engine CHRYSLER VOYAGER 2002 Service Manual

CRANKSHAFT MAIN
BEARINGS
REMOVAL
The engine must be removed from vehicle and com-
pletely disassembled to replace the front main bear-
ing.
CRANKSHAFT MAIN BEARINGS
(1) With crankshaft assembly removed from
engine.
(2) Remove crankshaft supports from crankshaft
and remove bearing halves from supports (Fig. 64).
CRANKSHAFT FRONT MAIN BEARING
(1) Using special tool VM.1073 push front main
bearing out of front of engine block (Fig. 65).
Fig. 64 CRANKSHAFT ASSEMBLY
1 - CRANKSHAFT SUPPORT HALVE
2 - MAIN BEARING HALVE
3 - CRANKSHAFT
4 - MAIN BEARING HALVE
5 - CRANKSHAFT SUPPORT HALVE
6 - MAIN BEARING SUPPORT BOLTS
7 - WASHERS
Fig. 65 FRONT MAIN BEARING REMOVAL
1 - VM.1073
2 - FRONT CRANKSHAFT MAIN BEARING
3 - ENGINE BLOCK
9a - 44 ENGINERG
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INSTALLATION
CRANKSHAFT MAIN BEARINGS
(1) Install bearing halves in crankshaft supports.
(2) Lubricate crankshaft and main bearings with
clean engine oil.
(3) Install crankshaft supports on crankshaft (Fig.
66). Torque bolts to 44.1N´m.
FRONT CRANKSHAFT MAIN BEARING
(1) Using special tool VM.1073, push front crank-
shaft main bearing in engine block (Fig. 67).
(2) Be sure oil hole in bearing lines up with oil gal-
lery in engine block (Fig. 68).
(3) Reassemble engine and install in vehicle.
Fig. 66 CRANKSHAFT ASSEMBLY
1 - CRANKSHAFT SUPPORT HALVE
2 - MAIN BEARING HALVE
3 - CRANKSHAFT
4 - MAIN BEARING HALVE
5 - CRANKSHAFT SUPPORT HALVE
6 - MAIN BEARING SUPPORT BOLTS
7 - WASHERS
Fig. 67 FRONT MAIN BEARING INSTALLATION
1 - FRONT CRANKSHAFT MAIN BEARING
2 - ENGINE BLOCK
3 - SPECIAL TOOL VM.1073
Fig. 68 FRONT MAIN BEARING ALIGNMENT
1 - ENGINE BLOCK
2 - OIL HOLE IN BEARING
3 - FRONT CRANKSHAFT MAIN BEARING
RGENGINE9a-45
CRANKSHAFT MAIN BEARINGS (Continued)
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CRANKSHAFT OIL SEAL -
REAR
REMOVAL
This must be done with either the engine or trans-
mission removed from vehicle.
(1) Remove flywheel assembly.
(2) Pry out old crankshaft oil seal.
INSTALLATION
(1) Using special tool VM.1050, install rear crank-
shaft oil seal in rear main bearing support (Fig. 69).
(2) Install engine or tranmission in vehicle.
OIL PAN
REMOVAL
(1) Disconnect negative battery cable.
(2) Raise vehicle on hoist.
(3) Drain engine oil from engine.
(4) Remove all oil pan retaining bolts and oil pan
(Fig. 70).
INSTALLATION
(1) Clean oil pan and sealing surfaces. Inspect oil
pan and engine block.
(2) Install oil pan, gasket, and retaining bolts (Fig.
70).
(3) Be sure power steering line brackets are in
proper location (Fig. 70).
(4) Torque oil pan bolts to 11.8N´m.
(5) Lower vehicle.
(6) Refill engine oil to proper level.
(7) Connect negative battery cable.
Fig. 69 REAR CRANKSHAFT OIL SEAL
INSTALLATION USING VM.1050
1 - SPECIAL TOOL VM.1050
2 - REAR MAIN BEARING SUPPORT
3 - OIL PAN
4 - ENGINE TO TRANSMISSION ADAPTER PLATE
Fig. 70 OIL PAN AND PRESSURE RELIEF VALVE
1 - OIL PAN RETAINING BOLTS
2 - POWER STEERING LINE BRACKETS
3 - OIL PAN GASKET
4 - OIL PRESSURE SENSOR
5 - ENGINE BLOCK
6 - OIL PRESSURE RELIEF VALVE
7 - OIL PAN RETAINING BOLTS
8 - OIL PAN
9a - 46 ENGINERG
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OIL PUMP
REMOVAL
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(3) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(4) Remove timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(5) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL).
