battery CHRYSLER VOYAGER 2003 Service Manual

DIAGNOSIS AND TESTING - INTAKE
MANIFOLD LEAKS
An intake manifold air leak is characterized by
lower than normal manifold vacuum. Also, one or
more cylinders may not be functioning.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
(1) Start the engine.
(2) Spray a small stream of water (Spray Bottle) at
the suspected leak area.
(3) If engine RPM'S change, the area of the sus-
pected leak has been found.
(4) Repair as required.
INTAKE MANIFOLD - UPPER
STANDARD PROCEDURE
STANDARD PROCEDURE - MANIFOLD
STRIPPED THREAD REPAIR
The composite upper intake manifold thread
bosses, if stripped out, can be repaired by utilizing a
repair screw available through Mopartparts. Repair
screws are available for the following manifold
attached components:
²MAP sensor
²Power steering reservoir
²EGR tube
²Throttle cable bracket
The repair screws require a unique tightening
torque specification from the original screw. Refer to
the following chart for specification.
DESCRIPTION TORQUE*
STRIP-OUT REPAIR SCREWS ONLY
MAP Sensor Repair
Screw4 N´m (35 in. lbs.)
Power Steering Reservoir
Repair Screw9 N´m (80 in. lbs.)
EGR Tube Attaching
Repair Screw9 N´m (80 in. lbs.)
Throttle Cable Bracket
Repair Screw9 N´m (80 in. lbs.)
*Install Slowly Using Hand Tools Only
STANDARD PROCEDURE - INTAKE MANIFOLD
VACUUM PORT REPAIR
The composite intake manifold vacuum ports can
be repaired. Although, if the manifold plenum cham-
ber is damaged or cracked, the manifold must be
replaced.
To repair a broken or damaged vacuum nipple
(port) on the composite intake manifold, perform the
following procedure:
PARTS REQUIRED TOOLS REQUIRED
´ Brass Nipple ± 1/49
O.D. x 1/89pipe thread
(LDP/Speed Control Port)´ Pipe Tap ± 1/89-18
NPT
´ Drill Bit ± 11/329
´ File/Sandpaper
´ Brass Nipple ± 1/29
O.D. x 1/49pipe thread
(Brake Booster Port)´ Pipe Tap ± 1/49-18
NPT
´ Drill Bit ± 7/169
´ File/Sandpaper
NOTE: While performing this procedure, avoid get-
ting the manifold material residue into the plenum
chamber.
(1) File or sand the remaining port back until a
flat surface is obtained (plane normal to nipple (port)
axis).
(2) Drill out the nipple (port) base using a 7/16º
(brake booster port) or 11/32º (LDP/speed control port
) drill bit (Fig. 113).
(3) Using a 1/4º±18 NPT (brake booster port) or
1/8º±18 NPT (LDP/speed control port ) pipe tap, cut
internal threads (Fig. 113). Use caution to start tap
in a axis same as original nipple.
(4) Apply MopartThread Sealant to threads of
repair nipple(s).
(5) Install repair nipple(s). Do not over torque
repair nipple(s).
REMOVAL - UPPER INTAKE MANIFOLD
(1) Disconnect battery negative cable.
(2) Disconnect inlet air temperature (IAT) sensor
electrical connector.
(3) Remove air inlet resonator to throttle body
hose assembly.
(4) Disconnect throttle and speed control cables
from throttle body (Refer to 14 - FUEL SYSTEM/
FUEL INJECTION/THROTTLE CONTROL CABLE -
REMOVAL).
(5) Disconnect make-up air hose support clip from
throttle cable bracket.
(6) Disconnect the automatic idle speed (AIS)
motor and throttle position sensor (TPS) wiring con-
nectors from throttle body.
RSENGINE 3.3/3.8L9 - 145
INTAKE MANIFOLD (Continued)
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CAUTION: The special screws used for attaching
the EGR tube and power steering reservoir to the
manifold must be installed slowly using hand tools
only. This requirement is to prevent the melting of
material that causes stripped threads. If threads
become stripped, an oversize repair screw is avail-
able. For more information and procedure (Refer to
9 - ENGINE/MANIFOLDS/INTAKE MANIFOLD - STAN-
DARD PROCEDURE - MANIFOLD STRIPPED
THREAD REPAIR).
(7) Install the power steering reservoir (Fig. 115).
Tighten screws to manifold to 5.6 N´m (50 in. lbs.).
