2001 CHRYSLER VOYAGER engine cooling

CAUTION: Excessive pressure or high RPM (beyond
the recommended speed), can damage the sealing
surfaces. The mild (white, 120 grit) bristle disc is
recommended. If necessary, the medium (yellow, 80
grit) bristle disc may be used on cast iron surfaces
with care.
STANDARD PROCEDURE - HYDROSTATIC
LOCKED ENGINE
When an engine is suspected to be hydrostatically
locked, regardless of what caused the problem, the
following steps should be used.
CAUTION: DO NOT use starter motor to rotate the
engine, severe damage may occur.
(1) Inspect air cleaner, induction system and
intake manifold to insure system is dry and clear of
foreign material.
(2) Remove negative battery cable.
(3) Place a shop towel around the spark plugs
when removing them from the engine. This will catch
any fluid that may possibly be in the cylinder under
pressure.
(4) With all spark plugs removed, rotate engine
crankshaft using a breaker bar and socket.
(5) Identify the fluid in the cylinder(s) (i.e., cool-
ant, fuel, oil or other).
(6) Make sure all fluid has been removed from the
cylinders. Inspect engine for damage (i.e., connecting
rods, pistons, valves, etc.)(7) Repair engine or components as necessary to
prevent this problem from re-occurring.
CAUTION: Squirt approximately one teaspoon of oil
into the cylinders, rotate engine to lubricate the cyl-
inder walls to prevent damage on restart.
(8) Install new spark plugs.
(9) Drain engine oil and remove oil filter.
(10) Install a new oil filter.
(11) Fill engine with specified amount of approved
oil.
(12) Connect negative battery cable.
(13) Start engine and check for any leaks.
STANDARD PROCEDURE - REPAIR OF
DAMAGED OR WORN THREADS
Damaged or worn threads (excluding spark plug
and camshaft bearing cap attaching threads) can be
repaired. Essentially, this repair consists of drilling
out worn or damaged threads, tapping the hole with
a special Heli-Coil Tap, (or equivalent) and installing
an insert into the tapped hole. This brings the hole
back to its original thread size.
CAUTION: Be sure that the tapped holes maintain
the original center line.
Heli-Coil tools and inserts are readily available
from automotive parts jobbers.
STANDARD PROCEDURE - ENGINE CORE AND
OIL GALLERY PLUGS
Using a blunt tool such as a drift and a hammer,
strike the bottom edge of the cup plug. With the cup
plug rotated, grasp firmly with pliers or other suit-
able tool and remove plug (Fig. 5).
CAUTION: Do not drive cup plug into the casting as
restricted cooling can result and cause serious
engine problems.
Thoroughly clean inside of cup plug hole in cylin-
der block or head. Be sure to remove old sealer.
Lightly coat inside of cup plug hole with Mopart
Stud and Bearing Mount. Make certain the new plug
is cleaned of all oil or grease. Using proper drive
plug, drive plug into hole so that the sharp edge of
the plug is at least 0.5 mm (0.020 in.) inside the
lead-in chamfer.
It is not necessary to wait for curing of the sealant.
The cooling system can be refilled and the vehicle
placed in service immediately.
Fig. 4 PROPER TOOL USAGE FOR SURFACE
PREPARATION
1 - ABRASIVE PAD
2 - 3M ROLOCYBRISTLE DISC
3 - PLASTIC/WOOD SCRAPER
RSENGINE 3.3/3.8L9-81
ENGINE 3.3/3.8L (Continued)

REMOVAL - ENGINE ASSEMBLY
(1) Perform fuel pressure release procedure. (Refer
to 14 - FUEL SYSTEM/FUEL DELIVERY - STAN-
DARD PROCEDURE)
(2) Disconnect the battery.
(3) Remove air cleaner and hoses.
(4) Disconnect the fuel line from fuel rail. (Refer to
14 - FUEL SYSTEM/FUEL DELIVERY/QUICK
CONNECT FITTING - STANDARD PROCEDURE)
(5) Remove the wiper module. (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
REMOVAL)
(6) Block off heater hoses to the rear heater sys-
tem, if equipped, using pinch-off pliers.
