water pump CHRYSLER VOYAGER 2004 Owner's Manual

(5) Install the radiator upper hose.
(6) Fill the cooling system. (Refer to 7 - COOLING
- STANDARD PROCEDURE)
WATER PUMP INLET TUBE -
3.3/3.8L
REMOVAL
(1) Drain the cooling system. (Refer to 7 - COOL-
ING - STANDARD PROCEDURE)
(2) Raise vehicle on hoist and remove the belt
splash shield.
(3) Remove the radiator lower hose from inlet tube
(Fig. 34).
(4) Remove the oil cooler outlet/heater return hose
from inlet tube (only if equipped with engine oil
cooler) (Fig. 35).
(5) Remove the inlet tube bolts (Fig. 36).
(6) Remove the inlet tube (Fig. 36). Discard the
O-ring seal.
INSTALLATION
(1) Clean the inlet tube O-ring sealing surfaces on
the timing cover housing and tube.
(2) Apply MopartDielectric Grease or equivalent
to the O-ring before installation.
(3) Position new O-ring seal on inlet tube (Fig. 36).
(4) Install the inlet tube (Fig. 36). Tighten bolts to
28 N´m (250 in. lbs.).(5) Connect radiator lower hose (Fig. 34) and
heater return hose (if equipped with engine oil
cooler) (Fig. 35) to the inlet tube.
(6) Install the drive belt splash shield and lower
vehicle.
(7) Fill the cooling system. (Refer to 7 - COOLING
- STANDARD PROCEDURE)
Fig. 34 RAD HOSES TO ENGINE - 3.3/3.8L
1 - UPPER HOSE
2 - LOWER HOSE
Fig. 35 Engine Oil Cooler Hoses (Engine Oil Cooler
Equipped)
1 - OIL COOLER INLET TUBE
2 - INLET HOSE
3 - OIL COOLER OUTLET TUBE
4 - OUTLET HOSE
5 - WATER PUMP INLET TUBE
Fig. 36 WATER PUMP INLET TUBE
1 - TIMING CHAIN COVER
2 - INLET TUBE
3 - BOLT
4 - BOLT
5 - O-RING
7 - 36 ENGINERS
WATER PUMP INLET TUBE - 2.4L (Continued)

FRONT WASHER PUMP
MOTOR
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the engine fresh air housing inside the
engine compartment (Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER HOUSING -
REMOVAL).
(3) Disconnect the washer hose at the in-line con-
nector forward of the cowl grille so that the in-line
connector remains with the washer hose from the
fresh air plenum.
(4) Disconnect the washer hose from the hose clip
located on the front fender side shield.
(5) Remove the filler tube screw.
(6) Hoist and support vehicle on hoist or jack
stands.
(7) Remove the right front wheel and tire assembly
(Refer to 22 - TIRES/WHEELS - REMOVAL).
(8) Disconnect the left right front wheelhouse
splash shield and move aside (Refer to 23 - BODY/
EXTERIOR/WHEELHOUSE SPLASH SHIELD -
REMOVAL).
(9) Drain washer fluid from the reservoir and into
a suitable clean container. This can be done by dis-
connecting the windshield washer hose from the
front (outboard) washer pump and allowing the
washer fluid to drain into a container through a tem-
porary jumper hose connected to the front washer
pump.
(10) Disconnect the electrical body harness connec-
tors to the washer pump motors and the fluid level
sensor. Slide the red lock on the connector to the
release position, then, depress the black tab and pull
the connector off the pump or sensor.
(11) Remove the two reservoir mounting screws.
(12) Disconnect the reservoir from the body mount
by raising the reservoir upward slightly and then
down so that the reservoir filler neck and front
washer hose pull through the opening in the front
fender side shield.
(13) Remove pump from reservoir by pulling pump
upper retention tab away from reservoir cavity and
then lifting pump up from mounting grommet. Do
not damage reservoir/pump sealing surface or punc-
ture reservoir during removal.