(8) Connect throttle and speed control cables to
throttle body (Refer to 14 - FUEL SYSTEM/FUEL
INJECTION/THROTTLE CONTROL CABLE -
INSTALLATION)
(9) Attach make up air hose clip into the hole in
the throttle cable bracket.
(10) Connect the wiring connectors to the throttle
position sensor (TPS) and Automatic Idle Speed (AIS)
motor.
(11) Install air cleaner and air inlet hose assembly.
(12) Connect the inlet air temperature (IAT) sen-
sor electrical connector.
(13) Connect battery negative cable.
INTAKE MANIFOLD - LOWER
REMOVAL - LOWER INTAKE MANIFOLD
(1) Perform fuel system pressure release procedure
(before attempting any repairs).(Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY - STANDARD
PROCEDURE)
(2) Drain the cooling system. (Refer to 7 - COOL-
ING - STANDARD PROCEDURE)
(3) Remove the upper intake manifold. (Refer to 9
- ENGINE/MANIFOLDS/INTAKE MANIFOLD -
REMOVAL)
(4) Remove the fuel line. (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/FUEL LINES - STANDARD
PROCEDURE) (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY/QUICK CONNECT FITTING - STAN-
DARD PROCEDURE)
(5) Remove ignition coil and bracket (Fig. 119).
(6) Disconnect heater supply hose and engine cool-
ant temperature sensor (Fig. 120).
(7) Disconnect the fuel injector wire harness.
(8) Remove the fuel injectors and rail assembly
(Fig. 119).
(9) Remove radiator upper hose.
(10) Remove the intake manifold bolts.
(11) Remove lower intake manifold (Fig. 121).WARNING: INTAKE MANIFOLD GASKET IS MADE
OF VERY THIN METAL AND MAY CAUSE PER-
SONAL INJURY, HANDLE WITH CARE.
(12) Remove intake manifold seal retainers screws
(Fig. 121). Remove intake manifold gasket.
(13) Inspect and clean manifold. (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSPECTION) (Refer to 9 - ENGINE/MANIFOLDS/
INTAKE MANIFOLD - CLEANING)
CLEANING
(1) Discard gasket(s).
(2) Clean all sealing surfaces.
INSPECTION
Check for:
²Damage and cracks of each section.
²Clogged water passages in end cross-overs (if
equipped).
Fig. 119 FUEL RAIL AND IGNITION COIL &
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
9 - 148 ENGINE 3.3/3.8LRS
INTAKE MANIFOLD - UPPER (Continued)
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²Check for cylinder head mounting surface distor-
tion using a straightedge and thickness gauge. (Refer
to 9 - ENGINE/CYLINDER HEAD - INSPECTION)
INSTALLATION - LOWER INTAKE MANIFOLD
(1) Place a bead (approximately 1/4 in. diameter)
of MopartEngine RTV GEN II onto each of thefour
manifold to cylinder head gasket corners (Fig. 122).
(2) Carefully install the new intake manifold gas-
ket (Fig. 121). Tighten end seal retainer screws to 12
N´m (105 in. lbs.).
(3) Install lower intake manifold (Fig. 121). Install
the bolts and torque to 1 N´m (10 in. lbs.). Then
torque bolts to 22 N´m (200 in. lbs.) in sequence
shown in (Fig. 123). Then torque again to 22 N´m
(200 in. lbs.). After intake manifold is in place,
inspect to make sure seals are in place.
(4) Install the fuel injectors and rail assembly.
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/
FUEL RAIL - INSTALLATION)
(5) Connect fuel injector electrical harness.
(6) Connect the engine coolant temperature sensor
(Fig. 120).
(7) Connect the heater supply (Fig. 120) and radi-
ator upper hoses to manifold.
(8) Connect the fuel line. (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/QUICK CONNECT FIT-
TING - STANDARD PROCEDURE)(9) Install the upper intake manifold. (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSTALLATION)
(10) Connect negative battery cable.
Fig. 120 ECT SENSOR & HEATER SUPPLY
1 - ENGINE COOLANT TEMPERATURE SENSOR
2 - CONNECTOR - ENGINE COOLANT SENSOR
3 - FITTING - HEATER SUPPLY
Fig. 121 INTAKE MANIFOLD - LOWER
1 - INTAKE MANIFOLD - LOWER
2 - BOLT - GASKET END SEAL RETAINER
3 - GASKET
4 - BOLT - LOWER INTAKE MANIFOLD
Fig. 122 Intake Manifold Gasket Sealing
1 - SEALER LOCATIONS
RSENGINE 3.3/3.8L9 - 149
INTAKE MANIFOLD - LOWER (Continued)
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(11) Fill the cooling system. (Refer to 7 - COOL-
ING - STANDARD PROCEDURE)
EXHAUST MANIFOLD - RIGHT
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove the wiper module. (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
REMOVAL)
(3) Disconnect spark plug wires.
