COOLING SYSTEM CHRYSLER VOYAGER 2001 Manual PDF

OPERATION
The cylinder head closes the combustion chamber,
allowing the pistons to compress the fuel/air mixture
for ignition. The valves are actuated by the lobe pro-
files on the camshaft to open and close at specified
duration to either allow clean air in the combustion
chamber or the exhaust gases out; depending on the
stroke of the engine.
DIAGNOSIS AND TESTINGÐCYLINDER HEAD
GASKET
A cylinder head gasket leak can be located between
adjacent cylinders or between a cylinder and the
adjacent water jacket.
Possible indications of the cylinder head gasket
leaking between adjacent cylinders are:
²Loss of engine power
²Engine misfiring
²Poor fuel economy
Possible indications of the cylinder head gasket
leaking between a cylinder and an adjacent water
jacket are:
²Engine overheating
²Loss of coolant
²Excessive steam (white smoke) emitting from
exhaust
²Coolant foaming
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determine if an engine cylinder head gasket is
leaking between adjacent cylinders, follow the proce-
dures in Cylinder Compression Pressure Test (Refer
to 9 - ENGINE - DIAGNOSIS AND TESTING). An
engine cylinder head gasket leaking between adja-
cent cylinders will result in approximately a 50±70%
reduction in compression pressure.
CYLINDER-TO-WATER JACKET LEAKAGE TEST
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING WITH COOLANT PRES-
SURE CAP REMOVED.
VISUAL TEST METHOD
With the engine cool, remove the coolant pressure
cap. Start the engine and allow it to warm up until
thermostat opens.
If a large combustion/compression pressure leak
exists, bubbles will be visible in the coolant.
COOLING SYSTEM TESTER METHOD
WARNING: WITH COOLING SYSTEM TESTER IN
PLACE, PRESSURE WILL BUILD UP FAST. EXCES-
SIVE PRESSURE BUILT UP, BY CONTINUOUS
ENGINE OPERATION, MUST BE RELEASED TO A
SAFE PRESSURE POINT. NEVER PERMIT PRES-
SURE TO EXCEED 138 kPa (20 psi).
Install Cooling System Tester 7700 or equivalent to
pressure cap neck. Start the engine and observe the
tester's pressure gauge. If gauge pulsates with every
power stroke of a cylinder a combustion pressure
leak is evident.
CHEMICAL TEST METHOD
Combustion leaks into the cooling system can also
be checked by using Bloc-Chek Kit C-3685-A or
equivalent. Perform test following the procedures
supplied with the tool kit.
REMOVAL - CYLINDER HEAD
(1) Perform fuel system pressure release procedure
before attempting any repairs.(Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY - SPECIFICA-
TIONS)
(2) Disconnect battery negative cable.
(3) Drain cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(4) Remove air filter housing and inlet tube.
(5) Remove upper intake manifold. (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
REMOVAL)
Fig. 13 Cylinder Head and Camshafts
1 - CAMSHAFT BEARING CAPS
2 - PLUG
3 - CAMSHAFT
4 - CYLINDER HEAD
5 - CAMSHAFT OIL SEAL
RSENGINE 2.4L9-23
CYLINDER HEAD (Continued)

(13) Raise vehicle and install the exhaust pipe to
the manifold.
(14) Install accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION)
(15) Install heater tube support bracket to cylinder
head.
(16) Connect radiator upper and heater hoses to
intake manifold water outlet connections.
(17) Install upper intake manifold. (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSTALLATION)
(18) Using new gaskets, install EGR tube and
tighten fasteners to 11 N´m (95 in. lbs.).
(19) Install air inlet tube and housing.
(20) Connect all vacuum lines, electrical wiring,
ground straps and fuel line.
(21) Fill cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(22) Connect battery negative cable.
CAMSHAFT OIL SEAL(S)
REMOVAL
(1) Remove timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL)
(2) Hold each camshaft sprocket with Special Tool
6847 while removing center bolt (Fig. 20).
(3) Remove camshaft sprockets.