(6) Remove timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(7) Remove front engine cover (Refer to 9 -
ENGINE/ENGINE BLOCK/ENGINE COVER -
REMOVAL).
(8) Remove crankshaft sprocket (Fig. 71).
(9) Remove oil pump retaining bolts and remove
pump from engine block (Fig. 71).
REMOVAL
(1) Disconnect negative battery cable.
(2) Raise vehicle on hoist.
(3) Remove oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - REMOVAL).
(4) Remove oil pump pickup tube retaining bolt
and pull pickup tube from engine block (Fig. 72).
INSTALLATION
INSTALLATION
(1) Lubricate oil pump rotor with engine oil.
(2) Install oil pump in bore in engine block (Fig.
71).
Fig. 71 OIL PUMP AND VACUUM PUMP
1 - VACUUM PUMP
2 - CRANKSHAFT SPROCKET
3 - OIL PUMP
4 - ENGINE BLOCK
5 - CRANKSHAFT
Fig. 72 OIL PUMP PICKUP TUBE ASSEMBLY
1 - BALANCE SHAFT
2 - OIL JET RETAINING BOLT
3 - OIL JET
4 - ENGINE BLOCK
5 - CRANKSHAFT
6 - BALANCE SHAFT RETAINING BOLTS
7 - OIL DIPSTICK TUBE RETAINER
8 - RUBBER BUSHING
9 - RETAINING BOLT
RGENGINE9a-47
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(3) Install oil pump retaining bolts (Fig. 71).
Torque bolts to 10.8N´m.
(4) Install crankshaft sprocket (Fig. 71). Torque
bolts to 10.8N´m.
(5) Install front engine cover (Refer to 9 -
ENGINE/ENGINE BLOCK/ENGINE COVER -
INSTALLATION).
(6) Install timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(7) Install timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION) .
(8) Install timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(9) Install accessory drive belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(10) Install power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(11) Connect negative battery cable.
INSTALLATION
(1) Lubricate o-ring on oil pump pickup tube with
engine oil.
(2) Install pickup tube in engine block and install
retaining bolt (Fig. 72). Torque bolt to 32.4N´m.
(3) Install oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION).
(4) Refill engine oil to proper level.
(5) Connect negative battery cable.
OIL PRESSURE SENSOR/
SWITCH
DESCRIPTION
The oil pressure switch is located on the right side
of the engine block. The switch screws into the
engines main oil gallery (Fig. 73).
REMOVAL
(1) Disconnect negative battery cable.
(2) Raise vehicle on hoist.
(3) Disconnect oil pressure switch electrical con-
nector (Fig. 73).
(4) Remove oil pressure switch from engine block.
INSTALLATION
(1) Apply MopartThread Sealant to the switch
threads.
(2) Install oil pressure switch in engine block.
(3) Connect oil pressure switch electrical connector
(Fig. 73).(4) Lower vehicle.
(5) Start engine and check for leaks.
(6) Check and adjust oil level as necessary.
OIL TEMPERATURE SENSOR
DESCRIPTION
The oil temperature sensor is located on the right
side of the engine block. The sensor screws into the
engines main oil gallery (Fig. 74).
REMOVAL
(1) Disconnect negative battery cable.
(2) Raise vehicle on hoist.
(3) Disconnect oil temperature sensor electrical
connector (Fig. 74).
(4) Remove oil temperature sensor from engine
block.
INSTALLATION
(1) Apply MopartThread Sealant to the sensor
threads.
(2) Install oil temperature sensor in engine block.
(3) Connect oil temperature sensor electrical con-
nector (Fig. 74)
Fig. 73 REAR ENGINE VIEW
1 - SUSPENSION CRADLE
2 - ENGINE BLOCK
3 - OIL PRESSURE SWITCH
4 - OIL TEMPERATURE SENSOR
5 - VEHICLE SPEED SENSOR
6 - TRANSMISSION
9a - 48 ENGINERG
OIL PUMP (Continued)
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(4) Lower vehicle.
(5) Start engine and check for leaks.
(6) Check and adjust oil level as necessary.