(14) Remove pump grommet and discard.
INSTALLATION
(1) Use new grommet when installing a new pump
assembly.
(2) Assure pump upper retention tab is pressed
into reservoir slot and that pump is rotated flatagainst the reservoir and that pump connector is fac-
ing up in the fully seated position. Assure the pump
is aligned to and fully seated in the reservoir cavity.
(3) Push filler neck and front washer hose through
the opening in the front fender side shield. Connect
the reservoir to the body mount by lowering the res-
ervoir down.
(4) Install the two reservoir mounting screws.
Torque screws to 8.5 - 11.3 N´m (75 - 100 in. lbs.).
(5) Connect the electrical body harness connectors
to the washer pump motors and the fluid level sen-
sor. Slide the red lock on the connector to the closed
or locked position.
(6) Assure that washer hose is properly routed to
prevent pinching and possible inoperative washers.
(7) Connect the left right front wheelhouse splash
shield and move aside (Refer to 23 - BODY/EXTERI-
OR/WHEELHOUSE SPLASH SHIELD - INSTALLA-
TION).
(8) Install the right front wheel and tire assembly
(Refer to 22 - TIRES/WHEELS - INSTALLATION).
(9) lower vehicle from hoist or jack stands.
(10) Install the filler tube screw. Torque screw to
8.5 - 11.3 N´m (75 - 100 in. lbs.).
(11) Connect the washer hose to the hose clip
located on the front fender side shield.
(12) Connect the washer hose at the in-line con-
nector forward of the cowl grille.
(13) Install the engine fresh air housing inside the
engine compartment (Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER HOUSING -
INSTALLATION).
(14) Connect the battery negative cable.
(15) Verify system operation.
FRONT WIPER ARMS
STANDARD PROCEDURE - FRONT WIPER ARM
ALIGNMENT
(1) Verify wiper blade element condition and wiper
arm spring tension. Run wipers in low speed mode
while applying water to the windshield. Observe the
wiper blade that is chattering or skipping across the
windshield. If the wiper element is not rolling over
when the wiper direction reverses, align the wiper
arm. The extension bar portion of the wiper arm
must be twisted in the proper direction to allow the
wiper element to roll over when the direction
reverses.
(2) Place two small adjustable wrenches placed 50
mm (2 in.) apart on the wiper arm extension rod.
(3) Twist the extension rod slightly in the opposite
direction that the element is laying on the wind-
shield while holding the wrench closest to the pivot
stationary.
8R - 8 WIPERS/WASHERSRS

Component Page
Impact Sensors....................... 8W-43
Inlet Air Temperature Sensor............ 8W-30
Instrument Cluster.................... 8W-40
Instrument Panel Switch
Bank.................. 8W-43, 44, 52, 53, 63
Integrated Power Module............... 8W-10
Intrusion Sensors..................... 8W-39
Knock Sensor........................ 8W-30
Lamp Assemblies...................... 8W-51
License Lamp..................... 8W-51, 61
Lift Pump Motor...................... 8W-30
Lift Pump Relay...................... 8W-30
Liftgate Ajar Switch................ 8W-39, 61
Liftgate Cinch/Release Motor............ 8W-61
Liftgate Flood Lamps.................. 8W-44
Liftgate Pinch Sensors................. 8W-61
Low Beam Lamps..................... 8W-50
Low Note Horn....................... 8W-41
Manifold Absolute Pressure Sensor........ 8W-30
Mass Air Flow Sensor.................. 8W-30
Memory Seat/Mirror Module.......... 8W-62, 63
