2001 CHRYSLER VOYAGER length

DESCRIPTION SPECIFICATION
Weight
Ð3.3L 36265 grams
(12.7760.1764 oz.)
Ð3.8L 42665 grams
(15.0360.1764 oz.)
Piston Pins
Type Press Fit in Rod
(Serviced as an
Assembly)
Clearance in Piston @
21É C (70É F)0.006±0.019 mm
(0.0002±0.0007 in.)
Clearance in Connecting
Rod(Interference Fit)
Diameter 22.87±22.88 mm
(0.9007±0.9009 in.)
Length
Ð3.3L 67.25±67.75 mm
(2.648±2.667 in.)
Ð3.8L 71.25±71.75
(2.805±2.824 in.)
Piston Rings
Ring End GapÐTop
Compression Ring0.18±0.38 mm
(0.007±0.015 in.)
Wear Limit 1.0 mm
(0.039 in.)
Ring End GapÐ2nd
Compression Ring0.28±0.57 mm
(0.011±0.022 in.)
Wear Limit 1.0 mm
(0.039 in.)
Ring End GapÐOil
Control Steel Rails0.23±0.78 mm
(0.009±0.030 in.)
Wear Limit 1.88 mm
(0.074 in.)
Ring Side ClearanceÐ
Top Compression Ring
Ð3.3L 0.030±0.080 mm
(0.0012±0.0031 in.)
Ð3.8L 0.030±0.069 mm
(0.0012±0.0027 in.)
Wear Limit 0.10 mm
(0.004 in.)DESCRIPTION SPECIFICATION
Ring Side ClearanceÐ
2nd Compression Ring
Ð3.3L 0.030±0.095 mm
(0.0012±0.0037 in.)
Ð3.8L 0.041±0.085 mm
(0.0016±0.0033 in.)
Wear Limit 0.13 mm
(0.005 in.)
Ring Side ClearanceÐOil
Ring Pack0.039±0.200 mm
(0.0015±0.0078 in.)
Wear Limit 0.266 mm
(0.009 in.)
Ring WidthÐTop
Compression Ring
Ð3.3L 1.46±1.49 mm
(0.0575±0.058 in.)
Ð3.8L 1.175±1.190 mm
(0.0462±0.0468 in.)
Ring WidthÐ2nd
Compression Ring
Ð3.3/3.8L1.46±1.49 mm
(0.0575±0.058 in.)
Ring WidthÐOil Ring
(Steel Rails)
Ð3.3L 0.435±0.490 mm
(0.017±0.019 in.)
Ð3.8L 0.435±0.510 mm
(0.017±0.020 in.)
Connecting Rod
Bearing Clearance 0.019±0.065 mm
(0.0008±0.0026 in.)
Wear Limit 0.074 mm
(0.003 in.)
Side Clearance 0.13±0.32 mm
(0.005±0.013 in.)
Wear Limit 0.38 mm
(0.015 in.)
Crankshaft
Material Nodular Iron
Connecting Rod Journal
Diameter57.979±58.005 mm
(2.2827±2.2837 in.)
Main Bearing Journal
Diameter63.993±64.013 mm
(2.5194±2.5202 in.)
RSENGINE 3.3/3.8L9-87
SPECIFICATIONS (Continued)

DESCRIPTION SPECIFICATION
Face AngleÐIntake 45±45.5É
Face AngleÐExhaust 45±45.5É
Head DiameterÐIntake 47.87±48.13 mm
(1.88±1.89 in.)
Head DiameterÐExhaust 35.37±35.63 mm
(1.39±1.40 in.)
Valve Margin
Intake 0.825±0.973 mm
(0.032±0.038 in.)
Exhaust 1.565±1.713 mm
(0.061±0.067 in.)
Valve Length (Overall)
Intake 125.84±126.6 mm
(4.95±4.98 in.)
Exhaust 127.2±127.96 mm
(5.00±5.04 in.)