(4) Remove rear timing belt cover. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL)
(5) Remove camshaft seal using Special Tool
C-4679-A (Fig. 21).
CAUTION: Do not nick shaft seal surface or seal
bore.
INSTALLATION
(1) Shaft seal surface must be free of varnish, dirt
or nicks. Polish with 400 grit paper if necessary.
(2) Install camshaft seals into cylinder head using
Special Tool MD-998306 until flush with head (Fig.
22).
(3) Install timing belt rear cover. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION)
(4) Install camshaft sprockets. Hold each sprocket
with Special Tool 6847 and tighten center bolt to 101
N´m (75 ft. lbs.) (Fig. 20).
(5) Install timing belt and front covers. (Refer to 9
- ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - INSTALLATION) (Refer to 9 -ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION)
CAMSHAFT(S)
DESCRIPTION
Both nodular iron camshafts have six bearing jour-
nal surfaces and two cam lobes per cylinder (Fig. 23).
Flanges at the rear journals control camshaft end
play. Provision for a cam position sensor is located on
the intake camshaft on the rear of the cylinder head.
A hydrodynamic oil seal is used for oil control at the
front of the camshaft.
Fig. 20 Camshaft Sprocket - Removal/Installation
1 - SPECIAL TOOL 6847
Fig. 21 Camshaft Oil Seal - Removal With C-4679-A
1 - SPECIAL TOOL C-4679
9 - 26 ENGINE 2.4LRS
CYLINDER HEAD (Continued)

(9) Connect vacuum lines for power brake booster,
LDP, EGR transducer, and speed control vacuum res-
ervoir (if equipped) at upper intake manifold fittings.
(10) Connect vacuum lines for purge solenoid and
PCV valve.
(11) Connect electrical connectors for MAP sensor,
throttle position sensor (TPS), and idle air control
(IAC) motor.
(12) Install air cleaner upper housing and air
intake tube to throttle body.
(13) Connect inlet air temperature sensor connec-
tor (Fig. 104).
(14) Connect negative cable to battery.
INTAKE MANIFOLD - LOWER
REMOVAL
(1) Perform fuel system pressure release proce-
durebefore attempting any repairs.(Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY - STANDARD
PROCEDURE)
(2) Remove upper intake manifold. (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
REMOVAL)
CAUTION: Cover intake manifold openings to pre-
vent foreign material from entering engine.
(3) Disconnect fuel line. (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/QUICK CONNECT FIT-
TING - STANDARD PROCEDURE)
(4) Drain the cooling system. (Refer to 7 - COOL-
ING - STANDARD PROCEDURE)
(5) Remove heater supply and radiator upper
hoses at intake manifold.
(6) Disconnect coolant temperature sensor/fuel
injector wire harness connector.
(7) Remove lower intake manifold support bracket
bolts (Fig. 109).(8) Loosen the lower intake manfold support
bracket lower bolt (Fig. 109).
(9) Disconnect fuel injector harness.
(10) Remove the bolts attaching the power steering
reservoir to manifold. Set reservoir aside. Do not dis-
connect line
(11) Remove lower intake manifold fasteners (Fig.
110). Remove the manifold from engine.
(12) Inspect the manifold. (Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD - INSPECTION)
INSPECTION
(1) Check manifold surfaces for flatness with
straight edge. Surface must be flat within 0.15 mm
per 300 mm (0.006 in. per foot) of manifold length.
(2) Inspect manifold for cracks or distortion.
Replace manifold if necessary.
INSTALLATION
If the following items were removed, install and
torque to specifications:
²Fuel rail bolts - 22 N´m (200 in. lbs.)
²Coolant outlet connector bolts - 28 N´m (250 in.
lbs.)
²Coolant temperature sensor - 7 N´m (60 in. lbs.)
(1) Position a new gasket on cylinder head and
install lower manifold.
(2) Install and tighten intake manifold fasteners to
28 N´m (250 in. lbs.) in the sequence shown in (Fig.
110). Repeat procedure until all bolts are at specified
torque.
