2001 CHRYSLER VOYAGER torque

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 ± 1/49O.D.
x 1/89pipe thread
(LDP/Speed Control Port)Pipe Tap ± 1/49-18NPT
& 1/89-18NPT
Brass Nipple ± 1/29O.D.
x 1/49pipe thread (Brake
Booster Port)Drill Bit ± 7/169& 11/329
File/Sand Paper
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).
Fig. 120 INTAKE MANIFOLD - UPPER 3.8L
1 - BRACKET - THROTTLE CABLE
2 - BOLT
3 - SCREW
4 - MAP SENSOR
5 - MANIFOLD - UPPER
6 - WIRE HARNESS
7 - GASKET (1 PER CYL. BANK)
8 - Bolt
Fig. 121 INTAKE MANIFOLD - LOWER
1 - INTAKE MANIFOLD - LOWER
2 - BOLT - GASKET END SEAL RETAINER
3 - GASKET
4 - BOLT - LOWER INTAKE MANIFOLD
9 - 142 ENGINE 3.3/3.8LRS
INTAKE MANIFOLD - UPPER 3.3L (Continued)

(2) Drill out the nipple (port) base using a 7/16º
(brake booster port) or 11/32º (LDP/speed control
port) drill bit (Fig. 122).
(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. 122). 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 - 3.3L
(1) Disconnect battery negative cable.
(2) Disconnect air inlet sensor electrical connector.
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/IN-
LET AIR TEMPERATURE SENSOR - COMPONENT
LOCATION)
(3) Remove air inlet resonator to throttle body
hose assembly.
(4) Remove throttle and speed control cables.
(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. (Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANIFOLD - COMPONENT
LOCATION)
(7) Disconnect the manifold absolute pressure
(MAP) sensor electrical connector. (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/MAP SENSOR -
COMPONENT LOCATION)
(8) Disconnect the EGR transducer vacuum hose
from bottom of upper intake manifold (Fig. 123).
(9) Remove the EGR tube (Fig. 123).
(10) Disconnect the vapor purge vacuum hose from
throttle body.
(11) Disconnect the PCV hose (Fig. 124).
(12) Remove the power steering reservoir attach-
ing bolts and only loosen the nut (Fig. 125). Lift res-
ervoir up to disengage lower mount from stud. Set
reservoir aside.Do notdisconnect hose.
(13) Disconnect the brake booster and leak detec-
tion pump (LDP) hoses from intake manifold (Fig.
126).
NOTE: The cover on the upper intake manifold
should never be removed under any circumstance.
The fasteners attaching the upper intake manifold
can be accessed without removing this cover.
(14) Remove intake manifold bolts and remove the
manifold (Fig. 127).
(15) Cover the lower intake manifold with a suit-
able cover while the upper manifold is removed.
(16) Clean and inspect the upper intake manifold.
(Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANI-
FOLD - CLEANING) (Refer to 9 - ENGINE/MANI-
FOLDS/INTAKE MANIFOLD - INSPECTION)
Fig. 122 Intake Manifold Port Repair
1 - BRAKE BOOSTER PORT = 1/49±18 NPT PIPE TAP
1 - LDP/SPEED CONTROL PORT = 1/89±18 NPT PIPE TAP
2 - DRILL BIT = 7/169BRAKE BOOSTER PORT
2 - DRILL BIT = 11/329LDP/SPEED CONTROL PORT
3 - INTAKE MANIFOLD
Fig. 123 EGR COMPONENTS - 3.3L
1 - BOLT
2 - EGR VALVE ASSEMBLY
3 - EGR TUBE
RSENGINE 3.3/3.8L9 - 143
INTAKE MANIFOLD - UPPER 3.3L (Continued)