Valve Stem Tip Height
Intake (valve tip to spring
seat washer)48.1±49.7 mm
(1.89±1.95 in.)
Exhaust (valve tip to
spring seat washer)48.53±50.09 mm
(1.91±1.97 in.)
Valve Stem Diameter
Intake (Standard) 6.935±6.953 mm
(0.2730±0.2737 in.)
Exhaust (Standard) 6.906±6.924 mm
(0.2718±0.2725 in.)
Valve Stem to Guide Clearance
Intake 0.025±0.065 mm
(0.001±0.0025 in.)
Max. Allowable (Rocking
Method)0.247 mm
(0.010 in.)
Exhaust 0.059±0.094 mm
(0.002±0.0037 in.)
Max. Allowable (Rocking
Method)0.414 mm
(0.016 in.)
Push Rods
Length 135.438 mm
(5.33 in.)
Valve Springs
Free Length (Approx.) 51.4 mm
(2.02 in.)DESCRIPTION SPECIFICATION
Wire Diameter 3.95±4.77 mm
(0.15±0.19 in.)
Number of Coils 7.52
Spring Tension (Valve
Closed)376.4±424.4 N @ 41.9
mm
(84.6±95.6 lbs. @ 1.65
in.)
Installed Height 41.1±42.7 mm
(1.61±1.68 in.)
Oil Pump
Clearance Over
RotorsÐInner and Outer
(Max.)0.10 mm
(0.004 in.)
Cover Out-of-Flat (Max.) 0.025 mm
(0.001 in.)
Inner Rotor Thickness
(Min.)7.64 mm
(0.301 in.)
Outer Rotor Thickness
(Min.)7.64 mm
(0.301 in.)
Outer Rotor Clearance
(Max.)0.039 mm
(0.015 in.)
Outer Rotor Diameter
(Min.)79.95 mm
(3.148 in.)
Tip Clearance Between
Rotors (Max.)0.20 mm
(0.008 in.)
Oil Pressure
At Curb Idle Speed*
(Minimum with engine at
operating temerature)34.47 kPa
(5 psi)
At 3000 rpm 205±551 kPa
(30±80 psi)
Oil Filter By-pas Valve
Setting62±103 kPa
(9±15 psi)
Oil Pressure Switch
Actuating Pressure14±28 kPa
(2±4 psi)
caution:
*If pressure is ZERO at curb idle, DO NOT run
engine at 3000 rpm.
RSENGINE 3.3/3.8L9-89
SPECIFICATIONS (Continued)

(8) Locate the forcing screw and spring retainer
adapter assembly over the spring requiring removal
(Fig. 36).
(9) Slowly turn the forcing screw clockwise (com-
pressing the valve spring) until the valve keepers can
be removed.
(10) Turn forcing screw counterclockwise to relieve
spring tension. Remove retainer and valve spring.
(11) Repeat procedure for each cylinder requiring
valve spring removal.
INSPECTION
Whenever valves have been removed for inspection,
reconditioning or replacement, valve springs should
be tested (Fig. 37).As an example;the compression
length of a spring to be tested is 38.00 mm (1.496
in.). Turn the table of Tool C-647 until surface is in
line with the 38.00 mm (1.496 in.) mark on the
threaded stud and the zero mark on the front. Place
spring over stud on the table and lift compressing
lever to set tone device. Pull on torque wrench until
ping is heard. Take reading on torque wrench at this
instant. Multiply this reading by two. This will give
the spring load at test length. Fractional measure-
ments are indicated on the table for finer adjust-
ments. Refer to Engine Specifications to obtain
specified height and allowable tensions (Refer to 9 -
ENGINE - SPECIFICATIONS). Replace any springs
that do not meet specifications.
INSTALLATION - CYLINDER HEAD OFF
(1) If removed, install a new valve stem seal.