(3) Install lower intake manifold support bracket
bolts (Fig. 109) and tighten to:
Fig. 108 Upper Intake Manifold Tightening Sequence
- 2.4L
Fig. 109 Lower Intake Manifold Support Bracket
1 - SUPPORT BRACKET
2 - BOLTS - UPPER TO MANIFOLD
3 - BOLT - LOWER TO ENGINE BLOCK
9 - 58 ENGINE 2.4LRS
INTAKE MANIFOLD - UPPER (Continued)

²Bolts to intake 28 N´m (250 in. lbs.)
²Bolt to engine block 54 N´m (40 ft. lbs.)
(4) Position power steering reservoir on manifold
and install bolts.
(5) Connect the fuel line. (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/QUICK CONNECT FIT-
TING - STANDARD PROCEDURE)
(6) Connect coolant temperature sensor/fuel injec-
tor wiring harness electrical connector.
(7) Install the radiator upper and heater supply
hoses.
(8) Install the upper intake manifold. (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSTALLATION)
(9) Fill the cooling system. (Refer to 7 - COOLING
- STANDARD PROCEDURE)
EXHAUST MANIFOLD
DESCRIPTION
The exhaust manifold is made of Hi-Silicone Moly
nodular cast iron for strength and high tempera-
tures. The manifold attaches to the cylinder head.
OPERATION
The exhaust manifold collects the exhaust gasses
exiting the combustion chambers. Then it channels
the exhaust gasses to the exhaust pipe attached to
the manifold.
REMOVAL
(1) Raise vehicle and disconnect exhaust pipe from
the exhaust manifold.
(2) Disconnect upstream oxygen sensor connector
at the rear of exhaust manifold.
(3) Remove the bolts attaching the manifold to the
cylinder head.
(4) Remove exhaust manifold.
(5) Inspect the manifold. (Refer to 9 - ENGINE/
MANIFOLDS/EXHAUST MANIFOLD - INSPEC-
TION)
CLEANING
(1) Discard gasket (if equipped) and clean all sur-
faces of manifold and cylinder head.
INSPECTION
(1) Inspect manifold gasket surfaces for flatness
with straight edge. Surface must be flat within 0.15
mm per 300 mm (0.006 in. per foot) of manifold
length.
(2) Inspect manifolds for cracks or distortion.
Replace manifold as necessary.
INSTALLATION
(1) Install exhaust manifold with a new gasket.
Tighten attaching nuts in the sequence shown in
(Fig. 111) to 20 N´m (175 in. lbs.).
(2) Attach exhaust pipe to exhaust manifold and
tighten fasteners to 37 N´m (27 ft. lbs.).
(3) Install and connect the oxygen sensor. (Refer to
14 - FUEL SYSTEM/FUEL INJECTION/O2 SENSOR
- COMPONENT LOCATION)
Fig. 110 Lower Intake Manifold Tightening Sequence
Fig. 111 Exhaust Manifold Tightening Sequence
RSENGINE 2.4L9-59
INTAKE MANIFOLD - LOWER (Continued)

CAUTION: Excessive pressure or high RPM (beyond
the recommended speed), can damage the sealing
surfaces. The mild (white, 120 grit) bristle disc is
recommended. If necessary, the medium (yellow, 80
grit) bristle disc may be used on cast iron surfaces
with care.
STANDARD PROCEDURE - HYDROSTATIC
LOCKED ENGINE
When an engine is suspected to be hydrostatically
locked, regardless of what caused the problem, the
following steps should be used.
CAUTION: DO NOT use starter motor to rotate the
engine, severe damage may occur.
(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 - REPAIR OF
DAMAGED OR WORN THREADS
Damaged or worn threads (excluding spark plug
and camshaft bearing cap attaching threads) can be
repaired. Essentially, this repair consists of drilling
out worn or damaged threads, tapping the hole with
a special Heli-Coil Tap, (or equivalent) and installing
an insert into the tapped hole. This brings the hole
back to its original thread size.
CAUTION: Be sure that the tapped holes maintain
the original center line.
Heli-Coil tools and inserts are readily available
from automotive parts jobbers.
