2001 CHRYSLER VOYAGER radiator

NOTE: Plastigage is available in a variety of clear-
ance ranges. Use the most appropriate range for
the specifications you are checking.
(4) Install the proper crankshaft bearings to
achieve the specified bearing clearances. (Refer to 9 -
ENGINE/ENGINE BLOCK/CRANKSHAFT MAIN
BEARINGS - STANDARD PROCEDURE) (Refer to 9
- ENGINE/ENGINE BLOCK/CONNECTING ROD
BEARINGS - STANDARD PROCEDURE)
REMOVAL - ENGINE ASSEMBLY
(1) Perform fuel pressure release procedure (Refer
to 14 - FUEL SYSTEM/FUEL DELIVERY - STAN-
DARD PROCEDURE)
(2) Disconnect battery negative cable.
(3) Remove air cleaner housing and inlet tube.
(4) Disconnect the fuel line from fuel rail. (Refer to
14 - FUEL SYSTEM/FUEL DELIVERY/FUEL LINES
- STANDARD PROCEDURE)
(5) Disconnect all vacuum hoses.
(6) Drain cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(7) Remove radiator fans. (Refer to 7 - COOLING/
ENGINE/RADIATOR FAN - REMOVAL)
(8) Remove radiator upper and lower hoses.
(9) Disconnect automatic transmission cooler lines
and plug.(10) Disconnect transmission shift linkage and
electrical connectors.
(11) Disconnect throttle body linkage.
(12) Disconnect engine wiring harness.
(13) Disconnect heater hoses from heater (Fig. 5).
(14) Discharge air conditioning system. (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING
- STANDARD PROCEDURE)
(15) Hoist vehicle and remove front wheels and
tires.
(16) Remove accessory drive belt splash shield.
(17) Remove accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)
(18) Remove axle shafts. (Refer to 3 - DIFFEREN-
TIAL & DRIVELINE/HALF SHAFT - REMOVAL)
(19) Drain engine oil and remove oil filter. (Refer
to 9 - ENGINE/LUBRICATION/OIL - STANDARD
PROCEDURE)
(20) Remove crossmember cradle plate (Fig. 6).
(21) Disconnect exhaust pipe from manifold (Fig.
7).
(22) Remove engine front mount and bracket from
engine. (Refer to 9 - ENGINE/ENGINE MOUNTING/
FRONT MOUNT - REMOVAL)
(23) Remove structural collar. (Refer to 9 -
ENGINE/ENGINE BLOCK/STRUCTURAL COVER -
REMOVAL)
Fig. 5 HEATER HOSES - 2.4L
1 - HEATER HOSES TO HEATER 3 - HEATER HOSE TO ENGINE - SUPPLY AND RETURN
2 - BOLT - HEATER TUBE SUPPORT
9 - 12 ENGINE 2.4LRS
ENGINE 2.4L (Continued)

(16) Install axle shafts. (Refer to 3 - DIFFEREN-
TIAL & DRIVELINE/HALF SHAFT - INSTALLA-
TION)
(17) Install accessory drive belt splash shield.
(18) Install front wheels and tires.
(19) Connect automatic transmission cooler lines
to transaxle.
(20) Connect the transaxle shift linkage and elec-
trical connectors.
(21) Connect heater hoses (Fig. 5).
(22) Install ground straps.
(23) Connect all engine and throttle body electrical
connections.(24) Connect all vacuum lines.
(25) Connect the throttle cables.
(26) Connect the fuel line. (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY/QUICK CONNECT FIT-
TING - STANDARD PROCEDURE)
(27) Connect radiator lower and upper hoses.
(28) Install radiator fans. (Refer to 7 - COOLING/
ENGINE/RADIATOR FAN - INSTALLATION)
(29) Fill cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(30) Connect battery cables.
(31) Install air cleaner and inlet hose.
(32) Fill engine crankcase with proper oil to cor-
rect level.
(33) Start engine and run until operating temper-
ature is reached.
(34) Adjust transmission linkage, if necessary.
1 - SPECIAL TOOL POSTS 6848 4 - SPECIAL TOOL 6710 CRADLE
2 - SPECIAL TOOL 6135 DOLLY 5 - SPECIAL TOOL 6848 - POST CONTACT ON PAN RAIL
3 - SPECIAL TOOL POSTS 6848
Fig. 9 RIGHT MOUNT TO RAIL AND ENGINE
1 - BOLT - MOUNT TO RAIL 68 N´m (50 ft. lbs.)
2 - BOLT - MOUNT TO ENGINE 54 N´m (40 ft. lbs.)
3 - BOLT - MOUNT TO RAIL (HORIZONTAL) 68 N´m (50 ft. lbs.)
4 - RIGHT ENGINE MOUNT
5 - RIGHT FRAME RAIL
Fig. 10 LEFT MOUNT TO FRAME BRACKET
1 - FRAME BRACKET
2 - FRAME RAIL - LEFT
3 - BOLT
4 - TRANSAXLE MOUNT
RSENGINE 2.4L9-15
ENGINE 2.4L (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. 11).
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. 12).
(3) Remove the inlet hose to throttle body (Fig. 11).
(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.
12).
(5) Connect the negative battery cable.
CYLINDER HEAD
DESCRIPTION
The cross flow designed, aluminum cylinder head
contains dual over-head camshafts with four valves
per cylinder (Fig. 13). The valves are arrange in two
in-line banks. The intake valves face toward the
front of the vehicle. The exhaust valves face the dash
panel. The cylinder head incorporates powdered
metal valve guides and seats. The cylinder head is
sealed to the block using a multi-layer steel head
gasket and retaining bolts.
Integral oil galleries providing lubrication passages
to the hydraulic lash adjusters, camshafts, and valve
mechanisms.
Cylinder Compression Pressure Adaptor 8116
Fig. 11 AIR BOX COVER
Fig. 12 IAT SENSOR 2.4L
9 - 22 ENGINE 2.4LRS
SPECIAL TOOLS (Continued)