Memory Set Switch.................... 8W-63
Message Center....................... 8W-46
Mid Reading Lamps................... 8W-44
Mode Door Actuator................... 8W-42
Multi-Function Switch............ 8W-50, 52, 53
Name Brand Speaker Relay............. 8W-47
Natural Vacuum Leak Detection Assembly . . 8W-30
Overhead Console..................... 8W-49
Oxygen Sensors....................... 8W-30
Park Lamp Relay..................... 8W-10
Park Lamps.......................... 8W-50
Park/Turn Signal Lamps................ 8W-50
Parking Brake Switch.................. 8W-40
Power Folding Mirror Switch............ 8W-62
Power Liftgate Module................. 8W-61
Power Liftgate Motor.................. 8W-61
Power Mirror Switch................... 8W-62
Power Mirrors........................ 8W-62
Power Outlet......................... 8W-41
Power Seat Circuit Breaker.............. 8W-10
Power Seat Motors.................... 8W-63
Power Seat Position Sensors............. 8W-63
Power Seat Switches................... 8W-63
Power Window Circuit Breaker........... 8W-10
Power Window Motors.................. 8W-60
Power Window Switches................ 8W-60
Powertrain Control Module.............. 8W-30
PTCs............................... 8W-10
Radiator Fan Relays................... 8W-42
Radiator Fans........................ 8W-42
Radio............................... 8W-47
Reading Lamps....................... 8W-44Component Page
Rear A/C-Heater Unit.................. 8W-42
Rear Auto Temp Control Switch.......... 8W-42
Rear Blower Front Control Switch........ 8W-42
Rear Blower Motor Power Module......... 8W-42
Rear Blower Rear Control Switch......... 8W-42
Rear Dome Lamp..................... 8W-44
Rear Mode Motor..................... 8W-42
Rear Power Outlet..................... 8W-41
Rear Temperature Motor................ 8W-42
Rear Window Defogger Grid............. 8W-48
Rear Wiper Motor..................... 8W-53
Rear Wiper/Washer Indicator............ 8W-53
Rear Wiper/Washer Switch.............. 8W-53
Recirculation Door Actuator............. 8W-42
Remote Keyless Entry Antenna........ 8W-39, 61
Remote Radio Switches................. 8W-47
Repeater Lamps...................... 8W-52
Seat Belt Switch...................... 8W-43
Seat Belt Tensioners................... 8W-43
Sentry Key Remote Entry Module...... 8W-39, 61
Siren............................... 8W-39
Sliding Door Control Modules............ 8W-61
Sliding Door Latch Sensing Switches...... 8W-61
Sliding Door Lock Motor/Ajar Switches..... 8W-61
Sliding Door Lock Motors............... 8W-61
Sliding Door Motors................... 8W-61
Speakers............................ 8W-47
Speed Control Servo................... 8W-33
Speed Control Switches................. 8W-33
Speed Sensors........................ 8W-31
Splices.............................. 8W-70
Starter Motor........................ 8W-21
Starter Motor Relay................... 8W-21
Sunroof Module....................... 8W-64
Sunroof Switch....................... 8W-64
Thatcham Alarm Indicator.............. 8W-39
Thatcham Alarm Module................ 8W-39
Throttle Position Sensor................ 8W-30
Traction Control Switch................. 8W-35
Trailer Tow Connector.................. 8W-54
Transmission Control Relay............. 8W-31
Transmission Range Sensor.............. 8W-31
Transmission Solenoid/Pressure Switch
Assembly.......................... 8W-31