STANDARD PROCEDURE - ENGINE CORE AND
OIL GALLERY PLUGS
Using a blunt tool such as a drift and a hammer,
strike the bottom edge of the cup plug. With the cup
plug rotated, grasp firmly with pliers or other suit-
able tool and remove plug (Fig. 5).
CAUTION: Do not drive cup plug into the casting as
restricted cooling can result and cause serious
engine problems.
Thoroughly clean inside of cup plug hole in cylin-
der block or head. Be sure to remove old sealer.
Lightly coat inside of cup plug hole with Mopart
Stud and Bearing Mount. Make certain the new plug
is cleaned of all oil or grease. Using proper drive
plug, drive plug into hole so that the sharp edge of
the plug is at least 0.5 mm (0.020 in.) inside the
lead-in chamfer.
It is not necessary to wait for curing of the sealant.
The cooling system can be refilled and the vehicle
placed in service immediately.
Fig. 4 PROPER TOOL USAGE FOR SURFACE
PREPARATION
1 - ABRASIVE PAD
2 - 3M ROLOCYBRISTLE DISC
3 - PLASTIC/WOOD SCRAPER
RSENGINE 3.3/3.8L9-81
ENGINE 3.3/3.8L (Continued)

REMOVAL - ENGINE ASSEMBLY
(1) Perform fuel pressure release procedure. (Refer
to 14 - FUEL SYSTEM/FUEL DELIVERY - STAN-
DARD PROCEDURE)
(2) Disconnect the battery.
(3) Remove air cleaner and hoses.
(4) Disconnect the fuel line from fuel rail. (Refer to
14 - FUEL SYSTEM/FUEL DELIVERY/QUICK
CONNECT FITTING - STANDARD PROCEDURE)
(5) Remove the wiper module. (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
REMOVAL)
(6) Block off heater hoses to the rear heater sys-
tem, if equipped, using pinch-off pliers.
(7) Drain the cooling system. (Refer to 7 - COOL-
ING - STANDARD PROCEDURE)
(8) Disconnect the heater hoses.
(9) Remove the radiator upper support crossmem-
ber. (Refer to 23 - BODY/EXTERIOR/GRILLE OPEN-
ING REINFORCEMENT - REMOVAL)
(10) Remove the radiator fans. (Refer to 7 - COOL-
ING/ENGINE/RADIATOR FAN - REMOVAL)
(11) Disconnect the throttle cables from the throt-
tle body.
(12) Disconnect the MAP, IAC, and TPS electrical
connectors.
(13) Disconnect the EGR transducer electrical con-
nector.
(14) Disconnect the vacuum hoses from throttle
body.
(15) Disconnect the brake booster and speed con-
trol vacuum hoses.(16) Disengage wire harness clip from the right
side engine mount.
(17) Remove the power steering reservoir from
mounting position and set aside. Do not disconnect
hose.
(18) Disconnect ground strap from rear of cylinder
head.
(19) Disconnect engine coolant temperature (ECT)
sensor and ignition coil electrical connectors.
(20) Disconnect the fuel injector electrical harness
connector and disengage clip from support bracket.
(21) Disconnect crank sensor connector.
(22) Disconnect camshaft sensor connector.
(23) Evacuate air conditioning system.
(24) Disconnect A/C compressor electrical connec-
tor.
(25) Disconnect the A/C lines from compressor.
Cover and seal all openings of hoses and compressor.
(26) Remove the radiator upper hose.
(27) Disengage electrical harness clip at transaxle
dipstick tube.
(28) Remove transaxle dipstick tube. Seal opening
using a suitable plug.
(29) Disconnect cooler hoses from transaxle.
(30) Disconnect transaxle shift linkage and electri-
cal connectors.
(31) Raise vehicle on hoist and drain the engine
oil.
(32) Remove the axle shafts. (Refer to 3 - DIFFER-
ENTIAL & DRIVELINE/HALF SHAFT - REMOVAL)
(33) Remove crossmember cradle plate (Fig. 6).
(34)AWD equipped:Remove the power transfer
unit (PTU).
(35) Disconnect exhaust pipe from the manifold
(Fig. 7).