(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)
(15) Remove cylinder head cover. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL)
(16) Remove camshafts (Refer to 9 - ENGINE/
CYLINDER HEAD/CAMSHAFT(S) - REMOVAL).
NOTE: Identify rocker arm position to ensure cor-
rect re-installation in original position, if reused.
(17) Remove rocker arms. (Refer to 9 - ENGINE/
CYLINDER HEAD/ROCKER ARMS - REMOVAL)
(18) Remove cylinder head bolts in REVERSE
sequence of tightening (Fig. 19).
(19) Remove cylinder head from engine block.
(20) Inspect and clean cylinder head. (Refer to 9 -
ENGINE/CYLINDER HEAD - INSPECTION) (Refer
to 9 - ENGINE/CYLINDER HEAD - CLEANING)
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-
DURE) Be careful not to gouge or scratch the alumi-
num head sealing surface.
Clean all engine oil passages.
INSPECTION
(1) Cylinder head must be flat within 0.1 mm
(0.004 in.) (Fig. 14).
(2) Inspect camshaft bearing journals for scoring.
(3) Remove carbon and varnish deposits from
inside of valve guides with a reliable guide cleaner.
(4) Using a small hole gauge and a micrometer,
measure valve guides in 3 places top, middle and bot-
tom (Fig. 15). (Refer to 9 - ENGINE - SPECIFICA-
TIONS) Replace guides if they are not within
specification.
(5) Check valve guide height (Fig. 16).
INSTALLATION - CYLINDER HEAD
NOTE: The Cylinder head bolts should be examined
BEFORE reuse. If the threads are necked down, the
bolts must be replaced (Fig. 17).
Fig. 14 Checking Cylinder Head Flatness
1 - FEELER GAUGE
2 - STRAIGHT EDGE
Fig. 15 Checking Wear on Valve GuideÐTypical
1-TOP
2 - MIDDLE
3 - BOTTOM
4 - CUT AWAY VIEW OF VALVE GUIDE MEASUREMENT
LOCATIONS
9 - 24 ENGINE 2.4LRS
CYLINDER HEAD (Continued)

(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/CHAIN AND
SPROCKETS - REMOVAL)
(2) Hold each camshaft sprocket with Special Tool
6847 while removing center bolt (Fig. 20).
(3) Remove camshaft sprockets.
(4) Remove rear timing belt cover. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL)
(5) Remove camshaft seal using Special Tool
C-4679-A (Fig. 21).
CAUTION: Do not nick shaft seal surface or seal
bore.
INSTALLATION
(1) Shaft seal surface must be free of varnish, dirt
or nicks. Polish with 400 grit paper if necessary.
(2) Install camshaft seals into cylinder head using
Special Tool MD-998306 until flush with head (Fig.
22).
(3) Install timing belt rear cover. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION)
(4) Install camshaft sprockets. Hold each sprocket
with Special Tool 6847 and tighten center bolt to 101
N´m (75 ft. lbs.) (Fig. 20).
(5) Install timing belt and front covers. (Refer to 9
- ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - INSTALLATION) (Refer to 9 -ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION)
CAMSHAFT(S)
DESCRIPTION
Both nodular iron camshafts have six bearing jour-
nal surfaces and two cam lobes per cylinder (Fig. 23).
Flanges at the rear journals control camshaft end
play. Provision for a cam position sensor is located on
the intake camshaft on the rear of the cylinder head.
A hydrodynamic oil seal is used for oil control at the
front of the camshaft.
Fig. 20 Camshaft Sprocket - Removal/Installation
1 - SPECIAL TOOL 6847
Fig. 21 Camshaft Oil Seal - Removal With C-4679-A
1 - SPECIAL TOOL C-4679
9 - 26 ENGINE 2.4LRS
CYLINDER HEAD (Continued)

