2001 CHRYSLER VOYAGER air filter

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)

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)

OPERATION
The cylinder head closes the combustion chamber,
allowing the pistons to compress the fuel/air mixture
for ignition. The valves are actuated by the lobe pro-
files on the camshaft to open and close at specified
duration to either allow clean air in the combustion
chamber or the exhaust gases out; depending on the
stroke of the engine.
DIAGNOSIS AND TESTINGÐCYLINDER HEAD
GASKET
A cylinder head gasket leak can be located between
adjacent cylinders or between a cylinder and the
adjacent water jacket.
Possible indications of the cylinder head gasket
leaking between adjacent cylinders are:
²Loss of engine power
²Engine misfiring
²Poor fuel economy
Possible indications of the cylinder head gasket
leaking between a cylinder and an adjacent water
jacket are:
²Engine overheating
²Loss of coolant
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)
Fig. 13 Cylinder Head and Camshafts
1 - CAMSHAFT BEARING CAPS
2 - PLUG
3 - CAMSHAFT
4 - CYLINDER HEAD
5 - CAMSHAFT OIL SEAL
RSENGINE 2.4L9-23
CYLINDER HEAD (Continued)

CRANKSHAFT
DESCRIPTION
The crankshaft is made of nodular cast iron and
includes five main bearing journals and four connect-
ing rod journals (Fig. 47). The number three journal
is the location for the thrust bearing. The mains and
connecting rod journals have undercut fillet radiuses
that are rolled for added strength. To optimize bear-
ing loading, eight counterweights are used.
OPERATION
The crankshaft transfers force generated by com-
bustion within the cylinder to the flywheel or flex-
plate.
STANDARD PROCEDURE - CRANKSHAFT END
PLAY
(1) Using Dial Indicator C-3339 and Mounting
Post L-4438, attach to front of engine, locating probe
perpendicular on nose of crankshaft (Fig. 48).
(2) Move crankshaft all the way to the rear of its
travel.
(3) Zero the dial indicator.
(4) Move crankshaft all the way to the front and
read the dial indicator. Refer to Engine Specifica-
tions.
REMOVAL
NOTE: Crankshaft can not be removed when engine
is in vehicle.
(1) Remove engine assembly from vehicle. (Refer to
9 - ENGINE - REMOVAL)
(2) Separate engine from transaxle.
(3) Remove flex plate and crankshaft rear oil seal.
(4) Mount engine on a repair stand.
(5) Drain engine oil and remove oil filter.
(6) Remove the oil pan. (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL)
(7) Remove the timing belt covers. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL)
(8) Remove the timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL)
(9) Remove the oil pump. (Refer to 9 - ENGINE/
LUBRICATION/OIL PUMP - REMOVAL)
Fig. 46 Connecting Rod Side Clearance
Fig. 47 CRANKSHAFT - TYPICAL
1 - MAIN BEARING JOURNALS
2 - COUNTER BALANCE WEIGHTS
Fig. 48 CHECKING CRANKSHAFT END PLAY
9 - 36 ENGINE 2.4LRS
CONNECTING ROD BEARINGS (Continued)

RIGHT MOUNT
REMOVAL
(1) Remove air cleaner housing lid and clean air
hose from throttle body.
(2) Remove air cleaner element and housing.
(3) Disconnect make-up air hose from cylinder
head cover.
(4) Remove the load on the right engine mount by
carefully supporting the engine assembly with a floor
jack.
(5) Disconnect electrical harness support clips from
engine mount bracket.
(6) Remove the vertical bolts attaching the engine
mount to the frame rail (Fig. 87).
(7) Loosen the horizontal bolt attaching the engine
mount to the frame rail (Fig. 87).
(8) Remove the bolts attaching the engine mount
to the engine bracket (Fig. 87).
(9) Remove the right engine mount (Fig. 87).
INSTALLATION
(1) Position right engine mount and install frame
rail to mount vertical bolts (Fig. 87).(2) Tighten engine right mount to rail horizontal
bolt (Fig. 87).
(3) Install mount to engine bracket bolts (Fig. 87).
(4) Connect electrical harness support clips to
engine mount bracket.
(5) Remove jack from under engine.
(6) Connect make-up air hose to cylinder head
cover.
(7) Install air cleaner housing and element.
(8) Install air cleaner housing lid and clean air
tube to throttle body.
LUBRICATION
DESCRIPTION
The lubrication system is a full-flow filtration,
pressure feed type. The oil pump is mounted in the
front engine cover and driven by the crankshaft.
OPERATION
Engine oil drawn up through the pickup tube and
is pressurized by the oil pump and routed through
the full-flow filter to the main oil gallery running the
length of the cylinder block. A diagonal hole in each
bulkhead feeds oil to each main bearing. Drilled pas-
sages within the crankshaft route oil from main bear-
ing journals to connecting rod journals. Balance shaft
lubrication is provided through an oil passage from
the number one main bearing cap through the bal-
ance shaft carrier support leg. This passage directly
supplies oil to the front bearings and internal
machined passages in the shafts that routes oil from
front to the rear shaft bearing journals. A vertical
hole at the number five bulkhead routes pressurized
oil through a restrictor (integral to the cylinder head
gasket) up past a cylinder head bolt to an oil gallery
running the length of the cylinder head. The cam-
shaft journals are partially slotted to allow a prede-
termined amount of pressurized oil to pass into the
bearing cap cavities. Lubrication of the camshaft
lobes are provided by small holes in the camshaft
bearing caps that are directed towards each lobe. Oil
returning to the pan from pressurized components
supplies lubrication to the valve stems. Cylinder
bores and wrist pins are splash lubricated from
directed slots on the connecting rod thrust collars.
DIAGNOSIS AND TESTING - ENGINE OIL
PRESSURE
(1) Disconnect and remove oil pressure switch.
(Refer to 9 - ENGINE/LUBRICATION/OIL PRES-
SURE SENSOR/SWITCH - REMOVAL)
(2) Install Special Tools C-3292 Gauge with 8406
Adaptor fitting.
Fig. 87 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
9 - 50 ENGINE 2.4LRS