(4) Position upper manifold on lower manifold (Fig.
127). Install and tighten bolts to 12 N´m (105 in. lbs.)
following torque sequence in (Fig. 128).(5) Connect the MAP sensor electrical connector.
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
MAP SENSOR - COMPONENT LOCATION)
(6) Connect the brake booster and LDP vacuum
hose to intake manifold (Fig. 126).
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).
(7) Install the power steering reservoir (Fig. 125).
Tighten screws to manifold to 5.6 N´m (50 in. lbs.).
(8) Using new gaskets, install the EGR tube and
torque bolts to 5.6 N´m (50 in. lbs.).
(9) Connect the EGR transducer vacuum hose.
(10) Install throttle and speed control cables.
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
THROTTLE CONTROL CABLE - INSTALLATION)
(11) Attach make up air hose clip into the hole in
the throttle cable bracket.
(12) Connect the wiring connectors to the throttle
position sensor (TPS) and Automatic Idle Speed (AIS)
motor. (Refer to 9 - ENGINE/MANIFOLDS/INTAKE
MANIFOLD - COMPONENT LOCATION)
(13) Install air cleaner and air inlet hose assembly.
(14) Connect the inlet air sensor electrical connec-
tor. (Refer to 14 - FUEL SYSTEM/FUEL INJEC-
TION/INLET AIR TEMPERATURE SENSOR -
COMPONENT LOCATION)
(15) Connect battery negative cable.
INTAKE MANIFOLD - UPPER
3.8L
REMOVAL - 3.8L
(1) Disconnect battery negative cable.
(2) Disconnect air inlet sensor electrical connector.
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/IN-
LET AIR TEMPERATURE SENSOR - COMPONENT
LOCATION)
(3) Remove air inlet resonator to throttle body
hose assembly.
(4) Remove throttle and speed control cables.
(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-
Fig. 127 INTAKE MANIFOLD - UPPER 3.3L
1 - BOLT
2 - MAP SENSOR
3 - SCREW
4 - MANIFOLD - UPPER
5 - WIRE HARNESS
6 - GASKET (3 PER CYL. BANK)
Fig. 128 UPPER MANIFOLD TIGHTENING
SEQUENCE
RSENGINE 3.3/3.8L9 - 145
INTAKE MANIFOLD - UPPER 3.3L (Continued)

INSPECTION
Check manifold for:
²Damage and cracks.
²Mounting surface distortion by using a straight-
edge and thickness gauge.
INSTALLATION - 3.8L
(1) If the following components were removed from
manifold, install and tighten to specifications:
²MAP sensor - 3.4 N´m (30 in. lbs.)
²Throttle cable bracket - 12 N´m (105 in. lbs.)
(2) Remove covering on lower intake manifold and
clean surfaces.
(3) Position the new intake manifold gasket on
lower manifold.
(4) Position upper manifold on lower manifold (Fig.
133). Install and tighten bolts to 12 N´m (105 in. lbs.)
following torque sequence in (Fig. 134).
(5) Connect the MAP sensor electrical connector.
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
MAP SENSOR - COMPONENT LOCATION)
(6) Connect the brake booster and LDP vacuum
hose to intake manifold (Fig. 132).
(7) Connect the PCV hose (Fig. 130).
(8) Install the power steering reservoir (Fig. 131)
and torque fasteners to 12 N´m (105 in. lbs.).
(9) Connect the EGR transducer vacuum hose.
(10) Using new gaskets, install the EGR tube (Fig.
129) and torque bolts to 12 N´m (105 in. lbs.).
Fig. 132 BRAKE BOOSTER & LDP VACUUM HOSES
1 - LDP & SPEED CONTROL VACUUM HOSE
2 - BRAKE BOOSTER VACUUM HOSE
3 - MAP SENSOR
Fig. 133 INTAKE MANIFOLD - UPPER 3.8L
1 - BRACKET - THROTTLE CABLE
2 - BOLT
3 - SCREW
4 - MAP SENSOR
5 - MANIFOLD - UPPER
6 - WIRE HARNESS
7 - GASKET (1 PER CYL. BANK)
8 - BOLT
Fig. 134 UPPER MANIFOLD TIGHTENING
SEQUENCE
RSENGINE 3.3/3.8L9 - 147
INTAKE MANIFOLD - UPPER 3.8L (Continued)