(9) Connect vacuum lines for power brake booster,
LDP, EGR transducer, and speed control vacuum res-
ervoir (if equipped) at upper intake manifold fittings.
(10) Connect vacuum lines for purge solenoid and
PCV valve.
(11) Connect electrical connectors for MAP sensor,
throttle position sensor (TPS), and idle air control
(IAC) motor.
(12) Install air cleaner upper housing and air
intake tube to throttle body.
(13) Connect inlet air temperature sensor connec-
tor (Fig. 104).
(14) Connect negative cable to battery.
INTAKE MANIFOLD - LOWER
REMOVAL
(1) Perform fuel system pressure release proce-
durebefore attempting any repairs.(Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY - STANDARD
PROCEDURE)
(2) Remove upper intake manifold. (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
REMOVAL)
CAUTION: Cover intake manifold openings to pre-
vent foreign material from entering engine.
(3) Disconnect fuel line. (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/QUICK CONNECT FIT-
TING - STANDARD PROCEDURE)
(4) Drain the cooling system. (Refer to 7 - COOL-
ING - STANDARD PROCEDURE)
(5) Remove heater supply and radiator upper
hoses at intake manifold.
(6) Disconnect coolant temperature sensor/fuel
injector wire harness connector.
(7) Remove lower intake manifold support bracket
bolts (Fig. 109).(8) Loosen the lower intake manfold support
bracket lower bolt (Fig. 109).
(9) Disconnect fuel injector harness.
(10) Remove the bolts attaching the power steering
reservoir to manifold. Set reservoir aside. Do not dis-
connect line
(11) Remove lower intake manifold fasteners (Fig.
110). Remove the manifold from engine.
(12) Inspect the manifold. (Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD - INSPECTION)
INSPECTION
(1) Check manifold surfaces for flatness with
straight edge. Surface must be flat within 0.15 mm
per 300 mm (0.006 in. per foot) of manifold length.
(2) Inspect manifold for cracks or distortion.
Replace manifold if necessary.
INSTALLATION
If the following items were removed, install and
torque to specifications:
²Fuel rail bolts - 22 N´m (200 in. lbs.)
²Coolant outlet connector bolts - 28 N´m (250 in.
lbs.)
²Coolant temperature sensor - 7 N´m (60 in. lbs.)
(1) Position a new gasket on cylinder head and
install lower manifold.
(2) Install and tighten intake manifold fasteners to
28 N´m (250 in. lbs.) in the sequence shown in (Fig.
110). Repeat procedure until all bolts are at specified
torque.
(3) Install lower intake manifold support bracket
bolts (Fig. 109) and tighten to:
Fig. 108 Upper Intake Manifold Tightening Sequence
- 2.4L
Fig. 109 Lower Intake Manifold Support Bracket
1 - SUPPORT BRACKET
2 - BOLTS - UPPER TO MANIFOLD
3 - BOLT - LOWER TO ENGINE BLOCK
9 - 58 ENGINE 2.4LRS
INTAKE MANIFOLD - UPPER (Continued)

²Bolts to intake 28 N´m (250 in. lbs.)
²Bolt to engine block 54 N´m (40 ft. lbs.)
(4) Position power steering reservoir on manifold
and install bolts.
(5) Connect the fuel line. (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/QUICK CONNECT FIT-
TING - STANDARD PROCEDURE)
(6) Connect coolant temperature sensor/fuel injec-
tor wiring harness electrical connector.
(7) Install the radiator upper and heater supply
hoses.
(8) Install the upper intake manifold. (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSTALLATION)
(9) Fill the cooling system. (Refer to 7 - COOLING
- STANDARD PROCEDURE)
EXHAUST MANIFOLD
DESCRIPTION
The exhaust manifold is made of Hi-Silicone Moly
nodular cast iron for strength and high tempera-
tures. The manifold attaches to the cylinder head.
OPERATION
The exhaust manifold collects the exhaust gasses
exiting the combustion chambers. Then it channels
the exhaust gasses to the exhaust pipe attached to
the manifold.
REMOVAL
(1) Raise vehicle and disconnect exhaust pipe from
the exhaust manifold.
(2) Disconnect upstream oxygen sensor connector
at the rear of exhaust manifold.
(3) Remove the bolts attaching the manifold to the
cylinder head.
(4) Remove exhaust manifold.
(5) Inspect the manifold. (Refer to 9 - ENGINE/
MANIFOLDS/EXHAUST MANIFOLD - INSPEC-
TION)
CLEANING
(1) Discard gasket (if equipped) and clean all sur-
faces of manifold and cylinder head.
INSPECTION
(1) Inspect manifold gasket surfaces for flatness
with straight edge. Surface must be flat within 0.15
mm per 300 mm (0.006 in. per foot) of manifold
length.
(2) Inspect manifolds for cracks or distortion.
Replace manifold as necessary.
INSTALLATION
(1) Install exhaust manifold with a new gasket.
Tighten attaching nuts in the sequence shown in
(Fig. 111) to 20 N´m (175 in. lbs.).
(2) Attach exhaust pipe to exhaust manifold and
tighten fasteners to 37 N´m (27 ft. lbs.).
(3) Install and connect the oxygen sensor. (Refer to
14 - FUEL SYSTEM/FUEL INJECTION/O2 SENSOR
- COMPONENT LOCATION)
Fig. 110 Lower Intake Manifold Tightening Sequence
Fig. 111 Exhaust Manifold Tightening Sequence
RSENGINE 2.4L9-59
INTAKE MANIFOLD - LOWER (Continued)