Turn Signal Lamps.................... 8W-52
Vehicle Speed Sensor................... 8W-30
Vent Motors.......................... 8W-60
Visor/Vanity Lamps.................... 8W-44
Washer Fluid Level Switch.............. 8W-53
Washer Pump Motor................... 8W-53
Water In Fuel Sensor.................. 8W-30
Wheel Speed Sensors................... 8W-35
Wiper Module........................ 8W-53
8W - 02 - 2 8W-02 COMPONENT INDEXRS

8W-30 FUEL/IGNITION SYSTEM
Component Page
A/C Compressor Clutch.............. 8W-30-24
A/C Compressor Clutch Relay........ 8W-30-4, 24
A/C Pressure Sensor........... 8W-30-14, 19, 31
Accelerator Pedal Position Sensor...... 8W-30-38
Adjustable Pedals Module............ 8W-30-23
Adjustable Pedals Motor.............. 8W-30-23
Adjustable Pedals Relay.............. 8W-30-22
Adjustable Pedals Sensor............. 8W-30-23
Adjustable Pedals Switch............. 8W-30-22
Ambient Temperature Sensor........... 8W-30-8
Auto Shut Down Relay.... 8W-30-4, 12, 15, 17, 20
Battery........... 8W-30-2, 6, 10, 16, 21, 24, 32
Battery Temperature Sensor......... 8W-30-8, 31
Body Control Module.............. 8W-30-5, 25
Boost Pressure Sensor............... 8W-30-31
Brake Lamp Switch............ 8W-30-7, 27, 37
Cabin Heater Assist................. 8W-30-28
Camshaft Position Sensor........... 8W-30-8, 30
Clockspring................... 8W-30-5, 29, 36
Clutch Pedal Interlock Switch.......... 8W-30-4
Clutch Pedal Upstop Switch........... 8W-30-36
Crank Case Ventilation Heater......... 8W-30-25
Crankshaft Position Sensor...... 8W-30-13, 18, 30
Data Link Connector.............. 8W-30-3, 28
Dosing Pump...................... 8W-30-28
ECM/PCM Relay........ 8W-30-24, 26, 30, 32, 34
EGR Solenoid................... 8W-30-16, 34
Engine Control Module . . . 8W-30-24, 25, 26, 27, 28,
29, 30, 31, 32, 33, 34, 35, 36, 37, 38
Engine Coolant Temp Sensor.... 8W-30-14, 19, 31
Engine Oil Pressure Sensor........... 8W-30-27
Engine Oil Pressure Switch............ 8W-30-7
EVAP/Purge Solenoid................. 8W-30-4
Front Control Module...... 8W-30-2, 5, 22, 28, 36
Fuel Heater....................... 8W-30-35
Fuel Heater Relay................ 8W-30-25, 35
Fuel Injector No. 1............ 8W-30-15, 20, 33
Fuel Injector No. 2............ 8W-30-15, 20, 33
Fuel Injector No. 3............ 8W-30-15, 20, 33
Fuel Injector No. 4............ 8W-30-15, 20, 33
Fuel Injector No. 5.................. 8W-30-20
Fuel Injector No. 6.................. 8W-30-20
Fuel Pressure Sensor................ 8W-30-37
Fuel Pressure Solenoid............... 8W-30-26
Fuel Pump Module................ 8W-30-5, 25
Fuel Pump Relay.................... 8W-30-5
Fuse 14........................... 8W-30-22
Fuse 15..................... 8W-30-21, 28, 35
Fuse 16 . . 8W-30-4, 12, 15, 17, 20, 24, 26, 30, 32, 34
Fuse 17.................... 8W-30-2, 5, 25, 35
Fuse 18........................ 8W-30-22, 24
Fuse 26........................... 8W-30-37Component Page
Fuselink.......................... 8W-30-32
G100................... 8W-30-2, 6, 16, 21, 25
G101.............. 8W-30-2, 6, 7, 10, 16, 21, 24
G103....................... 8W-30-24, 25, 28
G200............................. 8W-30-22
G300................... 8W-30-4, 7, 23, 27, 36
G302........................ 8W-30-5, 25, 35
Generator....................... 8W-30-4, 25
Glow Plug No. 1.................... 8W-30-32
Glow Plug No. 2.................... 8W-30-32
Glow Plug No. 3.................... 8W-30-32
