engine CHRYSLER VOYAGER 2002 Service Manual

(3) Assemble gasket to cylinder cover by inserting
the bolt assemblies through each bolt hole on the
cover and gasket (Fig. 26).
(4) Install cylinder head cover and bolts (Fig. 27).(5) Tighten cylinder head cover bolts to 12 N´m
(105 in. lbs.) (Fig. 27).
(6) Connect PCV hose to cylinder head cover.
(7) Connect power steering pump supply hose sup-
port clip to cylinder head cover (Fig. 24).
(8) Connect spark plug wires to spark plugs.
(9) Install wiper module. (Refer to 8 - ELECTRI-
CAL/WIPERS/WASHERS/WIPER MODULE -
INSTALLATION)
(10) Connect negative cable to battery.
Fig. 24 P/S Supply Hose
1 - POWER STEERING RESERVOIR
2 - CLAMP
3 - SUPPLY HOSE
4 - CLIP
5 - POWER STEERING PUMP
Fig. 25 PCV Hose
1 - HOSE - PCV
2 - P C V VA LV E
Fig. 26 CYLINDER HEAD COVER GASKET
1 - CYLINDER HEAD COVER
2 - BOLT
3 - SEAL (SERVICED WITH BOLT)
4 - GASKET
Fig. 27 Cylinder Head Cover
1 - CYLINDER HEAD COVER
2 - BOLT
9 - 104 ENGINE 3.3/3.8LRS
CYLINDER HEAD COVER - RIGHT (Continued)
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CYLINDER HEAD COVER -
LEFT
REMOVAL
(1) Disconnect spark plug wires from spark plugs.
(2) Disconnect crankcase vent hose from cylinder
head cover.
(3) Remove cylinder head cover bolts.
(4) Remove cylinder head cover and gasket.
INSTALLATION
(1) Clean cylinder head and cover mating surfaces.
Inspect cylinder head cover surface for flatness.
Replace gasket as necessary.
(2) Assemble gasket to cylinder cover by inserting
the fasteners through each bolt hole on cover and
gasket (Fig. 26).
(3) Install the cylinder head cover and bolts (Fig.
27).
(4) Tighten cylinder head cover bolts to 12 N´m
(105 in. lbs.) (Fig. 27).
(5) Connect crankcase vent hose.
(6) Connect spark plug wires to spark plugs.
INTAKE/EXHAUST VALVES &
SEATS
DESCRIPTION
The valves have chrome plated valve stems with
four-bead lock grooves. The valve stem seals are
made of Viton rubber.
OPERATION
The two valves per cylinder are opened using
hydraulic lifters, push rods, and rocker arms.
STANDARD PROCEDURE - REFACING VALVES
AND VALVE SEATS
The intake and exhaust valves and seats are
machined to specific angles (Fig. 28).
VALVES
(1) Inspect the remaining margin after the valves
are refaced (Fig. 29). (Refer to 9 - ENGINE - SPEC-
IFICATIONS)
VALVE SEATS
CAUTION: Remove metal from valve seat only. Do
not remove material from cylinder head (Fig. 30).
(1)
When refacing valve seats, it is important that
the correct size valve guide pilot be used for reseating
stones. A true and complete surface must be obtained.
Fig. 28 Valve Face and Seat
1 - SEAT WIDTH
2 - FACE ANGLE
3 - SEAT ANGLE
4 - SEAT CONTACT AREA
Fig. 29 Valve Margin
1 - VALVE FACE
2 - VALVE MARGIN
Fig. 30 Refacing Valve Seats
1 - REFACING STONE MUST NOT CUT INTO CYLINDER HEAD
2-STONE
3 - PILOT
4 - SEAT
RSENGINE 3.3/3.8L9 - 105
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(2) Measure the concentricity of valve seat using
dial indicator (Fig. 31). Total runout should not
exceed 0.051 mm (0.002 in.) total indicator reading.
(3) Inspect the valve seat using Prussian blue to
determine where the valve contacts the seat. To do
this, coat valve seatLIGHTLYwith Prussian blue
then set valve in place. Rotate the valve with light
pressure. If the blue is transferred to the center of
valve face, contact is satisfactory. If the blue is trans-
ferred to top edge of valve face, lower valve seat with
a 15 degree stone. If the blue is transferred to the
bottom edge of valve face raise valve seat with a 65
degrees stone.
NOTE: Valve seats which are worn or burned can
be reworked, provided that correct angle and seat
width are maintained. Otherwise cylinder head must
be replaced.