Fig. 5 CORE HOLE PLUG REMOVAL
1 - CYLINDER BLOCK
2 - REMOVE PLUG WITH PLIERS
3 - STRIKE HERE WITH HAMMER
4 - DRIFT PUNCH
5 - CUP PLUG
Fig. 6 Crossmember Cradle Plate
1 - CRADLE PLATE
9 - 82 ENGINE 3.3/3.8LRS
ENGINE 3.3/3.8L (Continued)

(4) Slowly raise vehicle enough to remove the
engine dolly and cradle Special Tools 6135, 6710,
6848 and 6909 (Fig. 10).
(5) Remove Special Tools 6912 and 8444.
(6) Lower the vehicle.
(7) Install power steering pump and pressure line
support.(8) Install the generator and wiring harness.
(Refer to 8 - ELECTRICAL/CHARGING/GENERA-
TOR - INSTALLATION)
(9) Raise vehicle.
(10) Attach wiring harness support clip to the dip-
stick tube.
(11) Connect oil pressure switch electrical connec-
tor.
(12) Install the A/C compressor.
(13) Install the water pump pulley.
(14) Connect the radiator lower hose.
(15) Install the accessory drive belt and splash
shield. (Refer to 7 - COOLING/ACCESSORY DRIVE/
DRIVE BELTS - INSTALLATION)
(16) Connect the engine block heater electrical con-
nector, if equipped.
(17) Connect the knock sensor electrical connector
(3.8L only).
(18) Install the torque converter to flex plate bolts.
(19) Install the transaxle case cover (Fig. 8).
(20) Install the powertrain struts (Fig. 8).
(21) Install the engine rear mount bracket.
(22) Install the engine front mount and bracket
assembly.
(23)AWD equipped;Install the power transfer
unit (PTU).
(24) Install the axle shafts. (Refer to 3 - DIFFER-
ENTIAL & DRIVELINE/HALF SHAFT - INSTALLA-
TION)
(25) Connect exhaust pipe to manifold (Fig. 7).
(26) Install crossmember cradle plate (Fig. 6).
(27) Lower vehicle.
(28) Connect transaxle shift linkage.
(29) Connect transaxle electrical connectors.
(30) Connect transaxle cooler hoses.
(31) Install transaxle dipstick tube and attach
electrical harness clip.
(32) Connect the radiator upper hose.
(33) Connect the A/C lines to compressor.
(34) Connect the A/C compressor electrical connec-
tor.
(35) Evacuate and recharge A/C system.
(36) Connect crankshaft and camshaft position
sensors.
(37) Connect the fuel injector electrical harness
connector and engage clip to support bracket.
(38) Connect engine coolant temperature (ECT)
sensor and ignition coil electrical connectors.
(39) Connect the ground strap to rear of cylinder
head.
(40) Install power steering reservoir.
(41) Engage wire harness clip to engine right side
mount.
(42) Connect the brake booster and speed control
vacuum hoses.
Fig. 11 Right Mount to Engine
1 - BOLT
2 - MOUNT BRACKET
3 - ENGINE RIGHT MOUNT ASSEMBLY
Fig. 12 LEFT MOUNT TO FRAME BRACKET
1 - FRAME BRACKET
2 - FRAME RAIL - LEFT
3 - BOLT
4 - TRANSAXLE MOUNT
RSENGINE 3.3/3.8L9-85
ENGINE 3.3/3.8L (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)

AIR CLEANER ELEMENT
REMOVAL
(1) Unsnap 2 clips.
(2) Lift cover and pull toward the engine and
remove cover tabs from air box.
(3) Lift cover and remove the element (Fig. 13).
INSTALLATION
(1) Install the air filter element into air box (Fig.
11).
(2) Move cover so that the tabs insert into the air
box.
(3) Push cover down and snap the 2 clips.
AIR CLEANER HOUSING
REMOVAL
(1) Disconnect the negative battery cable.
(2) Disconnect the inlet air temperature sensor
(Fig. 14).
(3) Remove the inlet hose to throttle body.
