CHRYSLER VOYAGER 2002 Service Manual

(11) Install the cylinder heads. (Refer to 9 -
ENGINE/CYLINDER HEAD - INSTALLATION)
(12) Install the oil pan. (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - INSTALLATION)
(13) Fill engine crankcase with proper oil to cor-
rect level.
(14) Connect negative cable to battery.PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING
(1) Wipe cylinder bore clean. Insert the ring and
push down with piston to ensure squareness in bore
to approximately 12 mm (0.50 in.) from top of cylin-
der bore. Check ring gap with a feeler gauge (Fig.
83). For clearance specification (Refer to 9 - ENGINE
- SPECIFICATIONS).
(2) Check piston ring to groove side clearance (Fig.
84). For clearance specification (Refer to 9 - ENGINE
- SPECIFICATIONS)
Fig. 82 Piston and Connecting Rod Positioning (Front View of Engine)
1 - MAJOR THRUST SIDE OF PISTON 2 - OIL SQUIRT HOLE
9 - 130 ENGINE 3.3/3.8LRS
PISTON & CONNECTING ROD (Continued)
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REMOVAL
(1) Remove piston and connecting rod. (Refer to 9 -
ENGINE/ENGINE BLOCK/PISTON & CONNECT-
ING ROD - REMOVAL)
(2) Remove No. 1 and No.2 piston rings from pis-
ton using a ring expander tool (Fig. 87).
(3) Remove upper oil ring side rail (Fig. 86).
(4) Remove lower oil ring side rail (Fig. 86).
(5) Remove oil ring expander (Fig. 86).
INSTALLATION
(1) Install rings with manufacturers I.D. mark (if
present) facing up, to the top of the piston (Fig. 85).CAUTION: Install piston rings in the following
order:
a. Oil ring expander.
b. Upper oil ring side rail.
c. Lower oil ring side rail.
d. No. 2 Intermediate piston ring.
e. No. 1 Upper piston ring.
(2) Install the side rail by placing one end
between the piston ring groove and the expander.
Hold end firmly and press down the portion to be
installed until side rail is in position.Do not use a
piston ring expander(Fig. 86).
(3) Install upper side rail first and then the lower
side rail.
Fig. 83 Piston Ring Gap
1 - FEELER GAUGE
Fig. 84 Piston Ring Side Clearance
1 - FEELER GAUGE
Fig. 85 Piston Ring Installation
1 - NO. 1 PISTON RING
2 - NO. 2 PISTON RING
3 - SIDE RAIL
4 - OIL RING
5 - SPACER EXPANDER
Fig. 86 Oil Ring Side Rail
1 - SIDE RAIL END
RSENGINE 3.3/3.8L9 - 131
PISTON RINGS (Continued)
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(4) Install No. 2 piston ring and then No. 1 piston
ring (Fig. 87).
(5) Position piston ring end gaps as shown in (Fig.
88).
(6) Position oil ring expander gap at least 45É
from the side rail gaps butnoton the piston pin cen-
ter or on the thrust direction. Staggering ring gap is
important for oil control.VIBRATION DAMPER
REMOVAL
(1) Disconnect negative cable from battery.
(2) Raise vehicle on hoist.
(3) Remove the right front wheel and inner splash
shield.
(4) Remove the accessory drive belt. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)
(5) Remove vibration damper bolt.
(6) Insert Special Tool 8450 into crankshaft nose
(Fig. 89).
(7) Position 3-jaw puller Special Tool 1026 on
damper as shown in (Fig. 89). Turn puller forcing
screw until damper releases from crankshaft.
(8) Remove the crankshaft vibration damper.
INSTALLATION
(1) Install crankshaft vibration damper using the
forcing screw, nut, and thrust bearing/washer from
Special Tool 8452 (Fig. 90).
NOTE: To minimize friction and prolong tool life,
lubricate the threads on the forcing screw of Spe-
cial Tool 8452.