Glow Plug No. 4.................... 8W-30-32
Glow Plug Relay.................... 8W-30-32
Idle Air Control Motor................ 8W-30-9
Ignition Coil.................... 8W-30-12, 17
Ignition Switch..................... 8W-30-10
Inlet Air Temperature Sensor....... 8W-30-13, 18
Input Speed Sensor................. 8W-30-21
Integrated Power Module . . 8W-30-2, 3, 4, 5, 10, 12,
15, 17, 20, 21, 22, 24, 25,
26, 28, 30, 32, 34, 35, 36, 37
Knock Sensor....................... 8W-30-9
Left Speed Control Switch.......... 8W-30-5, 29
Lift Pump Motor.................... 8W-30-35
Lift Pump Relay.................... 8W-30-35
Manifold Absolute Pressure Sensor . . . 8W-30-14, 19
Mass Air Flow Sensor................ 8W-30-26
Memory Seat/Mirror Module.......... 8W-30-22
Natural Vacuum Leak Detection
Assembly....................... 8W-30-10
Output Speed Sensor................ 8W-30-21
Oxygen Sensor 1/1 Upstream........... 8W-30-6
Oxygen Sensor 1/2 Downstream......... 8W-30-6
Powertrain Control Module . . 8W-30-2, 3, 4, 5, 6, 7,
8, 9, 10, 11, 12, 13, 14, 15,
16, 17, 18, 19, 20, 21
Radiator Fan Relay............... 8W-30-12, 17
Radiator Fan Relay No. 1............. 8W-30-37
Radiator Fan Relay No. 2............. 8W-30-37
Radiator Fan Relay No. 3............. 8W-30-37
Right Speed Control Switch......... 8W-30-5, 29
Speed Control Servo.................. 8W-30-7
Starter Motor Relay............... 8W-30-5, 25
Throttle Position Sensor........... 8W-30-13, 18
Transmission Control Relay........... 8W-30-21
Transmission Range Sensor........... 8W-30-11
Transmission Solenoid/Pressure Switch
Assembly..................... 8W-30-11, 21
Vehicle Speed Sensor.............. 8W-30-9, 34
Water In Fuel Sensor................ 8W-30-36
RS8W-30 FUEL/IGNITION SYSTEM8W-30-1

Component Page
Right Front Door Lock Motor/Ajar Switch (Except
Base).......................... 8W-80-122
Right Front Impact Sensor (Except
Export)........................ 8W-80-122
Right Front Park/Turn Signal Lamp (Except
Export)........................ 8W-80-123
Right Front Wheel Speed Sensor...... 8W-80-123
Right Full Open Switch (Power Sliding
Door).......................... 8W-80-123
Right Headlamp (Except Export)...... 8W-80-123
Right Headlamp Leveling Motor
(Export)....................... 8W-80-124
Right High Beam Lamp (Export)...... 8W-80-124
Right Instrument Panel Speaker...... 8W-80-124
Right Liftgate Flood Lamp........... 8W-80-124
Right Low Beam Lamp (Export)....... 8W-80-125
Right Mid Reading Lamp (Premium/
Luxury)........................ 8W-80-125
Right Park Lamp (Export)........... 8W-80-125
Right Power Mirror................ 8W-80-125
Right Rear Lamp Assembly.......... 8W-80-126
Right Rear Pillar Speaker........... 8W-80-126
Right Rear Reading Lamp (Luxury).... 8W-80-126
Right Rear Speaker (Lowline)......... 8W-80-126
Right Rear Speaker (Highline)........ 8W-80-127
Right Rear Vent Motor.............. 8W-80-127
Right Rear Wheel Speed Sensor....... 8W-80-127
Right Remote Radio Switch.......... 8W-80-127
Right Repeater Lamp (Export)........ 8W-80-128
Right Seat Airbag.................. 8W-80-128
Right Side Impact Sensor 1 (Premium
ORC).......................... 8W-80-128
Right Sliding Door Control Module C1 (Power
Sliding Door)................... 8W-80-128Component Page
Right Sliding Door Control Module C2 (Power
Sliding Door)................... 8W-80-129
Right Sliding Door Latch Sensing Switch (Power
Sliding Door)................... 8W-80-129