(4) Remove the bolt for air box at upper radiator
cross member.(5) Pull air box up and off over the single locating
pin.
(6) Remove air box from vehicle
INSTALLATION
(1) Install air box into vehicle and onto the locat-
ing pin.
(2) Install bolt to hold air box to the upper radia-
tor cross member.
(3) Install the inlet hose to the throttle body.
(4) Connect the inlet air temperature sensor (Fig.
14).
(5) Connect the negative battery cable.
Cooling System Tester 7700
Combustion Leak Tester C-3685-A
Compression Test Adapter 8116
Fig. 13 AIR BOX COVER
Fig. 14 Inlet Air Temperature Sensor
RSENGINE 3.3/3.8L9-93
SPECIAL TOOLS (Continued)

CYLINDER-TO-CYLINDER LEAKAGE TEST
To determine if an engine cylinder head gasket is
leaking between adjacent cylinders, follow the proce-
dures in Cylinder Compression Pressure Test (Refer
to 9 - ENGINE - DIAGNOSIS AND TESTING). An
engine cylinder head gasket leaking between adja-
cent cylinders will result in approximately a 50±70%
reduction in compression pressure.
CYLINDER-TO-WATER JACKET LEAKAGE TEST
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING WITH COOLANT PRES-
SURE CAP REMOVED.
VISUAL TEST METHOD
With the engine cool, remove the coolant pressure
cap. Start the engine and allow it to warm up until
thermostat opens.
If a large combustion/compression pressure leak
exists, bubbles will be visible in the coolant.
COOLING SYSTEM TESTER METHOD
WARNING: WITH COOLING SYSTEM TESTER IN
PLACE, PRESSURE WILL BUILD UP FAST. EXCES-
SIVE PRESSURE BUILT UP, BY CONTINUOUS
ENGINE OPERATION, MUST BE RELEASED TO A
SAFE PRESSURE POINT. NEVER PERMIT PRES-
SURE TO EXCEED 138 kPa (20 psi).
Install Cooling System Tester 7700 or equivalent to
pressure cap neck. Start the engine and observe the
tester's pressure gauge. If gauge pulsates with every
power stroke of a cylinder a combustion pressure
leak is evident.
CHEMICAL TEST METHOD
Combustion leaks into the cooling system can also
be checked by using Bloc-Chek Kit C-3685-A or
equivalent. Perform test following the procedures
supplied with the tool kit.
REMOVAL - CYLINDER HEAD
(1) Drain the cooling system. (Refer to 7 - COOL-
ING - STANDARD PROCEDURE)
(2) Disconnect negative cable from battery.
(3) Remove upper and lower intake manifolds.
(Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANI-
FOLD - REMOVAL)
WARNING: INTAKE MANIFOLD GASKET IS MADE
OF VERY THIN METAL AND MAY CAUSE PER-
SONAL INJURY, HANDLE WITH CARE.(4) Remove the cylinder head covers. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL)
(5) Remove the spark plugs from cylinder head.
(6) Remove the dipstick and tube (Fig. 16).
(7) Remove exhaust manifold(s). (Refer to 9 -
ENGINE/MANIFOLDS/EXHAUST MANIFOLD -
REMOVAL)
(8) Remove rocker arm and shaft assemblies.(Refer
to 9 - ENGINE/CYLINDER HEAD/ROCKER ARMS -
REMOVAL) Remove push rods andmark positions
to ensure installation in original locations.
(9) Remove the eight head bolts from each cylinder
head and remove cylinder heads (Fig. 20).
CLEANING
To ensure engine gasket sealing, proper surface
preparation must be performed, especially with the
use of aluminum engine components and multi-layer
steel cylinder head gaskets.
NOTE: Multi-Layer Steel (MLS) head gaskets require
a scratch free sealing surface.
Remove all gasket material from cylinder head and
block. (Refer to 9 - ENGINE - STANDARD PROCE-
Fig. 16 DIPSTICK & TUBE
1 - DIPSTICK
2 - BOLT
3 - TUBE
RSENGINE 3.3/3.8L9-95
CYLINDER HEAD (Continued)