(Refer to 9 - ENGINE/CYLINDER HEAD/VALVE
STEM SEALS - INSTALLATION)
(2) Position valve spring and retainer on spring
seat.(3) Using Special Tool C-3422-C with 8464 Adapter
(Fig. 35), compress the spring only enough to install
the valve retainer locks.
(4) Slowly release the spring tension. Ensure the
retainer locks are seated properly.
INSTALLATION - CYLINDER HEAD ON
(1)The intake valve stem seals should be pushed
firmly and squarely over the valve guide using the
valve stem as guide.Do Not Force
seal against top of
guide. When installing the valve retainer locks, com-
press the springonly enoughto install the locks.
CAUTION: Do not pinch seal between retainer and
top of valve guide.
(2) Follow the same procedure on the remaining 5
cylinders using the firing sequence 1-2-3-4-5-6.Make
sure piston in cylinder is at TDC on the valve
spring that is being covered.
(3) Remove spark plug adapter tool.
(4) Install rocker arms and shaft assembly. (Refer
to 9 - ENGINE/CYLINDER HEAD/ROCKER ARMS -
INSTALLATION)
(5) Install cylinder head covers. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION)
(6) Install spark plugs and connect wires.
(7) Connect negative cable to battery.
ROCKER ARMS
DESCRIPTION - ROCKER ARMS
The rocker arms are installed on the rocker arm
shaft. The rocker arms and shaft assembly is attached
to the cylinder head with seven bolts and retainers.
The rocker arms are made of stamped steel.
Fig. 36 VALVE SPRING - REMOVE/INSTALL (HEAD ON)
1 - SPECIAL TOOL 8453
2 - BOLTS - SPECIAL TOOL ATTACHING
3 - AIR SUPPLY HOSE ADAPTER
Fig. 37 TESTING VALVE SPRING
1 - SPECIAL TOOL C-647
RSENGINE 3.3/3.8L9 - 103
VALVE SPRINGS (Continued)

DISASSEMBLY - ROCKER ARMS AND SHAFT
CAUTION: Do not attempt to drive the bolt from the
rocker shaft. This can damage the retainer and bolt
assembly.
(1) Remove the rocker arm retainer and bolt by
performing the following procedure:
(a) Using adjustable pliers, grip the edges of the
retainer (Fig. 39).
(b) Apply an upward force with a slight rocking
motion until the retainer disengages from shaft
(Fig. 39).
(2) Remove rocker arms (Fig. 40). Identify the
component locations for reassembly in original loca-
tions.
ASSEMBLY - ROCKER ARMS AND SHAFT
(1) Install rocker arms on the shaft (Fig. 40).
Install in the orginal positions if re-used.Ensurethe
rocker shaft, all the retainers and washers are prop-
erly positioned and installed in the correct locations
(Fig. 40).(2) Install rocker arms and shaft to the cylinder
head. (Refer to 9 - ENGINE/CYLINDER HEAD/
ROCKER ARMS - INSTALLATION)
INSTALLATION - ROCKER ARMS AND SHAFT
CAUTION: Ensure the longer shaft retaining bolt is
installed in the proper location on the rocker shaft.
(Refer to 9 - ENGINE/CYLINDER HEAD/ROCKER
ARMS - ASSEMBLY)
(1) Position the rocker arm and shaft assemblies
on the pedestal mounts.
CAUTION: Ensure all pushrods are properly located
on the lifter and the rocker arm socket.
(2) Align each rocker arm socket with each push-
rod end.
CAUTION: The rocker arm shaft should be tight-
ened down slowly, starting with the center bolts.
Allow 20 minutes lifter bleed down time after instal-
lation of the rocker shafts before engine operation.