(4) When seat is properly positioned the width of
intake and exhaust seats should be 1.50±2.00 mm
(0.059±0.078 in.) (Fig. 28).
(5) After grinding the valve seats or faces, install
the valve in cylinder head and check valve installed
height by measuring from valve tip to spring seat
(Fig. 32). Remove valve from cylinder head and grind
valve tip until within specifications. Check valve tip
for scoring. The tip chamfer should be reground (if
necessary) to prevent seal damage when the valve is
installed.
(6) Check the valve spring installed height after
refacing the valve and seat (Fig. 32).If valves
and/or seats are reground, measure the
installed height of springs (Fig. 32), make sure
measurements are taken from top of spring
seat to the bottom surface of spring retainer. If
height is greater than specifications, install a0.794 mm (0.0312 in.) spacer in head counter-
bore to bring spring height back within specifi-
cations.
REMOVAL
(1) With cylinder head removed, compress valve
springs using Valve Spring Compressor Tool
C-3422-D with adapter 8464 (Refer to 9 - ENGINE -
SPECIAL TOOLS).
(2) Remove valve retaining locks.
(3) Slowly release valve spring compressor.
Remove valve spring retainer, valve spring, and valve
stem seal.
(4) Before removing valves,remove any burrs
from valve stem lock grooves to prevent dam-
age to the valve guides.Identify valves to insure
installation in original location.
CLEANING
(1) Clean all valves thoroughly and discard
burned, warped and cracked valves.
INSPECTION
VALVES
(1) Clean and inspect valves thoroughly. Replace
burned, warped and cracked valves.
(2) Measure valve stems for wear (Fig. 33). For
valve specifications, (Refer to 9 - ENGINE - SPECI-
FICATIONS).
NOTE: Valve stems are chrome plated and should
not be polished (Fig. 33).
Fig. 31 Measurement of Valve Seat Runout
1 - DIAL INDICATOR
Fig. 32 Checking Valve and Spring Installed Height
1 - SPRING RETAINER
2 - VALVE INSTALLED HEIGHT* - 48.1±49.7 mm (1.89±1.95 in.)
3 - CYINDER HEAD SURFACE
4 - SPRING INSTALLED HEIGHT* - 41.1±42.7 mm (1.61±1.68 in.)
*(MEASURED FROM TOP OF SPRING SEAT)
9 - 106 ENGINE 3.3/3.8LRS
INTAKE/EXHAUST VALVES & SEATS (Continued)
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VALVE GUIDES
(1) Remove carbon and varnish deposits from
inside of valve guides with a reliable guide cleaner.
(2) Measure valve stem-to-guide clearance as fol-
lows:
(3) Install valve into cylinder head so it is 15 mm
(0.590 inch.) off the valve seat. A small piece of hose
may be used to hold valve in place.
(4) Attach dial indicator Tool C-3339 to cylinder
head and set it at right angle of valve stem being
measured (Fig. 34).
(5) Move valve to and from the indicator. For cler-
ance specifications, (Refer to 9 - ENGINE - SPECIFI-
CATIONS).
NOTE: Replace cylinder head if stem-to-guide clear-
ance exceeds specifications, or if guide is loose in
cylinder head.
INSTALLATION
(1) Coat valve stems with clean engine oil and
insert them in cylinder head.
(2) Install valve spring seat on head (Fig. 36).
(3) Install new seals on all valve stems and over
valve guides (Fig. 36). Install valve springs and valve
retainers (Fig. 36).
(4) Install the valve springs. (Refer to 9 -
ENGINE/CYLINDER HEAD/VALVE SPRINGS -
INSTALLATION)
VALVE SPRINGS
DESCRIPTION
The valve springs are a bee-hive shaped design
(Fig. 35). The springs are seated on a steel washer on
the cylinder head with retainers and locks retaining
the springs (Fig. 36). The springs are installed with
the smaller diameter against spring retainer (Fig.
35).
OPERATION
The valve spring returns the valve against its seat
for a positive seal of the combustion chamber.
Fig. 33 Intake and Exhaust Valves
1 - MARGIN
2-FACE
3 - STEM
4 - VALVE SPRING RETAINER LOCK GROOVES
Fig. 34 Measuring Valve Guide Wear - Typical
Fig. 35 Valve Spring
1 - VALVE SPRING (TOP - SMALLER DIAMETER)
RSENGINE 3.3/3.8L9 - 107
INTAKE/EXHAUST VALVES & SEATS (Continued)
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REMOVAL
REMOVAL - CYLINDER HEAD OFF
(1) With the cylinder head on a bench, position
Special Tool C-3422-D with 8464 Adapter on the
valve and spring retainer (Fig. 37).
