2001 CHRYSLER VOYAGER battery

INSTALLATION
(1) Before installing pistons and connecting rod
assemblies into the bore, ensure that compression
ring gaps are staggered so that neither is in line with
oil ring rail gap (Fig. 78).
(2) Before installing the ring compressor, ensure
the oil ring expander ends are butted and the rail
gaps located as shown in (Fig. 78).
(3) Lubricate the piston and rings with clean
engine oil. Position a ring compressor over the piston
and rings, and tighten the compressor (Fig. 79).Be
sure position of rings does not change during
this operation.(4) Position upper bearing onto connecting rod.
Lubricate bearing with oil.
(5) Install connecting rod bolt protectors (rubber
hose or equivalent) on the connecting rod bolts (Fig.
79).
(6) The pistons are marked with a ªFº located near
the piston pin. Install piston with this mark posi-
tioned to front of engine on both cylinder banks. The
connecting rod oil squirt hole faces the major thrust
(right) side of the engine block (Fig. 80).
(7) Rotate crankshaft until the connecting rod
journal is located in the center of the cylinder bore.
Insert connecting rod and piston into cylinder bore.
Carefully guide connecting rod over the crankshaft
journal (Fig. 79).
(8) Tap the piston down in cylinder bore, using a
hammer handle. At the same time, guide connecting
rod into position on connecting rod journal.
(9) Install lower bearing shell and connecting rod
cap (Fig. 79). Install nuts on cleaned and oiled rod
bolts and tighten to 54 N´m (40 ft. lbs.) PLUS
1¤4
turn.
(10) Repeat procedure for each piston and connect-
ing rod installation.
(11) Install the cylinder heads. (Refer to 9 -
ENGINE/CYLINDER HEAD - INSTALLATION)
(12) Install the oil pan. (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - INSTALLATION)
(13) Fill engine crankcase with proper oil to cor-
rect level.
(14) Connect negative cable to battery.Fig. 78 Piston Ring End Gap Position
1 - SIDE RAIL UPPER
2 - NO. 1 RING GAP
3 - PISTON PIN
4 - SIDE RAIL LOWER
5 - NO. 2 RING GAP AND SPACER EXPANDER GAP
9 - 122 ENGINE 3.3/3.8LRS
PISTON & CONNECTING ROD (Continued)

VIBRATION DAMPER
REMOVAL
(1) Disconnect negative cable from battery.
(2) Raise vehicle on hoist.
(3) Remove the right front wheel and inner splash
shield.
(4) Remove the accessory drive belt. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)(5) Remove vibration damper bolt.
(6) Insert Special Tool 8450 into crankshaft nose
(Fig. 87).
(7) Position 3-jaw puller Special Tool 1026 on
damper as shown in (Fig. 87). Turn puller forcing
screw until damper releases from crankshaft.
(8) Remove the crankshaft vibration damper.
INSTALLATION
(1) Install crankshaft vibration damper using Spe-
cial Tool 8451 with thrust bearing/washer (Fig. 88).
NOTE: To minimize friction and prolong tool life,
lubricate the threads on the forcing screw of Spe-
cial Tool 8451.
(2) Position vibration damper on crankshaft.
(3) Screw Special Tool 8451 into crankshaft until
the bolt seats. Turn the nut to install damper until it
seats fully.
(4) Remove Special Tool 8451.
(5) Install the accessory drive belt. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION)
(6) Install inner splash shield and right front
wheel.
(7) Connect negative cable to battery.
Fig. 85 Piston Ring Installation
Fig. 86 Piston Ring End Gap Position
1 - GAP OF LOWER SIDE RAIL
2 - NO. 1 RING GAP
3 - GAP OF UPPER SIDE RAIL
4 - NO. 2 RING GAP AND SPACER EXPANDER GAP
Fig. 87 Vibration Damper - Removal
1 - SPECIAL TOOL 8450 - INSERT
2 - SPECIAL TOOL 1026-3JAWPULLER
9 - 126 ENGINE 3.3/3.8LRS
PISTON RINGS (Continued)