Fig. 40 ROCKER ARMS AND SHAFT
1 - BOLT (ROCKER SHAFT OIL FEED - LONGER LENGTH) 5 - ROCKER ARM - EXHAUST
2 - SHAFT RETAINER/SPACER - 21.5 mm (0.84 in.) 6 - WASHER
3 -SHAFT RETAINER/SPACER - 37.5 mm (1.47 in.) 7 - ROCKER ARM - INTAKE (LARGER OFFSET)
4 - SHAFT RETAINER/SPACER - 40.9 mm (1.61 in.) 8 - ROCKER ARMS LUBRICATION FEED HOLE (POSITION
UPWARD & TOWARD VALVE SPRING_
RSENGINE 3.3/3.8L9 - 105
ROCKER ARMS (Continued)

(2) Alternative Method:
²Support the weight of the crankshaft with a jack
under the counterweight adjacent to the bearing
being checked.
(3) Remove oil film from surface to be checked.
Plastigage is soluble in oil.
(4) 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. 58). (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.
(5) Remove the bearing cap and compare the width
of the flattened Plastigage (Fig. 59) with the scale
provided on the package. Locate the band closest to
the same width. This band shows the amount of
clearance in thousandths. Differences in readings
between the ends indicate the amount of taper
present. Record all readings taken. (Refer to 9 -
ENGINE - SPECIFICATIONS)Plastigage gener-
ally is accompanied 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.PLASTIGAGE METHODÐENGINE OUT-OF-VEHICLE
(1) With engine in the inverted position (crank-
shaft up) and mounted on a repair stand, remove
main journal cap.
(2) Remove oil from journal and bearing shell.
(3) Cut Plastigage to same length as width of the
bearing and place it in parallel with the journal axis
(Fig. 58).
(4) Carefully install the main bearing cap and
tighten the bolts to specified torque.
CAUTION: Do not rotate crankshaft or the Plasti-
gage will be smeared.
(5) Carefully remove the bearing cap and measure
the width of the Plastigage at the widest part using
the scale on the Plastigage package (Fig. 59). Refer
to Engine Specifications for proper clearances (Refer
to 9 - ENGINE - SPECIFICATIONS). If the clearance
exceeds the specified limits, replace the main bear-
ing(s) with the appropriate size, and if necessary,
have the crankshaft machined to next undersize.
REMOVAL - CRANKSHAFT MAIN BEARINGS
(1) Remove the oil pan. (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL)
(2) Identify main bearing caps before removal.
(3) Remove bearing caps one at a time. Remove
upper half of bearing by inserting Special Main Bear-
ing Tool C-3059 (Fig. 60) into the oil hole of crank-
shaft.
(4) Slowly rotate crankshaft clockwise, forcing out
upper half of bearing shell.
Fig. 58 Plastigage Placed in Lower
1 - PLASTIGAGE
Fig. 59 Clearance Measurement
Fig. 60 Upper Main Bearing Removing/Installing
With Special Tool C-3059
1 - SPECIAL TOOL C-3059
2 - BEARING
3 - SPECIAL TOOL C-3059
4 - BEARING
9 - 114 ENGINE 3.3/3.8LRS
CRANKSHAFT MAIN BEARINGS (Continued)

(8) Remove oil pressure relief valve. (Refer to 9 -
ENGINE/LUBRICATION/OIL PRESSURE RELIEF
VALVE - REMOVAL)
(9) Inspect oil pressure relief valve and bore.
Inspect for scoring, pitting and free valve operation
in bore (Fig. 118). Small marks may be removed with
400-grit wet or dry sandpaper.
(10) The relief valve spring has a free length of
approximately 49.5 mm (1.95 inches) it should test
between 19.5 and 20.5 pounds when compressed to
34 mm (1-11/32 inches). Replace spring that fails to
meet specifications.(11) If oil pressure is low and pump is within spec-
ifications, inspect for worn engine bearings or other
reasons for oil pressure loss.
ASSEMBLY
(1) Assemble pump, using new parts as required.
Install the inner rotor with chamfer facing the
cast iron oil pump cover.
(2) Prime oil pump before installation by filling
rotor cavity with engine oil.