(7) Drain the cooling system. (Refer to 7 - COOL-
ING - STANDARD PROCEDURE)
(8) Disconnect the heater hoses.
(9) Remove the radiator upper support crossmem-
ber. (Refer to 23 - BODY/EXTERIOR/GRILLE OPEN-
ING REINFORCEMENT - REMOVAL)
(10) Remove the radiator fans. (Refer to 7 - COOL-
ING/ENGINE/RADIATOR FAN - REMOVAL)
(11) Disconnect the throttle cables from the throt-
tle body.
(12) Disconnect the MAP, IAC, and TPS electrical
connectors.
(13) Disconnect the EGR transducer electrical con-
nector.
(14) Disconnect the vacuum hoses from throttle
body.
(15) Disconnect the brake booster and speed con-
trol vacuum hoses.(16) Disengage wire harness clip from the right
side engine mount.
(17) Remove the power steering reservoir from
mounting position and set aside. Do not disconnect
hose.
(18) Disconnect ground strap from rear of cylinder
head.
(19) Disconnect engine coolant temperature (ECT)
sensor and ignition coil electrical connectors.
(20) Disconnect the fuel injector electrical harness
connector and disengage clip from support bracket.
(21) Disconnect crank sensor connector.
(22) Disconnect camshaft sensor connector.
(23) Evacuate air conditioning system.
(24) Disconnect A/C compressor electrical connec-
tor.
(25) Disconnect the A/C lines from compressor.
Cover and seal all openings of hoses and compressor.
(26) Remove the radiator upper hose.
(27) Disengage electrical harness clip at transaxle
dipstick tube.
(28) Remove transaxle dipstick tube. Seal opening
using a suitable plug.
(29) Disconnect cooler hoses from transaxle.
(30) Disconnect transaxle shift linkage and electri-
cal connectors.
(31) Raise vehicle on hoist and drain the engine
oil.
(32) Remove the axle shafts. (Refer to 3 - DIFFER-
ENTIAL & DRIVELINE/HALF SHAFT - REMOVAL)
(33) Remove crossmember cradle plate (Fig. 6).
(34)AWD equipped:Remove the power transfer
unit (PTU).
(35) Disconnect exhaust pipe from the manifold
(Fig. 7).
Fig. 5 CORE HOLE PLUG REMOVAL
1 - CYLINDER BLOCK
2 - REMOVE PLUG WITH PLIERS
3 - STRIKE HERE WITH HAMMER
4 - DRIFT PUNCH
5 - CUP PLUG
Fig. 6 Crossmember Cradle Plate
1 - CRADLE PLATE
9 - 82 ENGINE 3.3/3.8LRS
ENGINE 3.3/3.8L (Continued)

(36) Remove front engine mount and bracket as an
assembly.
(37) Remove the engine rear mount bracket.
(38) Remove the engine to transaxle struts (Fig. 8).
(39) Remove transaxle case cover (Fig. 8).
(40) Remove flex plate to torque converter bolts.
(41) Remove the power steering pressure hose sup-
port clip attaching bolt.
(42) Disconnect the knock sensor electrical connec-
tor (3.8L only).
(43) Disconnect the engine block heater electrical
connector, if equipped.
(44) Remove the accessory belt splash shield.
(45) Remove accessory drive belt. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)
(46) Disconnect the radiator lower hose.
(47) Remove air conditioning compressor from
engine.
(48) Remove the generator. (Refer to 8 - ELECTRI-
CAL/CHARGING/GENERATOR - REMOVAL)
(49) Remove the water pump pulley attaching
bolts and position pulley between pump hub and
housing.
(50) Disconnect the oil pressure switch electrical
connector.
(51) Disconnect wiring harness support clip from
dipstick tube.(52) Install Special Tools 6912 and 8444 Adapters
on the right side (rear) of engine block (Fig. 9).