Right Sliding Door Lock Motor (Power Sliding
Door).......................... 8W-80-129
Right Sliding Door Lock Motor/Ajar Switch (Manual
Sliding Door)................... 8W-80-130
Right Sliding Door Motor (Power Sliding
Door).......................... 8W-80-130
Right Speed Control Switch.......... 8W-80-130
Right Turn Signal Lamp (Export)...... 8W-80-130
Right Visor/Vanity Lamp (Premium/Luxury Except
Export)........................ 8W-80-131
Sentry Key Remote Entry Module
(SKREEM)..................... 8W-80-131
Siren (United Kingdom)............. 8W-80-131
Speed Control Servo (Gas)........... 8W-80-131
Sunroof Module (Except Export)....... 8W-80-132
Sunroof Switch (Except Export)....... 8W-80-132
Thatcham Alarm Module (United
Kingdom)...................... 8W-80-132
Throttle Position Sensor (Gas)........ 8W-80-133
Traction Control Switch............. 8W-80-133
Trailer Tow Connector (Except Export) . . 8W-80-133
Transmission Range Sensor.......... 8W-80-133
Transmission Solenoid/Pressure Switch
Assembly...................... 8W-80-134
Vehicle Speed Sensor (MTX).......... 8W-80-134
Washer Fluid Level Switch........... 8W-80-134
Washer Pump Motor................ 8W-80-134
Water In Fuel Sensor (Diesel)......... 8W-80-135
Wiper Module..................... 8W-80-135
RS8W-80 CONNECTOR PIN-OUTS8W-80-5

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Sentry Key Remote Entry Module
(Skreem)BK At Steering Column 20, 21, 22, 23, 31
Siren (United Kingdom) BK Left Front Body N/S
Speed Control Servo (Gas) BK Near Controller Antilock Brake 11, 17, 18
Sunroof Module (Except Export) BK At Sunroof N/S
Sunroof Switch (Except Export) Nat Near Overhead Console N/S
Thatcham Alarm Module C1
(United Kingdom)BK Top Right Side of Instrument Panel
Near SpeakerN/S
Throttle Position Sensor (Gas) GY On Throttle Body 10, 11, 17
Traction Control Switch BK Rear of Swtich 21, 22, 31
Trailer Tow Connector (Except
Export)BK Left Quarter Panel N/S
Transmission Range Sensor DKGY Top of Transmission 14, 19
Transmission Solenoid/Pressure
Switch AssemblyBK Side of Transmission 14, 18 19
Vehicle Speed Sensor (MTX) BK Rear of Transmission 16
Washer Fluid Level Switch BK Bottom of Reservoir 3
Washer Pump Motor BK Right Fender Well 3
Water in Fuel Sensor (Diesel) BK Left Rear Engine Compartment N/S
Wiper Module DKGY Left Side Cowl 6
GROUNDS
GROUND NUMBER LOCATION FIG.
G100 Body Ground Near Powertrain Control Module N/S
G101 Above Starter 13, 18
G102 Left Headlamp Area 1
G103 Above Starter 15
G200 Right Side of Instrument Panel 20, 24, 29
G201 Right Side of Instrument Panel 20, 24, 29
G202 Near Radio N/S
G300 Left B Pillar 32
G301 Right B Pillar 33, 39
G302 Left Rear Quarter 47
G303 Liftgate Ground 49
8W - 91 - 12 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

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)
(6) Remove heater tube support bracket from cyl-
inder head.
(7) Disconnect radiator upper and heater supply
hoses from intake manifold water outlet connections.
(8) Remove accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)
(9) Raise vehicle and remove exhaust pipe from
manifold.
(10) Remove power steering pump reservoir and
line support bracket from lower intake manifold and
set aside. Do not disconnect lines.
(11) Remove ignition coil and wires from engine.
(12) Disconnect cam sensor and fuel injector wir-
ing connectors.
(13) Remove timing belt and camshaft sprockets.