(3) Install cover and tighten screws to 12 N´m (105
in. lbs.).
(4) If removed, install the oil pressure relief valve.
(Refer to 9 - ENGINE/LUBRICATION/OIL PRES-
SURE RELIEF VALVE - INSTALLATION)
INSTALLATION
(1) Install oil pump. (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PUMP - ASSEMBLY)
(2) Install timing chain cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION) and oil pan (Refer to 9
- ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
INTAKE MANIFOLD
DESCRIPTION
The intake system is made up of an upper and
lower intake manifold. The upper intake manifold is
made of a composite for the 3.3L engine (Fig. 119)
and aluminum for the 3.8L engine (Fig. 120). The
lower intake manifold is common between the two
engines (Fig. 121). It also provides coolant crossover
Fig. 116 Measuring Clearance Between Rotors
1 - FEELER GAUGE
2 - INNER ROTOR
3 - OUTER ROTOR
Fig. 117 Measuring Clearance Over Rotors
1 - FEELER GAUGE
2 - STRAIGHT EDGE
Fig. 118 Oil Pressure Relief Valve
1 - RELIEF VALVE
2 - SPRING
3 - RETAINER CAP
9 - 140 ENGINE 3.3/3.8LRS
OIL PUMP (Continued)

DESCRIPTION SPECIFICATION
Top of Piston to Cylinder
Head0.69-0.92 mm
Piston Potrusion 0.40-0.60 Fit Gasket
Number (1.32), 0 notches
or holes
0.61-0.70 Fit Gasket
Number (1.42), 1 notch
or hole
0.71-0.83 Fit Gasket
Number (1.52), 2 notches
or holes
PISTON PINS
Type Full Floating
Pin Diameter 29.992-29.996 mm
Clearance 0.004-0.012 mm
PISTON RINGS
Clearance in Groove
Top 0.080-0.130 mm
Second 0.070-0.110 mm
Oil Control 0.040-0.080 mm
Fitted Gap
Top 0.30-0.45 mm
Second 0.30-0.45 mm
Oil Control 0.25-0.50 mm
CAMSHAFT
Journal Diameter±Front 38.980-39.000 mm
Bearing Clearance 0.100-0.150 mm
Journal Diameter±Center 38.980-39.000 mm
Bearing Clearance 0.100-0.150 mm
Journal Diameter±Rear 38.980-39.000 mm
Bearing Clearance 0.100-0.150 mm
TAPPETS
Outside Diameter 14.965-14.985 mm
ROCKER GEAR
Shaft Diameter 29.960-29.980 mm
Bushing Internal
Diameter30.020-30.060 mm
Assembly Clearance 0.040-0.100 mm
VA LV E S
Intake Valve
Opens 16É B.T.D.C.
Closes 58É A.B.D.C.
Exhaust ValveDESCRIPTION SPECIFICATION
Opens 65É B.B.D.C.
Closes 29É A.T.D.C.
Face Angle
Intake 45É 25'-55É 35'
Exhaust 45É 25'-45É 35'
Head Diameter
Intake 32.30-32.50 mm
Exhaust 30.80-31.00 mm
Head Stand Down
Intake 1.08-1.34 mm
Exhaust 0.99-1.25 mm
Stem Diameter
Intake 5.952-5.970 mm
Exhaust 5.942-5.960 mm
Clearance in Guide
Intake 0.030-0.060 mm
Exhaust 0.040-0.070 mm
VALVE GUIDE
Inside Diameter 6.00-6.012 mm
Fitted Height 14.5-15.0 mm
VALVE SPRINGS
Free Length 45.26 mm
Fitted Length 38.00 mm
Load at Fitted Length 182   5-10% Kg
Load at Top of Lift 395   5% Kg
Number of Coils 8
LUBRICATION
System Pressure at 4000
RPM4.5-5.0 bar (oil at
90-100ÉC)
Pressure Relief Valve
Opens7.00 bar
Pressure Relief Valve
Spring-Free Length51.5 mm
OIL PUMP
Outer Rotor End Float 0.060-0.160 mm
Inner Rotor End Float 0.060-0.160 mm
Outer Rotor to Body
Diameter Clearance0.130-0.240 mm
Rotor Body to Drive Gear
Clearance (pump not
fitted)0.90-1.50 mm
RGENGINE 2.5L TURBO DIESEL9a-9
ENGINE 2.5L TURBO DIESEL (Continued)

CYLINDER HEAD
STANDARD PROCEDURE - VALVE SERVICE
This procedure is done with the engine cylinder
head removed from the block.