(2) Compress the spring only enough to remove the
valve retainer locks.
(3) Slowly release the spring tension and remove
the valve spring and retainer.
(4) For removal of the valve stem seal (Refer to 9 -
ENGINE/CYLINDER HEAD/VALVE STEM SEALS -
REMOVAL).
REMOVAL - CYLINDER HEAD ON
(1) Disconnect negative cable from battery.
(2) Remove spark plug wires and all spark plugs.
(3) Remove cylinder head cover(s). (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL)(4) Remove rocker arms and shaft. (Refer to 9 -
ENGINE/CYLINDER HEAD/ROCKER ARMS -
REMOVAL)
(5) Rotate engine until the piston in the cylinder
bore requiring spring removal is at TDC.
(6) Install Special Tool 8453 to the cylinder head
(Fig. 38). Tighten the attaching bolts to 23 N´m (200
in. lbs.).
(7) Install a spark plug adapter in the spark plug
hole. Connect air hose that can supply 620.5±689 kPa
(90±100 psi) of air pressure to adapter. This is to
hold valves in place while servicing components.
(8) Locate the forcing screw and spring retainer
adapter assembly over the spring requiring removal
(Fig. 38).
(9) Slowly turn the forcing screw clockwise (com-
pressing the valve spring) until the valve keepers can
be removed.
(10) Turn forcing screw counterclockwise to relieve
spring tension. Remove retainer and valve spring.
Fig. 36 VALVE COMPONENTS
1 - VALVE LOCKS 5 - SPRING SEATS
2 - RETAINERS 6 - CYLINDER HEAD
3 - VALVE SPRINGS 7 - VALVE - EXHAUST
4 - VALVE STEM SEALS 8 - VALVE - INTAKE
9 - 108 ENGINE 3.3/3.8LRS
VALVE SPRINGS (Continued)
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(11) Repeat procedure for each cylinder requiring
valve spring removal.
INSPECTION
Whenever valves have been removed for inspection,
reconditioning or replacement, valve springs should
be tested (Fig. 39).As an example;the compression
length of a spring to be tested is 38.00 mm (1.496
in.). Turn the table of Tool C-647 until surface is in
line with the 38.00 mm (1.496 in.) mark on the
threaded stud and the zero mark on the front. Placespring over stud on the table and lift compressing
lever to set tone device. Pull on torque wrench until
ping is heard. Take reading on torque wrench at this
instant. Multiply this reading by two. This will give
the spring load at test length. Fractional measure-
ments are indicated on the table for finer adjust-
ments. Refer to Engine Specifications to obtain
specified height and allowable tensions (Refer to 9 -
ENGINE - SPECIFICATIONS). Replace any springs
that do not meet specifications.
INSTALLATION
INSTALLATION - CYLINDER HEAD OFF
(1) If removed, install a new valve stem seal (Refer
to 9 - ENGINE/CYLINDER HEAD/VALVE STEM
SEALS - INSTALLATION).
(2) Position valve spring and retainer on spring
seat.
(3) Using Special Tool C-3422-D with 8464 Adapter
(Fig. 37), compress the spring only enough to install
the valve retainer locks. Install valve retainer locks.
(4) Slowly release the spring tension. Ensure the
retainer locks are seated properly.
INSTALLATION - CYLINDER HEAD ON
(1) The intake valve stem seals should be pushed
firmly and squarely over the valve guide using the
valve stem as guide.Do Not Forceseal against top
of guide. When installing the valve retainer locks,
compress the springonly enoughto install the
locks.
CAUTION: Do not pinch seal between retainer and
top of valve guide.
Fig. 37 VALVE SPRING - REMOVE/INSTALL
1 - SPECIAL TOOL C-3422-D SPRING COMPRESSOR
2 - SPECIAL TOOL 8464 ADAPTER
Fig. 38 VALVE SPRING - REMOVE/INSTALL (HEAD
ON)
1 - SPECIAL TOOL 8453
2 - BOLTS - SPECIAL TOOL ATTACHING
3 - AIR SUPPLY HOSE ADAPTER
Fig. 39 TESTING VALVE SPRING
1 - SPECIAL TOOL C-647
RSENGINE 3.3/3.8L9 - 109
VALVE SPRINGS (Continued)
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(2) Follow the same procedure on the remaining 5
cylinders using the firing sequence 1-2-3-4-5-6.Make
sure piston in cylinder is at TDC on the valve
spring that is being covered.