(3) Using a suitable filter wrench, turn oil filter
(Fig. 89) counterclockwise to remove.
INSTALLATION
(1) Clean and check filter mounting surface. The
surface must be smooth, flat and free of debris or
pieces of gasket.
(2) Lubricate new oil filter gasket with clean
engine oil.
(3) Screw oil filter (Fig. 89) on until the gasket
contacts base. Tighten to 21 N´m (15 ft. lbs.).
OIL PAN
REMOVAL
(1) Raise vehicle on hoist and drain engine oil.
(2) Remove structural collar. (Refer to 9 -
ENGINE/ENGINE BLOCK/STRUCTURAL COVER -
REMOVAL)
(3) Remove air conditioning compressor bracket to
oil pan bolt.
(4) Remove bolts attaching oil pan.
(5) Remove oil pan.
(6) Clean oil pan and all gasket surfaces.
INSTALLATION
(1) Apply MopartEngine RTV GEN II at the oil
pump to engine block parting line (Fig. 90).
(2) Install the oil pan gasket to the block.
(3) Install pan and tighten the screws to 12 N´m
(105 in. lbs.).
(4) Install air conditioning compressor bracket to
oil pan bolt.
(5) Install structural collar. (Refer to 9 - ENGINE/
ENGINE BLOCK/STRUCTURAL COVER - INSTAL-
LATION)
(6) Lower vehicle and fill engine crankcase with
proper oil to correct level.
OIL PUMP
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL)
(3) Remove timing belt rear cover. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL)
(4) Remove oil pan. (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - REMOVAL)
(5) Remove crankshaft sprocket using Special
Tools 6793 and C-4685-C2 (Fig. 91).
(6) Remove crankshaft key (Fig. 92).
(7) Remove oil pick-up tube.
(8) Remove oil pump (Fig. 93) and front crankshaft
seal.
Fig. 89 Oil Filter
Fig. 90 Oil Pan Sealing - Typical
1 - SEALER LOCATIONS
9 - 52 ENGINE 2.4LRS
OIL FILTER (Continued)