Fig. 7 Catalytic Converter to Exhaust Manifold
1 - FLAG NUT
2 - GASKET
3 - BOLT
4 - CATALYTIC CONVERTER
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
RSENGINE 3.3/3.8L9-83
ENGINE 3.3/3.8L (Continued)

(4) Slowly raise vehicle enough to remove the
engine dolly and cradle Special Tools 6135, 6710,
6848 and 6909 (Fig. 10).
(5) Remove Special Tools 6912 and 8444.
(6) Lower the vehicle.
(7) Install power steering pump and pressure line
support.(8) Install the generator and wiring harness.
(Refer to 8 - ELECTRICAL/CHARGING/GENERA-
TOR - INSTALLATION)
(9) Raise vehicle.
(10) Attach wiring harness support clip to the dip-
stick tube.
(11) Connect oil pressure switch electrical connec-
tor.
(12) Install the A/C compressor.
(13) Install the water pump pulley.
(14) Connect the radiator lower hose.
(15) Install the accessory drive belt and splash
shield. (Refer to 7 - COOLING/ACCESSORY DRIVE/
DRIVE BELTS - INSTALLATION)
(16) Connect the engine block heater electrical con-
nector, if equipped.
(17) Connect the knock sensor electrical connector
(3.8L only).
(18) Install the torque converter to flex plate bolts.
(19) Install the transaxle case cover (Fig. 8).
(20) Install the powertrain struts (Fig. 8).
(21) Install the engine rear mount bracket.
(22) Install the engine front mount and bracket
assembly.
(23)AWD equipped;Install the power transfer
unit (PTU).
(24) Install the axle shafts. (Refer to 3 - DIFFER-
ENTIAL & DRIVELINE/HALF SHAFT - INSTALLA-
TION)
(25) Connect exhaust pipe to manifold (Fig. 7).
(26) Install crossmember cradle plate (Fig. 6).
(27) Lower vehicle.
(28) Connect transaxle shift linkage.
(29) Connect transaxle electrical connectors.
(30) Connect transaxle cooler hoses.
(31) Install transaxle dipstick tube and attach
electrical harness clip.
(32) Connect the radiator upper hose.
(33) Connect the A/C lines to compressor.
(34) Connect the A/C compressor electrical connec-
tor.
(35) Evacuate and recharge A/C system.
(36) Connect crankshaft and camshaft position
sensors.
(37) Connect the fuel injector electrical harness
connector and engage clip to support bracket.
(38) Connect engine coolant temperature (ECT)
sensor and ignition coil electrical connectors.
(39) Connect the ground strap to rear of cylinder
head.
(40) Install power steering reservoir.
(41) Engage wire harness clip to engine right side
mount.
(42) Connect the brake booster and speed control
vacuum hoses.
Fig. 11 Right Mount to Engine
1 - BOLT
2 - MOUNT BRACKET
3 - ENGINE RIGHT MOUNT ASSEMBLY
Fig. 12 LEFT MOUNT TO FRAME BRACKET
1 - FRAME BRACKET
2 - FRAME RAIL - LEFT
3 - BOLT
4 - TRANSAXLE MOUNT
RSENGINE 3.3/3.8L9-85
ENGINE 3.3/3.8L (Continued)

(43) Connect the vacuum hoses to the throttle
body.
(44) Connect the EGR transducer electrical connec-
tor.
(45) Connect the TPS, IAC, and MAP sensor elec-
trical connectors.
(46) Connect throttle cables to throttle body.
(47) Install the radiator fans. (Refer to 7 - COOL-
ING/ENGINE/RADIATOR FAN - INSTALLATION)
(48) Connect the radiator upper hose.
(49) Connect the heater hoses. Remove pinch-off
pliers from the rear heater hoses, if equipped.