the cylinder in question.The recommended com-
pression pressures are to be used only as a
guide to diagnosing engine problems. An engine
should not be disassembled to determine the
cause of low compression unless some malfunc-
tion is present.
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE
The combustion pressure leakage test provides an
accurate means for determining engine condition.
Combustion pressure leakage testing will detect:
²Exhaust and intake valve leaks (improper seat-
ing).
²Leaks between adjacent cylinders or into water
jacket.
²Any causes for combustion/compression pressure
loss.
WARNING: DO NOT REMOVE THE RADIATOR CAP
WITH THE SYSTEM HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM COOLANT CAN
OCCUR.
Check the coolant level and fill as required. DO
NOT install the radiator cap.
Start and operate the engine until it attains nor-
mal operating temperature, then turn the engine
OFF.
Clean spark plug recesses with compressed air.
Remove the spark plugs.
Remove the oil filler cap.
Remove the air cleaner.
Calibrate the tester according to the manufactur-
er's instructions. The shop air source for testing
should maintain 483 kPa (70 psi) minimum, 1,379
kPa (200 psi) maximum, with 552 kPa (80 psi) rec-
ommended.
Perform the test procedures on each cylinder
according to the tester manufacturer's instructions.
While testing, listen for pressurized air escaping
through the throttle body, tailpipe and oil filler cap
opening. Check for bubbles in the radiator coolant.
All gauge pressure indications should be equal,
with no more than 25% leakage per cylinder.
FOR EXAMPLE:At 552 kPa (80 psi) input pres-
sure, a minimum of 414 kPa (60 psi) should be main-
tained in the cylinder.
STANDARD PROCEDURE - MEASURING
BEARING CLEARANCE USING PLASTIGAGE
Engine crankshaft bearing clearances can be deter-
mined by use of Plastigage or equivalent. The follow-
ing is the recommended procedure for the use of
Plastigage:(1) Remove oil film from surface to be checked.
Plastigage is soluble in oil.
(2) Place a piece of Plastigage across the entire
width of the bearing shell in the cap approximately
6.35 mm (1/4 in.) off center and away from the oil
holes (Fig. 3). (In addition, suspected areas can be
checked by placing the Plastigage in the suspected
area). Torque the bearing cap bolts of the bearing
being checked to the proper specifications.
(3) Remove the bearing cap and compare the
width of the flattened Plastigage with the metric
scale provided on the package. Locate the band clos-
est to the same width. This band shows the amount
of clearance in thousandths of a millimeter. Differ-
ences in readings between the ends indicate the
amount of taper present. Record all readings taken.
Compare clearance measurements to specs found in
engine specifications (Refer to 9 - ENGINE - SPECI-
FICATIONS).Plastigage generally is accompa-
nied by two scales. One scale is in inches, the
other is a metric scale.
NOTE: Plastigage is available in a variety of clear-
ance ranges. Use the most appropriate range for
the specifications you are checking.
(4) Install the proper crankshaft bearings to
achieve the specified bearing clearances. (Refer to 9 -
ENGINE/ENGINE BLOCK/CRANKSHAFT MAIN
BEARINGS - STANDARD PROCEDURE) (Refer to 9
- ENGINE/ENGINE BLOCK/CONNECTING ROD
BEARINGS - STANDARD PROCEDURE)
STANDARD PROCEDURE - FORM-IN-PLACE
GASKETS AND SEALERS
There are numerous places where form-in-place
gaskets are used on the engine. Care must be taken
Fig. 3 Plastigage Placed in Lower ShellÐTypical
1 - PLASTIC GAUGE
RSENGINE 3.3/3.8L9-79
ENGINE 3.3/3.8L (Continued)