(4) Remove bolts fastening crossover pipe to
exhaust manifold (Fig. 124).
(5) Disconnect and remove the upstream oxygen
sensor (Fig. 127).(6) Remove the heat shield attaching screws (Fig.
127).
(7) Remove the upper heat shield (Fig. 127).
(8) Raise vehicle on hoist and remove drive belt
shield.
(9) Loosen the power steering pump support strut
lower bolt (Fig. 125).
(10) Disconnect downstream oxygen sensor connec-
tor.
(11) Disconnect catalytic converter pipe from
exhaust manifold (Fig. 126).
Fig. 123 LOWER MANIFOLD TIGHTENING
SEQUENCE
Fig. 124 CROSS-OVER PIPE
1 - CROSS-OVER PIPE
2 - BOLT
3 - GASKET
4 - FLAG NUT
Fig. 125 P/S PUMP STRUT
1 - BOLT - LOWER
2 - STRUT - P/S PUMP
3 - BOLT - UPPER
Fig. 126 Catalytic Converter to Exhaust Manifold
1 - FLAG NUT
2 - GASKET
3 - BOLT
4 - CATALYTIC CONVERTER
9 - 150 ENGINE 3.3/3.8LRS
INTAKE MANIFOLD - LOWER (Continued)
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(12) Lower vehicle and remove the power steering
pump support strut upper bolt (Fig. 125).
(13) Remove bolts attaching exhaust manifold to
cylinder head and remove manifold (Fig. 127).
(14) Inspect and clean manifold. (Refer to 9 -
ENGINE/MANIFOLDS/EXHAUST MANIFOLD -
CLEANING) (Refer to 9 - ENGINE/MANIFOLDS/
EXHAUST MANIFOLD - INSPECTION)
CLEANING
(1) Discard gasket (if equipped) and clean all sur-
faces of manifold and cylinder head.
INSPECTION
Inspect exhaust manifolds for damage or cracks
and check distortion of the cylinder head mounting
surface and exhaust crossover mounting surface with
a straightedge and thickness gauge (Fig. 128).
Manifold surface flatness limits should not exceed
1.0 mm (0.039 in.).
INSTALLATION
(1) Position exhaust manifold on cylinder head and
install bolts to center runner (cylinder #3) and initial
tighten to 2.8 N´m (25 in. lbs.) (Fig. 127)
(2) Using a new gasket, attach crossover pipe to
exhaust manifold and tighten bolts to 41 N´m (30 ft.
lbs.) (Fig. 124).NOTE: Inspect crossover pipe fasteners for damage
from heat and corrosion. The cross-over bolts are
made of a special stainless steel alloy. If replace-
ment is required, OEM bolts are highly recom-
mended.
(3) Install the remaining manifold attaching bolts.
Tighten all bolts to 23 N´m (200 in. lbs.).
(4) Position the power steering pump support strut
and install upper bolt (Fig. 125).
(5) Install heat shield and attaching screws (Fig.
127).
(6) Install and connect upstream oxygen sensor
(Fig. 127).
(7) Raise the vehicle.
(8) Attach catalytic converter pipe to exhaust man-
ifold using new gasket and tighten bolts to 37 N´m
(27 ft. lbs.) (Fig. 126).
(9) Connect downstream oxygen sensor connector.
(10) Tighten the power steering pump support
strut lower bolt (Fig. 125).
(11) Install the belt splash shield and lower the
vehicle.
(12) Install the wiper module. (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
INSTALLATION)
(13) Connect battery negative cable.
Fig. 127 EXHAUST MANIFOLD - RIGHT
1 - SCREW - HEAT SHIELD
2 - HEAT SHIELD - UPPER
3 - BOLT - EXHAUST MANIFOLD
4 - HEAT SHIELD - LOWER
5 - EXHAUST MANIFOLD - RIGHT
6 - OXYGEN SENSOR - UPSTREAM
Fig. 128 Check Exhaust Manifold Mounting
1 - STRAIGHT EDGE
2 - CROSSOVER PIPE MOUNTING SURFACE
3 - FEELER GAUGE
RSENGINE 3.3/3.8L9 - 151
EXHAUST MANIFOLD - RIGHT (Continued)
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EXHAUST MANIFOLD - LEFT
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove bolts attaching crossover pipe to
exhaust manifold (Fig. 129).