(50) Install the radiator upper support crossmem-
ber. (Refer to 23 - BODY/EXTERIOR/GRILLE OPEN-
ING REINFORCEMENT - INSTALLATION)
(51) Install the wiper module. (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
INSTALLATION)
(52) Connect the fuel line to fuel rail. (Refer to 14
- FUEL SYSTEM/FUEL DELIVERY/FUEL LINES -
STANDARD PROCEDURE)
(53) Install the air cleaner and hoses.
(54) Install new oil filter. Fill engine crankcase
with proper oil to correct level.
(55) Connect negative cable to battery.
(56) Fill the cooling system. (Refer to 7 - COOL-
ING - STANDARD PROCEDURE)
(57) Start engine and run until operating temper-
ature is reached.
(58) Adjust transmission linkage, if necessary.
SPECIFICATIONS
3.3/3.8L ENGINE
DESCRIPTION SPECIFICATION
General Specification
Type 60É V-6 Engine
Number of Cylinders 6
Displacement
Ð3.3L 3.3 Liters
(201 cu. in.)
Ð3.8L 3.8 Liters
(231 cu. in.)
Bore
Ð3.3L 93.0 mm
(3.66 in.)
Ð3.8L 96.0 mm
(3.779 in.)
DESCRIPTION SPECIFICATION
Stroke
Ð3.3L 81.0 mm
(3.188 in.)
Ð3.8L 87.0 mm
(3.425 in.)
Compression Ratio
Ð3.3L 9.35:1
Ð3.8L 9.6:1
Firing Order 1-2-3-4-5-6
Cylinder Number (Front
to Rear)
ÐFront Bank 2,4,6
ÐRear Bank 1,3,5
Compression PressureÐ
Minimum689.5 kPa
(100 psi)
Max. Variation Between
Cylinders25%
Cylinder Block
Cylinder Bore Diameter
(Standard)
Ð3.3L 92.993±93.007 mm
(3.661±3.6617 in.)
Ð3.8L 95.993±96.007 mm
(3.7792±3.780 in.)
Out-of-Round (Service
Limits)0.076 mm
(0.003 in.)
Taper (Service Limits) 0.051 mm
(0.002 in.)
Lifter Bore Diameter 22.980±23.010 mm
(0.905±0.906 in.)
Deck Surface Flatness
(Max.)0.1 mm
(0.004 in.)
Pistons
Piston Diameter
Ð3.3L ÐMeasured 39.8
mm (1.567 in.) from
piston top92.968±92.998 mm
(3.660±3.661 in.)
Ð3.8L ÐMeasured 33.01
mm (1.30 in.) from piston
top95.968±95.998 mm
(3.778±3.779 in.)
Clearance in Bore @
Size Location (New)-0.005±0.039 mm
(-0.0002±0.0015 in.)
9 - 86 ENGINE 3.3/3.8LRS
ENGINE 3.3/3.8L (Continued)

AIR CLEANER ELEMENT
REMOVAL
(1) Unsnap 2 clips.
(2) Lift cover and pull toward the engine and
remove cover tabs from air box.
(3) Lift cover and remove the element (Fig. 13).
INSTALLATION
(1) Install the air filter element into air box (Fig.
11).
(2) Move cover so that the tabs insert into the air
box.
(3) Push cover down and snap the 2 clips.
AIR CLEANER HOUSING
REMOVAL
(1) Disconnect the negative battery cable.
(2) Disconnect the inlet air temperature sensor
(Fig. 14).
(3) Remove the inlet hose to throttle body.
(4) Remove the bolt for air box at upper radiator
cross member.(5) Pull air box up and off over the single locating
pin.
(6) Remove air box from vehicle
INSTALLATION
(1) Install air box into vehicle and onto the locat-
ing pin.
(2) Install bolt to hold air box to the upper radia-
tor cross member.
(3) Install the inlet hose to the throttle body.
(4) Connect the inlet air temperature sensor (Fig.
14).
(5) Connect the negative battery cable.