(2) Position vibration damper on crankshaft.
(3) Screw Special Tool 8452 into crankshaft until
the bolt seats. Turn the nut to install damper until it
seats fully.
(4) Remove Special Tool 8452.
(5) Install vibration damper bolt. Torque bolt to 54
N´m (40 ft. lbs.).
Fig. 87 Piston Ring Installation
Fig. 88 Piston Ring End Gap Position
1 - GAP OF LOWER SIDE RAIL
2 - NO. 1 RING GAP
3 - GAP OF UPPER SIDE RAIL
4 - NO. 2 RING GAP AND SPACER EXPANDER GAP
Fig. 89 Vibration Damper - Removal
1 - SPECIAL TOOL 8450 - INSERT
2 - SPECIAL TOOL 1026-3JAWPULLER
9 - 132 ENGINE 3.3/3.8LRS
PISTON RINGS (Continued)
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(6) Install the accessory drive belt. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION)
(7) Install inner splash shield and right front
wheel.
(8) Connect negative cable to battery.
ENGINE MOUNTING
DESCRIPTION
The engine mounting system consist of four
mounts; right and a left side support the powertrain,
and a front and a rear mount control powertrain
torque. The right side mount is a hydro-type (Fig.
91), all others are of molded rubber material.
FRONT MOUNT
REMOVAL
(1) Support the engine and transmission assembly
with a floor jack so it will not rotate.
(2) Remove the front engine mount through bolt
from the insulator and front crossmember mounting
bracket (Fig. 92).
(3) Remove six screws from air dam to allow
access to the front mount screws.
(4) Remove the front engine mount screws and
remove the insulator assembly (Fig. 92).
(5) Remove the front mounting bracket, if neces-
sary (Fig. 92).
INSTALLATION
(1) Install the front mounting bracket, if removed
(Fig. 92).
(2) Install the front engine mount through bolt
from the insulator and front crossmember mounting
bracket (Fig. 92).
(3) Install the insulator assembly and mounting
screws (Fig. 92).
Fig. 90 Vibration Damper - Installation
1 - FORCING SCREW / NUT FROM SPECIAL TOOL 8452
2 - VIBRATION DAMPER
3 - THRUST BEARING / WASHER
Fig. 91 Engine Hydro-type Mount - Right Side
1 - BOLT
2 - BOLT
3 - FRAME RAIL
4 - RIGHT MOUNT - 2.4L ENGINE
5 - RIGHT MOUNT - 3.3/3.8L ENGINE
RSENGINE 3.3/3.8L9 - 133
VIBRATION DAMPER (Continued)
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LEFT MOUNT
REMOVAL
(1) Raise the vehicle on hoist.
(2) Remove the left front wheel.
(3) Remove the left mount through bolt access
cover.
(4) Support the transaxle with a suitable jack.
(5) Remove the engine front mount through bolt to
allow left mount removal clearance (Fig. 92).
(6) Remove the left mount through frame rail bolt
(Fig. 93).
(7) Lower transaxle for access to horizontal bolts.
(8) Remove the horizontal bolts from the mount to
the transaxle (Fig. 94) or (Fig. 95).NOTE: To remove mount, additional lowering of
transaxle may be required.
(9) Remove left mount.
INSTALLATION
(1) Install left mount on transaxle (Fig. 94) or (Fig.
95).
(2) Raise transaxle with jack until left mount is in
position.
(3) Install left mount through bolt (Fig. 93).
(4) Install left mount through bolt access cover.
(5) Install front mount through bolt (Fig. 92).
(6) Install left front wheel.
(7) Lower vehicle.
Fig. 92 Engine Mounting - Front
1 - CROSSMEMBER 5 - BOLT 54 N´m (40 ft. lbs.)
2 - BOLT - 68 N´m (50 ft. lbs.) 6 - NUT - 68 N´m (50 ft. lbs.)