DISASSEMBLY
(1) Remove the engine cylinder head from the cyl-
inder block. Refer to cylinder head removal and
installation in this section.
(2) Use Valve Spring Compressor Tool and com-
press each valve spring.
(3) Remove the valve locks, retainers, and springs.
(4) Use an Arkansas smooth stone or a jewelers
file to remove any burrs on the top of the valve stem,
especially around the groove for the locks.
(5) Remove the valves, and place them in a rack in
the same order as removed.
VALVE CLEANING
(1) Clean all carbon deposits from the combustion
chambers, valve ports, valve stems, valve stem
guides and head.
(2) Clean all grime and gasket material from the
engine cylinder head machined gasket surface.
INSPECTION
(1) Inspect for cracks in the combustion chambers
and valve ports.
(2) Inspect for cracks on the exhaust seat.
(3) Inspect for cracks in the gasket surface at each
coolant passage.
(4) Inspect valves for burned, cracked or warped
heads.
(5) Inspect for scuffed or bent valve stems.
(6) Replace valves displaying any damage.
(7) Check valve spring height (Fig. 12).
VALVE REFACING
(1) Use a valve refacing machine to reface the
intake and exhaust valves to the specified angle.
(2) After refacing, a margin of at least 4.52-4.49
mm (.178-.177 inch) must remain (Fig. 13). If the
margin is less than 4.49 mm (.177 inch), the valve
must be replaced.
VALVE SEAT REFACING
(1) Install a pilot of the correct size in the valve
guide bore. Reface the valve seat to the specified
angle with a good dressing stone. Remove only
enough metal to provide a smooth finish.
(2) Use tapered stones to obtain the specified seat
width when required.
VALVE STAND DOWN
Valve stand down is to maintain the adequate com-
pression ratio.
(1) Invert cylinder head.
(2) Fit each valve to its respective valve guide.
(3) Using a straight edge and feeler gauge, check
valve head stand down: Inlet valve head stand down
1.08 to 1.34 mm (.042 to .052 ins.) and exhaust valve
stand down .99 to 1.25 mm (.035 to .049 ins.).
(4) If valve head stand down is not in accordance
with above, discard original valves, check stand down
with new valves and recut valve seat inserts to
obtain correct stand down.
VALVE GUIDES
(1) Valve Guides height requirement.
(2) Measurement A (Fig. 14): 13.50 - 14.00 mm.
VALVE STEM-TO-GUIDE CLEARANCE
MEASUREMENT
(1) Measure and record internal diameter of valve
guides. Valve guide internal diameter is 8.0 to 8.015
mm (.3149 to .3155 ins.).
(2) Measure valve stems and record diameters.
Intake valve stem diameter 7.94 to 7.96 mm (.3125 to
.3133 in). Exhaust valve stem diameter 7.92 to 7.94
mm (.3118 to .31215 in).
Fig. 12 VALVE SPRING CHART
LOAD Kg HEIGHT mm STATE
P1 0.00 H1 45.26 FREE LENGTH
P2 182 5 -
10%H2 38.00 VALVE CLOSED
P3 395 5% H3 28.20 VALVE OPEN
9a - 18 ENGINE 2.5L TURBO DIESELRG