OIL PRESSURE RELIEF VALVE
DESCRIPTION
The oil pressure relief valve mounts in the front of
the engine block and is used to control oil flow
through the engines lubrication system (Fig. 75).
REMOVAL
(1) Remove engine oil pan (Refer to 9 - ENGINE/
LUBRICATION/OIL PAN - REMOVAL).
(2) Using special tool VM.1054, remove oil pres-
sure relief valve from engine block (Fig. 76).
INSTALLATION
(1) Thoroughly clean all components and relief
valve pocket in cylinder block.
(2) Lubricate all oil pressure relief valve compo-
nents with engine oil.
(3) Install oil pressure relief valve plunger, spring,
and cap.
Fig. 74 REAR ENGINE VIEW
1 - SUSPENSION CRADLE
2 - ENGINE BLOCK
3 - OIL PRESSURE SWITCH
4 - OIL TEMPERATURE SENSOR
5 - VEHICLE SPEED SENSOR
6 - TRANSMISSION
Fig. 75 OIL PRESSURE RELIEF VALVE
1 - O-RING
2 - OIL PRESSURE RELIEF VALVE CAP
3 - OIL PRESSURE RELIEF VALVE SPRING
4 - OIL PRESSURE RELIEF VALVE PLUNGER
Fig. 76 OIL PRESSURE RELIEF VALVE REMOVAL
1 - VM.1054
2 - OIL PRESSURE RELIEF VALVE
3 - ENGINE BLOCK
4 - OIL PUMP
RGENGINE9a-49
OIL TEMPERATURE SENSOR (Continued)
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(4) Using special tool VM.1059, push oil pressure
relief valve cap in untill flush with engine block (Fig.
77).
(5) Install oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION).
OIL COOLER & LINES
REMOVAL
(1) Drain cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(2) Raise vehicle on hoist.
(3) Remove oil filter cap and filter (Refer to 9 -
ENGINE/LUBRICATION/OIL FILTER - REMOVAL).
(4) Remove oil filter housing retaining nut and
housing (Fig. 78).
(5) Disconnect coolant hoses at cooler (Fig. 79).
(6) Remove oil cooler retaining bolt at engine block
(Fig. 79).
(7) Remove oil cooler retaining stud and remove oil
cooler from engine block (Fig. 79).
INSTALLATION
(1) Clean oil cooler and engine block sealing sur-
faces.
Fig. 77 OIL PRESSURE RELIEF VALVE
INSTALLATION
1 - VM.1059
2 - OIL PRESSURE RELIEF VALVE
3 - ENGINE BLOCK
4 - OIL PUMP
Fig. 78 OIL FILTER HOUSING RETAINING NUT
1 - OIL FILTER HOUSING
2 - OIL FILTER HOUSING RETAINING NUT
3 - OIL COOLER
Fig. 79 WATER PUMP AND OIL COOLER
ASSEMBLIES
1 - WATER PUMP HOUSING STUDS
2 - WATER PUMP
3 - RETAINING NUTS
4 - OIL COOLER RETAINING STUD
5 - OIL COOLER TO ENGINE BLOCK RETAINING BOLT
6 - OIL COOLER COOLANT HOSE
7 - ENGINE BLOCK
9a - 50 ENGINERG
OIL PRESSURE RELIEF VALVE (Continued)
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(2) Install oil cooler, retaining bolt, and stud (Fig.
79). Torque retaining bolt to 47.1N´m and stud to
50N´m.
(3) Connect coolant hoses at cooler (Fig. 79).
(4) Install oil filter housing and retaining nut (Fig.
78). Torque retaining nut to 3.5 Kg.
(5) Install oil filter cartridge and oil filter cap
(Refer to 9 - ENGINE/LUBRICATION/OIL FILTER -
INSTALLATION).
(6) Lower vehicle.
(7) Refill cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(8) Start engine and check for leaks.
(9) Check and adjust oil level as necessary.
OIL FILTER
DESCRIPTION
The oil filter used on this engine is a cartridge
style filter (Fig. 80).
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove oil filter cap drain plug and drain oil
from oil filter housing (Fig. 81).
(3) Remove oil filter cap with suitable oil filter
wrench (Fig. 81).
(4) Remove oil filter cartridge from housing.
INSTALLATION
(1) Clean oil filter cap and drain plug with suit-
able solvent.
(2) Install new oil filter cartridge in oil filter hous-
ing.
(3) Install oil filter cap and drain plug
(4) Lower vehicle from hoist.