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT/CHAIN AND SPROCKETS - REMOVAL)
(14) Remove timing belt idler pulley and rear tim-
ing belt cover. (Refer to 9 - ENGINE/VALVE TIM-
ING/TIMING BELT / CHAIN COVER(S) -
REMOVAL)Fig. 13 Cylinder Head and Camshafts
1 - CAMSHAFT BEARING CAPS
2 - PLUG
3 - CAMSHAFT
4 - CYLINDER HEAD
5 - CAMSHAFT OIL SEAL
RSENGINE 2.4L9-25
CYLINDER HEAD (Continued)

(2) Position cylinder head gasket on engine block
(Fig. 18).
(3) Install cylinder head on engine block.
(4) Tighten the cylinder head bolts in the sequence
shown in (Fig. 19). Using the 4 step torque turn
method, tighten according to the following values:
²First All to 34 N´m (25 ft. lbs.)
²Second All to 68 N´m (50 ft. lbs.)
²Third All to 68 N´m (50 ft. lbs.)
CAUTION: Do not use a torque wrench for the fol-
lowing step.
²Fourth Turn an additional 1/4 Turn,
(5) Install rocker arms. (Refer to 9 - ENGINE/
CYLINDER HEAD/ROCKER ARMS - INSTALLA-
TION)
(6) Install camshafts. (Refer to 9 - ENGINE/CYL-
INDER HEAD/CAMSHAFT(S) - INSTALLATION).
(7) Install cylinder head cover. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION)(8) Install timing belt rear cover and timing belt
idler pulley. (Refer to 9 - ENGINE/VALVE TIMING/
TIMING BELT / CHAIN COVER(S) - INSTALLA-
TION)
(9) Install timing belt and camshaft sprockets.
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT/CHAIN AND SPROCKETS - INSTALLATION)
(10) Connect cam sensor and fuel injectors wiring
connectors.
(11) Install ignition coil and wires. Connect igni-
tion coil wiring connector.
(12) Install power steering pump reservoir and
line support bracket to cylinder head.
(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 AND SPROCKETS -
REMOVAL).
Fig. 17 Checking Bolts for Stretching (Necking)
1 - STRETCHED BOLT
2 - THREADS ARE NOT STRAIGHT ON LINE
3 - THREADS ARE STRAIGHT ON LINE
4 - UNSTRETCHED BOLT
Fig. 18 Cylinder Head Gasket Positioning
1 - PART NUMBER FACES UP
2 - NO. 1 CYLINDER
Fig. 19 Cylinder Head Tightening Sequence
RSENGINE 2.4L9-27
CYLINDER HEAD (Continued)

INSTALLATION
INSTALLATION - CRANKSHAFT SPROCKET
CAUTION: The crankshaft sprocket is set to a pre-
determined depth from the factory for correct tim-
ing belt tracking. If removed, use of Special Tool
6792 is required to set the sprocket to original
installation depth. An incorrectly installed sprocket
will result in timing belt and engine damage.
(1) Install crankshaft sprocket using Special Tool
6792 (Fig. 120).
(2) Install timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION)
INSTALLATION - CAMSHAFT SPROCKETS
(1) Install camshaft sprockets. Hold camshaft
sprockets with Special Tool 6847 while tightening
center bolts to 115 N´m (85 ft. lbs.) (Fig. 118).
(2) Install timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
INSTALLATION).
(3) Connect negative battery cable.
INSTALLATION - TIMING BELT
(1) Set crankshaft sprocket to TDC by aligning the
sprocket with the arrow on the oil pump housing.
(2) Set camshafts timing marks so that the
exhaust camshaft sprocket is a 1/2 notch below the
intake camshaft sprocket (Fig. 121).
CAUTION: Ensure that the arrows on both camshaft
sprockets are facing up.
(3) Install timing belt. Starting at the crankshaft,
go around the water pump sprocket, idler pulley,
camshaft sprockets and then around the tensioner
(Fig. 122).
(4) Move the exhaust camshaft sprocket counter-
clockwise (Fig. 122) to align marks and take up belt
slack.