INSTALLATION
(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. 138).
(2) Carefully install the new intake manifold gas-
ket (Fig. 139). Tighten end seal retainer screws to 12
N´m (105 in. lbs.).
(3) Install lower intake manifold (Fig. 139). 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. 140). 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. 136).
(7) Connect the heater supply (Fig. 136) 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.(11) Fill the cooling system. (Refer to 7 - COOL-
ING - STANDARD PROCEDURE)
Fig. 136 ECT SENSOR & HEATER SUPPLY
1 - ENGINE COOLANT TEMPERATURE SENSOR
2 - CONNECTOR - ENGINE COOLANT SENSOR
3 - FITTING - HEATER SUPPLY
Fig. 137 INTAKE MANIFOLD - LOWER
1 - INTAKE MANIFOLD - LOWER
2 - BOLT - GASKET END SEAL RETAINER
3 - GASKET
4 - BOLT - LOWER INTAKE MANIFOLD
Fig. 138 Intake Manifold Gasket Sealing
1 - SEALER LOCATIONS
RSENGINE 3.3/3.8L9 - 149
INTAKE MANIFOLD - LOWER (Continued)

TIMING CHAIN AND
SPROCKETS
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. 156).
(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. 157). Be careful not to
damage the crankshaft surfaces.
INSPECTION
(1) Position a scale next to timing chain so that
any movement of chain may be measured.
(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
Fig. 155 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)

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. 158).
(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.). (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - REMOVAL)
INSTALLATION - TIMING CHAIN AND
CAMSHAFT SPROCKET
(1) Rotate crankshaft so the timing arrow is to the
12 o'clock position (Fig. 156).
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.
156).
(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.).
Fig. 156 Timing Mark Alignment
1 - CAMSHAFT SPROCKET TIMING MARK (DOT)
2 - PLATED LINK
3 - CRANKSHAFT SPROCKET TIMING MARK (DOT)
4 - ARROWS
Fig. 157 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. 158 Measuring Timing Chain Wear
1 - TORQUE WRENCH
RSENGINE 3.3/3.8L9 - 157
TIMING CHAIN AND SPROCKETS (Continued)

(47) Remove left engine mount through bolt.
(48) Raise vehicle, leaving engine and transmis-
sion on engine cradle.
(49) Lift engine from engine cradle and diassemble
as necessary.
REMOVAL - ENGINE COVER
(1) Remove the engine cover retaining bolts.
(2) Remove the engine cover from the engine.
INSTALLATION - 2.5L TURBO DIESEL ENGINE
(1) Reassembly engine and transmission assembly
and install on engine cradle.
(2) Position engine and cradle assembly under
vehicle.
(3) Slowly lower the vehicle down over the engine
and cradle assembly.
(4) Install right engine mount bolts. Torque to
54N´m (40 ft. lbs.)
(5) Install left engine mount through bolt. Torque
to 75N´m (55 ft. lbs.)
(6) Raise vehicle and engine from engine cradle.
Fig. 9 ENGINE COMPONENT LOCATIONS
1 - FUEL INJECTOR RETURN LINE
2 - FUEL INJECTOR SUPPLY LINE
3 - OIL SEPARATOR
4 - FUEL INJECTOR
5 - CAMSHAFT POSITION SENSOR
6 - BOOST PRESSURE/INTAKE AIR TEMPERATURE SENSOR
7 - EGR SOLENOID
8 - FUEL PRESSURE SENSOR
9 - CYLINDER HEAD COVER/INTAKE MANIFOL
10 - FUEL RAIL
11 - WIRING HARNESS RETAINING CLIPS
Fig. 10 REAR ENGINE VIEW
1 - SUSPENSION CRADLE
2 - ENGINE BLOCK
3 - OIL PRESSURE SWITCH
4 - OIL TEMPERATURE SENSOR
5 - VEHICLE SPEED SENSOR
6 - TRANSMISSION
Fig. 11 Figure Caption Here
1 - ENGINE COVER MOUNTING BOLTS
2 - ENGINE COVER
9a - 6 ENGINE 2.5L TURBO DIESELRG
ENGINE 2.5L TURBO DIESEL (Continued)