(3) Disconnect left cylinder bank spark plug wires.
(4) Remove heat shield attaching bolts (Fig. 130).
(5) Remove bolts attaching exhaust manifold to
cylinder head (Fig. 130).
(6) Remove the exhaust manifold (Fig. 130).(7) Inspect and clean manifold. (Refer to 9 -
ENGINE/MANIFOLDS/EXHAUST MANIFOLD -
INSPECTION) (Refer to 9 - ENGINE/MANIFOLDS/
EXHAUST MANIFOLD - CLEANING)
CLEANING
(1) Discard gasket (if equipped) and clean all sur-
faces of manifold and cylinder head.
INSPECTION
Inspect exhaust manifolds for damage or cracks
and check distortion of the cylinder head mounting
surface and exhaust crossover mounting surface with
a straightedge and thickness gauge (Fig. 131).
Manifold surface flatness limits should not exceed
1.0 mm (0.039 in.).
INSTALLATION
(1) Position exhaust manifold on cylinder head
(Fig. 130). Install bolts to center runner (cylinder #4)
and initial tighten to 2.8 N´m (25 in. lbs.).
(2) Using a new gasket, attach crossover pipe to
exhaust manifold and tighten bolts to 41 N´m (30 ft.
lbs.) (Fig. 129).
NOTE: Inspect crossover pipe fasteners for damage
from heat and corrosion. The cross-over bolts are
made of a special stainless steel alloy. If replace-
ment is required, OEM bolts are highly recom-
mended.
(3) Position heat shield on manifold (Fig. 130).
(4) Install the remaining manifold attaching bolts.
Tighten all bolts to 23 N´m (200 in. lbs.).
(5) Install and tighten heat shield attaching nut to
12 N´m (105 in. lbs.) (Fig. 130).
(6) Connect battery negative cable.
Fig. 129 CROSS-OVER PIPE
1 - CROSS-OVER PIPE
2 - BOLT
3 - GASKET
4 - FLAG NUT
Fig. 130 EXHAUST MANIFOLD - LEFT
1 - EXHAUST MANIFOLD - LEFT BANK
2 - HEAT SHIELD
3 - NUT - HEAT SHIELD
4 - BOLT - EXHAUST MANIFOLD
Fig. 131 Check Exhaust Manifold Mounting
1 - STRAIGHT EDGE
2 - CROSSOVER PIPE MOUNTING SURFACE
3 - FEELER GAUGE
9 - 152 ENGINE 3.3/3.8LRS
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VALVE TIMING
STANDARD PROCEDURE
STANDARD PROCEDURE - VALVE TIMING
VERIFICATION
(1) Remove front cylinder head cover and all 6
spark plugs.
(2) Rotate engine until the #2 piston is at TDC of
the compression stroke.
(3) Install a degree wheel on the crankshaft pulley.
(4) With proper adaptor, install a dial indicator
into #2 spark plug hole. Using the indicator find TDC
on the compression stroke.
(5) Position the degree wheel to zero.
(6) Remove dial indicator from spark plug hole.
(7) Place a 5.08 mm (0.200 in.) spacer between the
valve stem tip of #2 intake valve and rocker arm pad.
Allow tappet to bleed down to give a solid tappet
effect.
(8) Install a dial indicator so plunger contacts the
#2 intake valve spring retainer as nearly perpendic-
ular as possible. Zero the indicator.
(9) Rotate the engine clockwise until the intake
valve has lifted .254 mm (0.010 in.).
CAUTION: Do not turn crankshaft any further clock-
wise as intake valve might bottom and result in
serious damage.
(10) Degree wheel should read 6 degrees BTDC to
6 degrees ATDC.
STANDARD PROCEDURE - MEASURING
TIMING CHAIN WEAR
NOTE: This procedure must be performed with the
timing chain cover removed (Refer to 9 - ENGINE/
VALVE TIMING/TIMING CHAIN COVER - REMOVAL).
(1) Position a scale next to timing chain so that
any movement of chain may be measured (Fig. 132).