(5) Inserta6mmAllen wrench into the hexagon
opening located on the top plate of the belt tensioner
pulley. Rotate the top plateCOUNTERCLOCK-
WISE. The tensioner pulley will move against the
belt and the tensioner setting notch will eventually
start to move clockwise. Watching the movement of
the setting notch, continue rotating the top plate
counterclockwise until the setting notch is aligned
with the spring tang (Fig. 123). Using the allen
wrench to prevent the top plate from moving, torque
the tensioner lock bolt to 25 N´m (220 in. lbs.). Set-
Fig. 118 Camshaft Sprocket - Removal/Installation
1 - SPECIAL TOOL 6847
Fig. 119 Crankshaft Sprocket - Removal
1 - SPECIAL TOOL 6793
2 - SPECIAL TOOL C-4685±C2
3 - CRANKSHAFT SPROCKET
Fig. 120 Crankshaft Sprocket - Installation
1 - SPECIAL TOOL 6792
2 - TIGHTEN NUT TO INSTALL
RSENGINE 2.4L9-65
TIMING BELT AND SPROCKET(S) (Continued)

(41) Disconnect the knock sensor electrical connec-
tor (3.8L only).
(42) Disconnect the engine block heater electrical
connector (if equipped).
(43) Remove the accessory belt splash shield.
(44) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(45) Disconnect the radiator lower hose.
(46) Remove air conditioning compressor from
engine.
(47) Remove the generator (Refer to 8 - ELECTRI-
CAL/CHARGING/GENERATOR - REMOVAL).
(48)
Remove the water pump pulley attaching bolts
and position pulley between pump hub and housing.
(49) Disconnect the oil pressure switch electrical
connector.
(50) Disconnect wiring harness support clip from
engine oil dipstick tube.
(51) Install Special Tools 6912 and 8444 Adapters
on the right side (rear) of engine block (Fig. 9).
(52) Lower the vehicle.
(53) Remove the power steering pump and set
aside.
(54) Raise vehicle enough to allow engine dolly
Special Tool 6135 and cradle Special Tool 6710 withpost Special Tool 6848 and adaptor Special Tool 6909
to be installed under vehicle (Fig. 12).
(55) Loosen cradle/post mounts to allow movement
for positioning posts into locating holes on the engine
(Fig. 10) and (Fig. 11). Slowly lower vehicle and posi-
tion cradle/post mounts until the engine is resting on
posts. Tighten all cradle/post mounts to cradle frame.
This will keep mounts from moving when removing
or installing engine and transmission.
(56) Lower vehicle so the weight ofONLY THE
ENGINE AND TRANSMISSIONis on the cradle.
(57) Install and secure the safety straps to the cra-
dle fixture and around the engine (Fig. 12).
(58) Remove the engine right side mount to engine
attaching bolts (Fig. 13).
(59) Remove the left mount through bolt (Fig. 14).
(60) Raise vehicle slowly. It is necessary to move
the engine/transmission assembly with the dolly to
allow for removal around body flanges.
Fig. 8 POWERTRAIN SUPPORTS AND DUST COVER
1 - BRACKET - ENGINE REAR MOUNT
2 - BOLT - TRANSAXLE CASE COVER
3 - STRUT - TRANSAXLE TO ENGINE HORIZONTAL
4 - BOLT - HORIZONTAL STRUT
5 - BOLT - STRUT TO TRANSAXLE
6 - COVER - TRANSAXLE CASE LOWER
7 - STRUT - TRANSAXLE TO ENGINE
8 - BOLT - STRUT TO ENGINE
9 - BOLT - ENGINE REAR MOUNT BRACKET
Fig. 9 ADAPTER TOOLS MOUNTED ON BLOCK
1 - SPECIAL TOOL 6912
2 - SPECIAL TOOL 8444
Fig. 10 Positioning Special Tool 6848 for use with
Adapters 8444 & 6912
1 - SLOTS
2 - SPECIAL TOOLS 6848
9 - 88 ENGINE 3.3/3.8LRS
ENGINE 3.3/3.8L (Continued)