(5) Start engine and check for leaks.
(6) Check and adjust oil level as necessary.
Fig. 80 OIL FILTER ASSEMBLY
1 - OIL FILTER CAP
2 - DRAIN PLUG
3 - OIL FILTER CARTRIDGE
Fig. 81 OIL COOLER AND FILTER ASSEMBLY
1 - WATER PUMP HOUSING
2 - OIL FILTER HOUSING
3 - OIL FILTER CAP
4 - OIL FILTER CAP DRAIN PLUG
5 - OIL COOLER
RGENGINE9a-51
OIL COOLER & LINES (Continued)
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OIL JET
DESCRIPTION
There are four oil jets installed in the engine block.
These oil jets are used to cool and lubricate the pis-
ton assemblies (Fig. 82).
REMOVAL
CAUTION: Use caution when removing and install-
ing oil jets. Damage to oil jet nozzle could cause
severe engine damage.
(1) Disconnect negative battery cable.
(2) Raise vehicle on hoist.
(3) Remove oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - REMOVAL).
(4) Using special tool VM.1060 to hold oil jet.
Remove oil jet retaining bolt and remove oil jet from
engine block (Fig. 83).
INSTALLATION
CAUTION: Use caution when removing and installa-
ing oil jets. Damage to oil jet nozzle could cause
severe engine damage.
(1) Lubricate o-ring on oil jet.
(2) Using special tool VM.1060, install oil jet in
engine block (Fig. 83).
(3) Install oil jet retaining bolt. Torque bolt to
10.8N´m.
(4) Install oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION).
(5) Refill engine oil to proper level.
(6) Connect negative battery cable.
INTAKE MANIFOLD
DESCRIPTION
(Refer to 9 - ENGINE/CYLINDER HEAD/CYLIN-
DER HEAD COVER(S) - DESCRIPTION)
REMOVAL
(1) (Refer to 9 - ENGINE/CYLINDER HEAD/CYL-
INDER HEAD COVER(S) - REMOVAL)
INSTALLATION
(1) (Refer to 9 - ENGINE/CYLINDER HEAD/CYL-
INDER HEAD COVER(S) - INSTALLATION)
Fig. 82 OIL JET ASSEMBLY
1 - RETAINING BOLT
2 - OIL JET
3 - O-RING
Fig. 83 OIL JET REMOVAL/INSTALLATION
1 - SPECIAL TOOL VM.1060
2 - OIL JET
3 - CONNECTING ROD
4 - CRANKSHAFT
9a - 52 ENGINERG
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VALVE TIMING
STANDARD PROCEDURE - LOCKING ENGINE
90É AFTER TDC
(1) Disconnect negative battery cable.
(2) Remove starter motor (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - REMOVAL).
(3) Rotate engine untill notch in hub is in the fol-
lowing position (Fig. 84).
(4) Special tool VM.1068 can be install in engine
block as shown at this time (Fig. 85). This will lock
the engine at 90É after TDC.
(5) Remove front wiper unit (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
REMOVAL).
(6) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(7) Remove plug in cylinder head cover/intake
manifold and insert VM.1053 to lock exhaust cam-
shaft in position (Fig. 86).
(8) Remove generator (Refer to 8 - ELECTRICAL/
CHARGING/GENERATOR - REMOVAL).
Fig. 84 CRANKSHAFT HUB ALIGNMENT
1 - VIBRATION DAMPER/CRANKSHAFT PULLEY
2 - CRANKSHAFT HUB NOTCH
3 - VIBRATION DAMPER/CRANKSHAFT PULLEY TO
CRANKSHAFT HUB BOLTS
Fig. 85 TDC AND 90 DEGREES AFTER TDC
ALIGNMENT PIN LOCATION
1 - ENGINE BLOCK
2 - VM.1051 TDC PIN OR VM.1068 90 DEGREES ATDC PIN
3 - FLYWHEEL
Fig. 86 EXHAUST CAMSHAFT LOCKING PIN
VM.1053
1 - EXHAUST MANIFOLD HEAT SHIELD
2 - EXHAUST CAMSHAFT LOCKING PIN VM.1053
3 - COOLANT TUBE FROM THERMOSTAT HOUSING TO UPPER
RADIATOR HOSE
4 - CYLINDER HEAD COVER/INTAKE MANIFOLD
RGENGINE9a-53
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