3 - BOLT - 102 N´m (75 ft. lbs.) 7 - MOUNT - ENGINE FRONT
4 - BOLT - 68 N´m (50 ft. lbs.) 8 - BRACKET - ENGINE FRONT MOUNT
9 - 134 ENGINE 3.3/3.8LRS
FRONT MOUNT (Continued)
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REAR MOUNT
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove the rear mount heat shield (Fig. 96).
(3) Remove the through bolt from the mount and
rear mount bracket (Fig. 97).
(4) Remove the mount bolts (Fig. 97).
(5) Remove the rear mount (Fig. 97).
(6) For rear mount bracket removal, remove the
bolts attaching bracket to transaxle (Fig. 98).
(7) Remove rear mount bracket.
Fig. 93 LEFT MOUNT TO BRACKET
1 - BOLT - BRACKET TO FRAME RAIL 68 N´m (50 ft. lbs.)
2 - BOLT - MOUNT TO RAIL THRU 75 N´m (55 ft. lbs.)
3 - BOLT - LEFT MOUNT TO TRANSAXLE 54 N´m (40 ft. lbs.)
4 - TRANSAXLE
5 - MOUNT - LEFT
6 - BRACKET - LEFT MOUNT
Fig. 94 LEFT MOUNT - 31TH TRANSAXLE
1 - LEFT MOUNT ASEMBLY
2 - BOLT - 54 N´m (40 ft. lbs.)
3 - TRANSAXLE - 31TH
Fig. 95 LEFT MOUNT - 41TE TRANSAXLE
1 - LEFT MOUNT ASSEMBLY
2 - BOLT - 54 N´m (40 ft. lbs.)
3 - TRANSAXLE - 41TE
Fig. 96 REAR MOUNT HEAT SHIELD
1 - BOLT - HEAT SHIELD 11 N´m (100 in. lbs.)
2 - HEAT SHIELD
3 - CLIP
4 - REAR MOUNT
RSENGINE 3.3/3.8L9 - 135
LEFT MOUNT (Continued)
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INSTALLATION
(1) Install rear mount bracket, if removed (Fig.
98).
(2) Install the rear mount and bolts (Fig. 97).
Tighten bolts to 54 N´m (40 ft. lbs.).
(3) Install the mount through bolt to the mount
and bracket (Fig. 97). Tighten through bolt to 54 N´m
(40 ft. lbs.).
(4) Install the rear mount heat shield (Fig. 96).
(5) Lower vehicle on hoist.
Fig. 97 REAR MOUNT
1 - BOLT 54 N´m (40 ft. lbs.)
2 - REAR MOUNT BRACKET
3 - THRU-BOLT 54 N´m (40 ft. lbs.)
4 - REAR MOUNT
Fig. 98 REAR MOUNT BRACKET - (all engines)
1 - BOLT - VERTICAL 102 N´m (75 ft. lbs.)
2 - BRACKET - REAR MOUNT3 - BOLT - HORIZONTAL 102 N´m (75 ft. lbs.)
9 - 136 ENGINE 3.3/3.8LRS
REAR MOUNT (Continued)
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RIGHT MOUNT
REMOVAL
(1) Remove air cleaner housing lid and clean air
hose from throttle body.
(2) Remove air cleaner element and housing.
(3) Disconnect make-up air hose from cylinder
head cover.
(4) Remove the load on the right engine mount by
carefully supporting the engine assembly with a floor
jack.
(5) Disconnect electrical harness support clips from
engine mount bracket.
(6) Remove the bolts attaching the engine mount
to the frame rail (Fig. 99).
(7) Remove the three bolts attaching the engine
mount to the engine bracket (Fig. 99).
(8) Remove the right engine mount (Fig. 99).
INSTALLATION
(1) Install engine bracket (if removed). Tighten
bolts to 33 N´m (24 ft. lbs.).
(2) Position right engine mount and install frame
rail to mount bolts (Fig. 99). Tighten bolts to 68 N´m
(50 ft. lbs.).