(2) Position a torque wrench and socket on the
camshaft sprocket attaching bolt. Apply force in the
direction of crankshaft rotation to take up slack to
the following torque:
²41 N´m (30 ft. lb.) with cylinder heads installed
²20 N´m (15 ft. lb.) with cylinder heads removed
NOTE: With torque applied to the camshaft
sprocket bolt, crankshaft should not be permitted to
move. It may be necessary to block crankshaft to
prevent rotation.
(3) Holding a measuring scale along edge of chain
links (Fig. 132).(4) Apply force in the reverse direction to the fol-
lowing torque:
²41 N´m (30 ft. lb.) with cylinder heads installed
²20 N´m (15 ft. lb.) with cylinder heads removed
(5) Measure amount of sprocket/chain movement.
(6) Install a new timing chain and sprockets if
movement exceeds 3.175 mm (1/8 in.).
TIMING CHAIN COVER
REMOVAL
(1) Disconnect negative cable from battery.
(2) Drain cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(3) Raise vehicle on hoist.
(4) Drain engine oil.
(5) Remove right wheel and inner splash shield.
(6) Remove oil pan. (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - REMOVAL)
(7) Remove oil pick-up tube (Fig. 133).
(8) Remove accessory drive belt. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)
(9) Remove A/C compressor and set aside.
(10) Remove crankshaft vibration damper. (Refer
to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL)
(11) Remove radiator lower hose.
(12) Remove heater hose from timing chain cover
housing (Fig. 134) or water pump inlet tube (if
engine oil cooler equipped) (Fig. 135).
(13) Remove the right side engine mount. (Refer to
9 - ENGINE/ENGINE MOUNTING/RIGHT MOUNT
- REMOVAL)
(14) Remove idler pulley from engine bracket (Fig.
136).
(15) Remove the engine mount bracket (Fig. 136).
Fig. 132 Measuring Timing Chain Wear
1 - TORQUE WRENCH
RSENGINE 3.3/3.8L9 - 153
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(17) Remove the water pump for cover removal
clearance. (Refer to 7 - COOLING/ENGINE/WATER
PUMP - REMOVAL)
(18) Remove the bolt attaching the power steering
pump support strut to the front cover (Fig. 137).
(19) Remove the timing chain cover fasteners.
Remove timing chain cover (Fig. 138).
INSTALLATION
(1) Be sure mating surfaces of chain case cover
and cylinder block are clean and free from burrs.
Crankshaft oil seal must be removed to insure cor-
rect oil pump engagement.
NOTE: DO NOT USE SEALER ON COVER GASKET
(2) Position new gasket on timing cover (Fig. 138).
Adhere new gasket to chain case cover, making sure
that the lower edge of the gasket is flush to 0.5 mm
(0.020 in.) passed the lower edge of the cover.
(3) Rotate crankshaft so that the oil pump drive
flats are in the vertical position.
(4) Position oil pump inner rotor so the mating
flats are in the same position as the crankshaft drive
flats (Fig. 138).
CAUTION: Make sure the oil pump is engaged on
the crankshaft correctly or severe damage may
result.
(5) Install timing cover (Fig. 138).
(6) Install timing chain cover bolts. Tighten M8
bolts to 27 N´m (20 ft. lbs.) and M10 bolts to 54 N´m
(40 ft. lbs.) (Fig. 139).
(7) Install crankshaft front oil seal. (Refer to 9 -
ENGINE/ENGINE BLOCK/CRANKSHAFT OIL
SEAL - FRONT - INSTALLATION)
(8) Install water pump and pulley. (Refer to 7 -
COOLING/ENGINE/WATER PUMP - INSTALLA-
TION)(9) Install crankshaft vibration damper. (Refer to 9
- ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
INSTALLATION)
(10) Install engine mount bracket (Fig. 136) and
tighten M10 to 54 N´m (40 ft. lbs.), M8 bolt to 28
N´m (21 ft. lb. lbs.).
(11) Install idler pulley on engine mount bracket
(Fig. 136).
(12) Install right side engine mount. (Refer to 9 -
ENGINE/ENGINE MOUNTING/RIGHT MOUNT -
INSTALLATION)
(13) Install camshaft position sensor (Refer to 8 -
ELECTRICAL/IGNITION CONTROL/CAMSHAFT
POSITION SENSOR - INSTALLATION).
(14) Connect the heater return hose at rear of tim-
ing chain cover (Fig. 134) or at water pump inlet
tube (if engine oil cooler equipped) (Fig. 135).
(15) Connect the radiator lower hose.
(16) Install A/C compressor.