(3) Remove spark plug adapter tool.
(4) Install rocker arms and shaft assembly. (Refer
to 9 - ENGINE/CYLINDER HEAD/ROCKER ARMS -
INSTALLATION)
(5) Install cylinder head covers. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION)
(6) Install spark plugs and connect wires.
(7) Connect negative cable to battery.
ROCKER ARMS
DESCRIPTION
DESCRIPTION - ROCKER ARMS
The rocker arms are installed on the rocker arm
shaft. The rocker arms and shaft assembly is
attached to the cylinder head with seven bolts and
retainers. The rocker arms are made of stamped
steel.
DESCRIPTION - PUSHRODS
The pushrods are made of steel and are a hollow
design. The pushrods are positioned between the
hydraulic lifter and the rocker arm.
OPERATION
OPERATION - ROCKER ARMS
The rocker arm pivots on the rocker shaft. Rocker
arms are used to translate up and down motions pro-
vided by the camshaft, hydraulic lifter, and pushrod
on one end, into a down and up motions on the valve
stem on the opposing end.
OPERATION - PUSHRODS
The pushrod is a solid link between the hydraulic
lifter and the rocker arm. Also, the pushrod supplies
engine oil from the hydraulic lifter to the rocker arm.
REMOVAL - ROCKER ARMS AND SHAFT
(1) Remove the cylinder head cover(s). (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL)
NOTE: Rocker arm shaft bolts are captured to the
shaft.
(2) Loosen the rocker shaft bolts (Fig. 40), rotating
one turn each, until all valve spring pressure is
relieved.
(3) Remove the rocker arms and shaft assembly
(Fig. 40).
(4) For rocker arm disassembly procedures, (Refer
to 9 - ENGINE/CYLINDER HEAD/ROCKER ARMS -
DISASSEMBLY).
DISASSEMBLY - ROCKER ARMS AND SHAFT
CAUTION: Do not attempt to drive the bolt from the
rocker shaft. This can damage the retainer and bolt
assembly.
(1) Remove the rocker arm retainer and bolt by
performing the following procedure:
(a) Using adjustable pliers, grip the edges of the
retainer (Fig. 41).
(b) Apply an upward force with a slight rocking
motion until the retainer disengages from shaft
(Fig. 41).
(2) Remove rocker arms (Fig. 42). Identify the
component locations for reassembly in original loca-
tions.
Fig. 40 ROCKER ARMS AND SHAFT
1 - ROCKER ARMS AND SHAFT ASSEMBLY
2 - ROCKER SHAFT BOLTS
9 - 110 ENGINE 3.3/3.8LRS
VALVE SPRINGS (Continued)
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ASSEMBLY - ROCKER ARMS AND SHAFT
(1) Install rocker arms on the shaft (Fig. 42).
Install in the orginal positions if re-used.Ensurethe
rocker shaft, all the retainers and washers are prop-
erly positioned and installed in the correct locations
(Fig. 42).
(2) Install rocker arms and shaft to the cylinder
head. (Refer to 9 - ENGINE/CYLINDER HEAD/
ROCKER ARMS - INSTALLATION)
INSTALLATION - ROCKER ARMS AND SHAFT
CAUTION: Ensure the longer shaft retaining bolt is
installed in the proper location on the rocker shaft.
(Refer to 9 - ENGINE/CYLINDER HEAD/ROCKER
ARMS - ASSEMBLY)(1) Position the rocker arm and shaft assemblies
on the pedestal mounts.
CAUTION: Ensure all pushrods are properly located
on the lifter and the rocker arm socket.
(2) Align each rocker arm socket with each push-
rod end.
CAUTION: The rocker arm shaft should be tight-
ened down slowly, starting with the center bolts.
Allow 20 minutes lifter bleed down time after instal-
lation of the rocker shafts before engine operation.
(3) Slowly tighten rocker shaft bolts evenly until
shaft is seated. Tighten bolts to 23 N´m (200 in. lbs.)
(Fig. 43).
(4) Install the cylinder head cover(s). (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION)
Fig. 41 ROCKER ARM RETAINER - REMOVAL
1 - ADJUSTABLE PLIERS 3 - ROCKER ARM RETAINER
2 - ROCKER SHAFT BOLT
RSENGINE 3.3/3.8L9 - 111
ROCKER ARMS (Continued)
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VALVE STEM SEALS
DESCRIPTION
The valve stem seals are made of Viton rubber. The
seals are positioned over the valve stem and seated
on the valve guide (Fig. 44).