(3) Install the mount to engine bracket bolts and
tighten to 54 N´m (40 ft. lbs.). (Fig. 99)
(4) Connect electrical harness support clips to
engine mount bracket.
(5) Remove jack from under engine.
(6) Connect make-up air hose to cylinder head
cover.
(7) Install air cleaner housing and element.
(8) Install air cleaner housing lid and clean air
tube to throttle body.
LUBRICATION
DESCRIPTION
The lubrication system is a full flow filtration pres-
sure feed type. The oil pump is mounted in the tim-
ing chain cover and is driven by the crankshaft
OPERATION
Oil from the oil pan is pumped by a internal gear
type oil pump directly coupled to the crankshaft. The
pressure is regulated by a relief valve located in the
timing chain cover. The oil is pumped through an oil
filter and feeds a main oil gallery. This oil gallery
feeds oil under pressure to the main and rod bear-
ings, camshaft bearings. Passages in the cylinder
block feed oil to the hydraulic lifters and rocker shaft
brackets which feeds the rocker arm pivots (Fig.
100).
DIAGNOSIS AND TESTING - ENGINE OIL
PRESSURE
(1) Disconnect and remove oil pressure switch
(Refer to 9 - ENGINE/LUBRICATION/OIL PRES-
SURE SENSOR/SWITCH - REMOVAL).
(2) Install Special Tools C-3292 Gauge with 8406
Adaptor. For Special Tool identification, (Refer to 9 -
ENGINE - SPECIAL TOOLS).
(3) Start engine and record oil pressure. Refer to
Oil Pressure in Engine Specifications for the correct
pressure (Refer to 9 - ENGINE - SPECIFICATIONS).
Fig. 99 Right Engine Mount
1 - RIGHT ENGINE MOUNT
2 - BOLT - MOUNT TO FRAME RAIL
3 - BOLT - MOUNT TO ENGINE
4 - ENGINE MOUNT BRACKET
5 - RIGHT FRAME RAIL
RSENGINE 3.3/3.8L9 - 137
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OIL
STANDARD PROCEDURE
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. DO
NOT 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) Open hood, remove oil fill cap.
(3) Hoist and support vehicle on safety stands.
Refer to Hoisting and Jacking Recommendations.
(Refer to LUBRICATION & MAINTENANCE/HOIST-
ING - STANDARD PROCEDURE)
(4) Place a suitable drain pan under crankcase
drain (Fig. 101).
(5) Remove drain plug from crankcase (Fig. 101)
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)
Fig. 100 Engine Oiling System
1 - OIL SUPPLY FOR BALL SOCKET THROUGH PUSH ROD 7 - OUTER ROTOR
2 - OIL SUPPLY PASSAGE FROM SHAFT TO ROCKER ARM 8 - INNER ROTOR
3 - ROCKER SHAFT 9 - RELIEF VALVE
4 - OIL FLOWS TO ONLY ONE PEDASTAL ON EACH HEAD; THIRD
FROM REAR ON RIGHT HEAD, THIRD FROM FRONT ON LEFT
HEAD10 - OIL PAN
5 - ROCKER SHAFT TOWER 11 - OIL SCREEN
6 - CRANKSHAFT 12 - OIL PUMP CASE
9 - 138 ENGINE 3.3/3.8LRS
LUBRICATION (Continued)
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(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.
STANDARD PROCEDURE - 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 (Fig. 102). Add only when the level is at or
below the ADD mark.
Fig. 102 Engine Oil Level Dipstick and Fill Locations
1 - COOLANT RECOVERY CONTAINER 3 - ENGINE OIL LEVEL DIPSTICK
2 - ENGINE OIL FILL CAP 4 - RADIATOR PRESSURE CAP
Fig. 101 Engine Oil Drain Plug and Oil Filter
1 - DRAIN PLUG
2 - OIL FILTER
RSENGINE 3.3/3.8L9 - 139
OIL (Continued)
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