous bead
approximately 3 mm (0.120 in.) in diameter. All
mounting holes must be circled. For corner sealing, a
3.17 or 6.35 mm (1/8 or 1/4 in.) drop is placed in the
center of the gasket contact area. Uncured sealant
may be removed with a shop towel. Components
should be torqued in place while the sealant is still
wet to the touch (within 10 minutes). The usage of a
locating dowel is recommended during assembly to
prevent smearing material off the location.
9 - 10 ENGINE 2.4LRS
ENGINE 2.4L (Continued)

(3) Start engine and record oil pressure. Refer to
Specifications for correct oil pressure requirements.
(Refer to 9 - ENGINE - SPECIFICATIONS)
CAUTION: If oil pressure is 0 at idle, do not perform
the 3000 RPM test
(4) If oil pressure is 0 at idle. Shut off engine,
check for pressure relief valve stuck open, a clogged
oil pick-up screen or a damaged oil pick-up tube
O-ring.
(5) After test is complete, remove test gauge and
fitting.
(6) Install oil pressure switch and connector. (Refer
to 9 - ENGINE/LUBRICATION/OIL PRESSURE
SENSOR/SWITCH - INSTALLATION)
OIL
ENGINE OIL LEVEL CHECK
The best time to check engine oil level is after it
has sat overnight, or if the engine has been running,
allow the engine to be shut off for at least 5 minutes
before checking oil level.
Checking the oil while the vehicle is on level
ground will improve the accuracy of the oil level
reading. Remove dipstick and observe oil level. Add
oil only when the level is at or below the ADD mark
(Fig. 88).
STANDARD PROCEDURE - ENGINE OIL AND
FILTER CHANGE
Change engine oil at mileage and time intervals
described in the Maintenance Schedule. (Refer to
LUBRICATION & MAINTENANCE/MAINTE-
NANCE SCHEDULES - DESCRIPTION)
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DONOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY. CONTACT YOUR DEALER OR GOVERN-
MENT AGENCY FOR LOCATION OF COLLECTION
CENTER IN YOUR AREA.
Run engine until achieving normal operating tem-
perature.
(1) Position the vehicle on a level surface and turn
engine off.
(2) Hoist and support vehicle on safety stands.
Refer to Hoisting and Jacking Recommendations.
(Refer to LUBRICATION & MAINTENANCE/HOIST-
ING - STANDARD PROCEDURE)
(3) Remove oil fill cap.
(4) Place a suitable drain pan under crankcase
drain.
(5) Remove drain plug from crankcase and allow
oil to drain into pan. Inspect drain plug threads for
stretching or other damage. Replace drain plug and
gasket if damaged.
(6) Remove oil filter. (Refer to 9 - ENGINE/LUBRI-
CATION/OIL FILTER - REMOVAL)
(7) Install and tighten drain plug in crankcase.
(8) Install new oil filter. (Refer to 9 - ENGINE/LU-
BRICATION/OIL FILTER - INSTALLATION)
(9) Lower vehicle and fill crankcase with specified
type and amount of engine oil. (Refer to LUBRICA-
TION & MAINTENANCE/FLUID TYPES -
DESCRIPTION)
(10) Install oil fill cap.
(11) Start engine and inspect for leaks.
(12) Stop engine and inspect oil level.
NOTE: Care should be exercised when disposing
used engine oil after it has been drained from a
vehicle engine. Refer to the WARNING listed above.
OIL FILTER
DESCRIPTION
The engine oil filter (Fig. 89) is a high quality full-
flow, disposable type. Replace the oil filter with a
Mopartor the equivalent.
REMOVAL
(1) Raise vehicle on hoist.
(2) Position an oil collecting container under oil fil-
ter location.
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.
Fig. 88 Oil Level
1 - ENGINE OIL LEVEL DIPSTICK
RSENGINE 2.4L9-51
LUBRICATION (Continued)

(43) Connect the vacuum hoses to the throttle
body.
(44) Connect the EGR transducer electrical connec-
tor.
(45) Connect the TPS, IAC, and MAP sensor elec-
trical connectors.
(46) Connect throttle cables to throttle body.
(47) Install the radiator fans. (Refer to 7 - COOL-
ING/ENGINE/RADIATOR FAN - INSTALLATION)
(48) Connect the radiator upper hose.
(49) Connect the heater hoses. Remove pinch-off
pliers from the rear heater hoses, if equipped.
(50) Install the radiator upper support crossmem-
ber. (Refer to 23 - BODY/EXTERIOR/GRILLE OPEN-
ING REINFORCEMENT - INSTALLATION)
(51) Install the wiper module. (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
INSTALLATION)
(52) Connect the fuel line to fuel rail. (Refer to 14
- FUEL SYSTEM/FUEL DELIVERY/FUEL LINES -
STANDARD PROCEDURE)
(53) Install the air cleaner and hoses.
(54) Install new oil filter. Fill engine crankcase
with proper oil to correct level.
(55) Connect negative cable to battery.
(56) Fill the cooling system. (Refer to 7 - COOL-
ING - STANDARD PROCEDURE)
(57) Start engine and run until operating temper-
ature is reached.
(58) Adjust transmission linkage, if necessary.
SPECIFICATIONS
3.3/3.8L ENGINE
DESCRIPTION SPECIFICATION
General Specification
Type 60É V-6 Engine
Number of Cylinders 6
Displacement
Ð3.3L 3.3 Liters
(201 cu. in.)
Ð3.8L 3.8 Liters
(231 cu. in.)
Bore
Ð3.3L 93.0 mm
(3.66 in.)
Ð3.8L 96.0 mm
(3.779 in.)
DESCRIPTION SPECIFICATION
Stroke
Ð3.3L 81.0 mm
(3.188 in.)
Ð3.8L 87.0 mm
(3.425 in.)
Compression Ratio
Ð3.3L 9.35:1
Ð3.8L 9.6:1
Firing Order 1-2-3-4-5-6
Cylinder Number (Front
to Rear)
ÐFront Bank 2,4,6
ÐRear Bank 1,3,5
Compression PressureÐ
Minimum689.5 kPa
(100 psi)
Max. Variation Between
Cylinders25%
Cylinder Block
Cylinder Bore Diameter
(Standard)
Ð3.3L 92.993±93.007 mm
(3.661±3.6617 in.)
Ð3.8L 95.993±96.007 mm
(3.7792±3.780 in.)
Out-of-Round (Service
Limits)0.076 mm
(0.003 in.)
Taper (Service Limits) 0.051 mm
(0.002 in.)
Lifter Bore Diameter 22.980±23.010 mm
(0.905±0.906 in.)
Deck Surface Flatness
(Max.)0.1 mm
(0.004 in.)
Pistons
Piston Diameter
Ð3.3L ÐMeasured 39.8
mm (1.567 in.) from
piston top92.968±92.998 mm
(3.660±3.661 in.)
Ð3.8L ÐMeasured 33.01
mm (1.30 in.) from piston
top95.968±95.998 mm
(3.778±3.779 in.)
Clearance in Bore @
Size Location (New)-0.005±0.039 mm
(-0.0002±0.0015 in.)
9 - 86 ENGINE 3.3/3.8LRS
ENGINE 3.3/3.8L (Continued)