Fig. 42 ROCKER ARMS AND SHAFT
1 - BOLT (ROCKER SHAFT OIL FEED - LONGER LENGTH) 5 - ROCKER ARM - EXHAUST
2 - SHAFT RETAINER/SPACER - 21.5 mm (0.84 in.) 6 - WASHER
3 -SHAFT RETAINER/SPACER - 37.5 mm (1.47 in.) 7 - ROCKER ARM - INTAKE (LARGER OFFSET)
4 - SHAFT RETAINER/SPACER - 40.9 mm (1.61 in.) 8 - ROCKER ARMS LUBRICATION FEED HOLE (POSITION
UPWARD & TOWARD VALVE SPRING)
Fig. 43 ROCKER ARMS AND SHAFT
1 - ROCKER ARMS AND SHAFT ASSEMBLY
2 - ROCKER SHAFT BOLTS
Fig. 44 Valve Stem Seal
9 - 112 ENGINE 3.3/3.8LRS
ROCKER ARMS (Continued)
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REMOVAL
(1) Remove the valve springs. (Refer to 9 -
ENGINE/CYLINDER HEAD/VALVE SPRINGS -
REMOVAL)
(2) Remove the valve stem seal (Fig. 44).
INSTALLATION
(1) Install the valve stem seal squarely over the
valve guide, using the valve stem as a guide (Fig.
44). Do not force the seal against top of the valve
guide.
(2) Install the valve spring. (Refer to 9 - ENGINE/
CYLINDER HEAD/VALVE SPRINGS - INSTALLA-
TION)
ENGINE BLOCK
DESCRIPTION
The cylinder block is made of cast iron and is a
deep skirt design.
STANDARD PROCEDURE - CYLINDER BORE
HONING
(1) Used carefully, the cylinder bore resizing hone,
recommended tool C-823 or equivalent, equipped
with 220 grit stones, is the best tool for this honing
procedure. In addition to deglazing, it will reduce
taper and out-of-round as well as removing light
scuffing, scoring or scratches. Usually a few strokes
will clean up a bore and maintain the required lim-
its.
(2) Deglazing of the cylinder walls may be done
using a cylinder surfacing hone, recommended tool
C-3501 or equivalent, equipped with 280 grit stones,
if the cylinder bore is straight and round. 20±60
strokes depending on the bore condition, will be suf-
ficient to provide a satisfactory surface. Use a light
honing oil.Do not use engine or transmission oil,
mineral spirits or kerosene.Inspect cylinder walls
after each 20 strokes.
(3) Honing should be done by moving the hone up
and down fast enough to get a cross-hatch pattern.
When hone marksintersectat 40-60 degrees, the
cross hatch angle is most satisfactory for proper seat-
ing of rings (Fig. 45).
(4) A controlled hone motor speed between
200±300 RPM is necessary to obtain the proper cross-
hatch angle. The number of up and down strokes per
minute can be regulated to get the desired 40±60
degree angle. Faster up and down strokes increase
the cross-hatch angle.
(5) After honing, it is necessary that the block be
cleaned again to remove all traces of abrasive.CAUTION: Ensure all abrasives are removed from
engine parts after honing. It is recommended that a
solution of soap and hot water be used with a
brush and the parts then thoroughly dried. The bore
can be considered clean when it can be wiped
clean with a white cloth and cloth remains clean.
Oil the bores after cleaning to prevent rusting.
CLEANING
Clean cylinder block thoroughly using a suitable
cleaning solvent.
INSPECTION
ENGINE BLOCK
(1) Clean cylinder block thoroughly and check all
core hole plugs for evidence of leaking.
(2) If new core plugs are to be installed, (Refer to 9
- ENGINE - STANDARD PROCEDURE - ENGINE
CORE AND OIL GALLERY PLUGS).
(3) Examine block and cylinder bores for cracks or
fractures.
(4) Check block deck surfaces for flatness. Deck
surface must be within service limit of 0.1 mm (0.004
in.).
CYLINDER BORE
NOTE: The cylinder bores should be measured at
normal room temperature, 21ÉC (70ÉF).
Fig. 45 Cylinder Bore Cross-Hatch Pattern
1 - CROSS-HATCH PATTERN
2 - 40ɱ60É
RSENGINE 3.3/3.8L9 - 113
VALVE STEM SEALS (Continued)
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