REMOVAL.............................114
INSTALLATION..........................115
CRANKSHAFT OIL SEAL - FRONT
REMOVAL.............................115
INSTALLATION..........................115
CRANKSHAFT OIL SEAL - REAR
REMOVAL.............................116
INSTALLATION..........................117
CRANKSHAFT REAR OIL SEAL RETAINER
REMOVAL.............................117
INSTALLATION..........................117
FLEX PLATE
REMOVAL.............................118
INSTALLATION..........................118
HYDRAULIC LIFTERS (CAM IN BLOCK)
DESCRIPTION..........................118
DIAGNOSIS AND TESTING................118
HYDRAULIC LIFTERS...................118
REMOVAL.............................119
INSTALLATION..........................119
PISTON & CONNECTING ROD
DESCRIPTION..........................119
OPERATION............................120
STANDARD PROCEDURE.................120
CONNECTING ROD AND BEARING -
FITTING.............................120
PISTON - FITTING.....................121
REMOVAL.............................121
INSTALLATION..........................122
PISTON RINGS
STANDARD PROCEDURE.................124
PISTON RING - FITTING................124
REMOVAL.............................124
INSTALLATION..........................125
VIBRATION DAMPER
REMOVAL.............................126
INSTALLATION..........................126
ENGINE MOUNTING
DESCRIPTION..........................127
FRONT MOUNT
REMOVAL.............................127
INSTALLATION..........................127
LEFT MOUNT
REMOVAL.............................128
INSTALLATION..........................128
REAR MOUNT
REMOVAL.............................129
INSTALLATION..........................130
RIGHT MOUNT
REMOVAL.............................130
INSTALLATION..........................131
LUBRICATION
DESCRIPTION..........................131
OPERATION............................131
DIAGNOSIS AND TESTING................131
ENGINE OIL PRESSURE................131OIL
STANDARD PROCEDURE.................132
ENGINE OIL CHANGE..................132
ENGINE OIL LEVEL CHECK..............133
OIL COOLER & LINES
DESCRIPTION..........................134
OPERATION............................134
REMOVAL.............................134
INSTALLATION..........................134
OIL FILTER
REMOVAL.............................135
INSTALLATION..........................135
OIL FILTER ADAPTER
REMOVAL.............................135
INSTALLATION..........................135
OIL PAN
REMOVAL.............................136
CLEANING.............................136
INSPECTION...........................136
INSTALLATION..........................136
OIL PRESSURE RELIEF VALVE
REMOVAL.............................137
INSTALLATION..........................137
OIL PRESSURE SENSOR/SWITCH
DESCRIPTION..........................137
OPERATION............................138
REMOVAL.............................138
INSTALLATION..........................138
OIL PUMP
DESCRIPTION..........................138
REMOVAL.............................138
DISASSEMBLY..........................138
CLEANING.............................138
INSPECTION...........................138
ASSEMBLY............................140
INSTALLATION..........................140
INTAKE MANIFOLD
DESCRIPTION..........................140
OPERATION............................141
DIAGNOSIS AND TESTING................141
INTAKE MANIFOLD LEAKS..............141
INTAKE MANIFOLD - UPPER 3.3L
STANDARD PROCEDURE.................141
MANIFOLD STRIPPED THREAD REPAIR....141
INTAKE MANIFOLD VACUUM PORT REPAIR . 142
REMOVAL.............................143
CLEANING.............................144
INSPECTION...........................144
INSTALLATION..........................144
INTAKE MANIFOLD - UPPER 3.8L
REMOVAL.............................145
CLEANING.............................146
INSPECTION...........................147
INSTALLATION..........................147
INTAKE MANIFOLD - LOWER
REMOVAL.............................148
CLEANING.............................148
9 - 72 ENGINE 3.3/3.8LRS

CONDITION POSSIBLE CAUSE CORRECTION
ENGINE STALLS
OR IDLES
ROUGH1. Idle speed too low. 1. Test minimum air flow. (Refer to
Appropriate Diagnostic Information)
2. Incorrect fuel mixture. 2. (Refer to Appropriate Diagnostic
Information)
3. Intake manifold leakage. 3. Inspect intake manifold, manifold gasket,
and vacuum hoses.
4. Faulty ignition coil(s). 4. Test and replace as necessary. (Refer to
Appropriate Diagnostic Information)
ENGINE LOSS OF
POWER1. Dirty or incorrectly gapped plugs. 1. Clean plugs and set gap.
2. Contamination in fuel system. 2. Clean system and replace fuel filter.
3. Faulty fuel pump. 3. Test and replace as necessary. (Refer to
Appropriate Diagnostic Information)
4. Incorrect valve timing. 4. Correct valve timing.
5. Leaking cylinder head gasket. 5. Replace cylinder head gasket.
6. Low compression. 6. Test compression of each cylinder.
7. Burned, warped, or pitted valves. 7. Replace valves.
8. Plugged or restricted exhaust system. 8. Perform exhaust restriction test. (Refer to
11 - EXHAUST SYSTEM - DIAGNOSIS AND
TESTING) Install new parts, as necessary.
9. Faulty ignition coil(s). 9. Test and replace as necessary. (Refer to
Appropriate Diagnostic Information)
ENGINE MISSES
ON
ACCELERATION1. Dirty or incorrectly gapped spark plugs. 1. Clean spark plugs and set gap.
2. Contamination in Fuel System. 2. Clean fuel system and replace fuel filter.
3. Burned, warped, or pitted valves. 3. Replace valves.
4. Faulty ignition coil(s). 4. Test and replace as necessary. (Refer to
Appropriate Diagnostic Information)
ENGINE MISSES
AT HIGH SPEED1. Dirty or incorrect spark plug gap. 1. Clean spark plugs and set gap.
2. Faulty ignition coil(s). 2. Test and replace as necessary. (Refer to
Appropriate Diagnostic Information)
3. Dirty fuel injector(s). Test and replace as necessary. (Refer to
Appropriate Diagnostic Information)
4. Contamination in fuel system. 4. Clean system and replace fuel filter.
RSENGINE 3.3/3.8L9-75
ENGINE 3.3/3.8L (Continued)