Cooling System Tester 7700
Combustion Leak Tester C-3685-A
Compression Test Adapter 8116
Fig. 13 AIR BOX COVER
Fig. 14 Inlet Air Temperature Sensor
RSENGINE 3.3/3.8L9-93
SPECIAL TOOLS (Continued)

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) Drain the cooling system. (Refer to 7 - COOL-
ING - STANDARD PROCEDURE)
(2) Disconnect negative cable from battery.
(3) Remove upper and lower intake manifolds.
(Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANI-
FOLD - REMOVAL)
WARNING: INTAKE MANIFOLD GASKET IS MADE
OF VERY THIN METAL AND MAY CAUSE PER-
SONAL INJURY, HANDLE WITH CARE.(4) Remove the cylinder head covers. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL)
(5) Remove the spark plugs from cylinder head.
(6) Remove the dipstick and tube (Fig. 16).
(7) Remove exhaust manifold(s). (Refer to 9 -
ENGINE/MANIFOLDS/EXHAUST MANIFOLD -
REMOVAL)
(8) Remove rocker arm and shaft assemblies.(Refer
to 9 - ENGINE/CYLINDER HEAD/ROCKER ARMS -
REMOVAL) Remove push rods andmark positions
to ensure installation in original locations.
(9) Remove the eight head bolts from each cylinder
head and remove cylinder heads (Fig. 20).
CLEANING
To ensure engine gasket sealing, proper surface
preparation must be performed, especially with the
use of aluminum engine components and multi-layer
steel cylinder head gaskets.
NOTE: Multi-Layer Steel (MLS) head gaskets require
a scratch free sealing surface.
Remove all gasket material from cylinder head and
block. (Refer to 9 - ENGINE - STANDARD PROCE-
Fig. 16 DIPSTICK & TUBE
1 - DIPSTICK
2 - BOLT
3 - TUBE
RSENGINE 3.3/3.8L9-95
CYLINDER HEAD (Continued)

(9) Install the cylinder head covers. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION)
(10) Install the exhaust manifolds. (Refer to 9 -
ENGINE/MANIFOLDS/EXHAUST MANIFOLD -
INSTALLATION)
(11) Install new O-ring on dipstick tube. Install
dipstick tube assembly (Fig. 16).
(12) Install the spark plugs.
(13) Install upper and lower intake manifolds.
(Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANI-
FOLD - INSTALLATION)
(14) Fill the cooling system. (Refer to 7 - COOL-
ING - STANDARD PROCEDURE)
(15) Connect negative cable to battery.
CYLINDER HEAD COVER(S)
DESCRIPTION
The cylinder head covers are made of stamped
steel. The covers are sealed with steel reinforced sil-
icon rubber gaskets. The cylinder head cover uses
rubber isolators at each fastener location (Fig. 21).
NOTE: Due to the tight packaging near the cylinder
head covers, which makes spill clean-up difficult, a
spill during an engine oil change may be misinter-
preted as an oil leak. When investigating an oil leak
in the location of the cylinder head covers and
intake manifold, follow the procedure found in Oil
Leak Diagnosis (Refer to 9 - ENGINE - DIAGNOSIS
AND TESTING) for determining the source of a leak.
CYLINDER HEAD COVER -
RIGHT
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove the wiper module. (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
REMOVAL)
(3) Disconnect spark plug wires from plugs.(4) Disconnect power steering pump supply hose
support clip from cylinder head cover (Fig. 22).
(5) Disconnect PCV hose from cylinder head cover
(Fig. 23).
(6) Remove cylinder head cover bolts.
(7) Remove cylinder head cover and gasket (Fig.
21).
Fig. 20 CYLINDER HEAD TIGHTENING SEQUENCE
Fig. 21 Cylinder Head Cover
1 - CYLINDER HEAD COVER
2 - BOLT
Fig. 22 P/S Supply Hose
1 - POWER STEERING RESERVOIR
2 - CLAMP
3 - SUPPLY HOSE
4 - CLIP
5 - POWER STEERING PUMP
RSENGINE 3.3/3.8L9-97
CYLINDER HEAD (Continued)