(17) Install accessory drive belt. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION)
(18) Install oil pump pick-up tube with new
O-ring. Tighten attaching bolt to 28 N´m (250 in.
lbs.).
(19) Install oil pan. (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION)
(20) Install inner splash shield and right front
wheel.
(21) Fill crankcase with engine oil to proper level.
(22) Fill cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(23) Connect negative cable to battery.
Fig. 137 Power Steering Pump Strut
1 - BOLT - LOWER
2 - STRUT - P/S PUMP
3 - BOLT - UPPER
Fig. 138 Timing Chain Cover and Gasket
1 - GASKET
2 - TIMING CHAIN COVER
RSENGINE 3.3/3.8L9 - 155
TIMING CHAIN COVER (Continued)
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TIMING CHAIN AND
SPROCKETS
REMOVAL
REMOVAL - TIMING CHAIN AND CAMSHAFT
SPROCKET
(1) Disconnect negative cable from battery.
(2) Remove the timing chain cover. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL)
(3) Rotate engine by turning crankshaft until the
timing marks are aligned as shown in (Fig. 140).
(4) Remove camshaft sprocket attaching bolt.
(5) Remove the timing chain with camshaft
sprocket.(6) Remove the crankshaft sprocket. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - REMOVAL)
REMOVAL - CRANKSHAFT SPROCKET
(1) Remove the timing chain. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - REMOVAL)
(2) Using Special Tools 8539, 5048-6, and 5048-1,
remove the crankshaft sprocket while holding the
crankshaft from turning (Fig. 141). Be careful not to
damage the crankshaft surfaces.
INSTALLATION
INSTALLATION - CRANKSHAFT SPROCKET
(1) Position the sprocket on the crankshaft (timing
mark out) with the timing slot aligned with the tim-
ing pin.
Fig. 139 TIMING CHAIN COVER BOLT LOCATIONS
1 - BOLT - M8 x 1.25 x 95 4 - BOLT - M8 x 1.25 x 80
2 - BOLT - M10 x 1.5 x 100 5 - BOLT - M8 x 1.25 x 45
3 - BOLT - M10 x 1.5 x 85
9 - 156 ENGINE 3.3/3.8LRS
TIMING CHAIN COVER (Continued)
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(2) Install sprocket using Special Tool 8452 (Fig.
142). Install sprocket until it is fully seats on the
crankshaft.(3) Install the timing chain and camshaft sprocket.
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT/CHAIN AND SPROCKETS - INSTALLATION)
INSTALLATION - TIMING CHAIN AND
CAMSHAFT SPROCKET
(1) Rotate crankshaft so the timing arrow is to the
12 o'clock position (Fig. 140).
NOTE: Lubricate timing chain and sprockets with
clean engine oil before installation.
(2) While holding camshaft sprocket and chain in
hand, place timing chain around the sprocket, align-
ing the plated link with the dot on the sprocket. Posi-
tion the timing arrow to the 6 o'clock position (Fig.
140).
(3) Place timing chain around crankshaft sprocket
with the plated link lined up with the dot on the
sprocket. Install camshaft sprocket into position.
(4) Use a straight edge to check alignment of tim-
ing marks.
(5) Install camshaft sprocket bolt and washer.
Tighten bolt to 54 N´m (40 ft. lbs.).
(6) Rotate crankshaft 2 revolutions and check tim-
ing mark alignment (Fig. 140). If timing marks do
not line up, remove camshaft sprocket and realign.
(7) Install the timing chain cover. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION)
(8) Connect negative cable to battery.
Fig. 140 Timing Mark Alignment
1 - CAMSHAFT SPROCKET TIMING MARK (DOT)
2 - PLATED LINK
3 - CRANKSHAFT SPROCKET TIMING MARK (DOT)
4 - ARROWS
Fig. 141 CRANKSHAFT SPROCKET - REMOVAL
1 - SPECIAL TOOL 5048-6
2 - SPECIAL TOOL 5048-1
3 - SPECIAL TOOL 8450
4 - CRANKSHAFT SPROCKET
5 - SPECIAL TOOL 8539
Fig. 142 CRANKSHAFT SPROCKET - INSTALLATION
1 - SPECIAL TOOL 8452-3
2 - SPECIAL TOOL 8452-1
3 - CRANKSHAFT SPROCKET
4 - THRUST BEARING / WASHER
RSENGINE 3.3/3.8L9 - 157
TIMING CHAIN AND SPROCKETS (Continued)
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