OIL PAN
REMOVAL
(1) Disconnect negative cable from battery and
remove engine oil dipstick.
(2) Raise vehicle on hoist and drain engine oil.
(3) Remove drive belt splash shield.
(4) Remove strut to transaxle attaching bolt (Fig.
106). Loosen strut to engine block attaching bolts.
(5) Remove transaxle case cover (Fig. 106).
(6) Remove oil pan fasteners (Fig. 107).
(7) Remove the oil pan and gasket (Fig. 107).
CLEANING
(1) Clean oil pan with solvent and wipe dry with a
clean cloth.
(2) Clean all gasket material from mounting sur-
faces of pan and block.
(3) Clean oil screen and pick-up tube in clean sol-
vent.
INSPECTION
(1) Inspect oil drain plug and plug hole for
stripped or damaged threads and repair as necessary.
Install a new drain plug gasket. Tighten to 27 N´m
(20 ft. lbs.).
(2) Inspect oil pan mounting flange for bends or
distortion. Straighten flange if necessary.
(3) Inspect condition of oil screen and pick-up tube.
INSTALLATION
(1) Clean sealing surfaces and apply a 1/8 inch
bead of MopartEngine RTV GEN II at the parting
line of the chain case cover and the rear seal retainer
(Fig. 108).
(2) Position a new pan gasket on oil pan (Fig. 107).
(3) Install oil pan and tighten fasteners to 12 N´m
(105 in. lbs.) (Fig. 107).
(4) Install cover to transaxle case (Fig. 106).
(5) Install the strut bolt to transaxle housing (Fig.
106). Tighten all bending brace bolts.
(6) Install the drive belt splash shield.
(7) Lower vehicle and install oil dipstick.
Fig. 105 OIL FILTER ADAPTER
1 - SEAL
2 - OIL FILTER ADAPTER
3 - OIL FILTER
4 - BOLT
5 - OIL PRESSURE SWITCH
6 - BOLT
Fig. 106 Powertrain Struts and Transaxle Case
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
9 - 136 ENGINE 3.3/3.8LRS
OIL FILTER ADAPTER (Continued)

(8) Connect negative cable to battery.
(9) Fill crankcase with oil to proper level.
OIL PRESSURE RELIEF VALVE
REMOVAL
(1) Remove oil pan.
(2) Drill a 3.175 mm (1/8 in.) hole in the center of
the retainer cap (Fig. 109). Insert a self-threading
sheet metal screw into the cap.
(3) Using suitable pliers, remove cap and discard.
(4) Remove spring and relief valve (Fig. 109).
INSTALLATION
(1) Clean relief valve, spring and bore.
NOTE: Lubricate relief valve with clean engine oil
before installing.
(2) Install relief valve and spring into housing.
(3) Install new retainer cap until flush with seal-
ing surface.
(4) Install oil pan.
(5) Fill crankcase with proper oil to correct level.
OIL PRESSURE SENSOR/
SWITCH
DESCRIPTION
The engine oil pressure switch is located on the
lower left front side of the engine. It screws into the
oil filter adapter. The normally closed switch provides
an input through a single wire to the low pressure
indicator light on the instrument cluster.
Fig. 107 OIL PAN
1 - GASKET
2 - BOLT
3 - OIL PAN
4 - NUT
Fig. 108 Oil Pan Sealing
1 - SEALER LOCATIONS
Fig. 109 Oil Pressure Relief Valve
1 - RELIEF VALVE
2 - SPRING
3 - RETAINER CAP
RSENGINE 3.3/3.8L9 - 137
OIL PAN (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)

(11) Install throttle and speed control cables.
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
THROTTLE CONTROL CABLE - INSTALLATION)
(12) Attach make up air hose clip into the hole in
the throttle cable bracket.
(13) Connect the vapor purge vacuum hose to
throttle body.
(14) 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)
(15) Install air cleaner and air inlet hose assembly.
(16) Connect the inlet air sensor electrical connec-
tor. (Refer to 14 - FUEL SYSTEM/FUEL INJEC-
TION/INLET AIR TEMPERATURE SENSOR -
COMPONENT LOCATION)
(17) Connect battery negative cable.
INTAKE MANIFOLD - LOWER
REMOVAL
(1) Perform fuel system pressure release procedure
(before attempting any repairs).(Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY - STANDARD
PROCEDURE)
(2) Drain the cooling system. (Refer to 7 - COOL-
ING - STANDARD PROCEDURE)
(3) Remove the upper intake manifold. (Refer to 9
- ENGINE/MANIFOLDS/INTAKE MANIFOLD -
REMOVAL)
(4) Remove the fuel line. (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/FUEL LINES - STANDARD
PROCEDURE) (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY/QUICK CONNECT FITTING - STAN-
DARD PROCEDURE)
(5) Remove ignition coil and bracket (Fig. 135).
(6) Disconnect heater supply hose and engine cool-
ant temperature sensor (Fig. 136).
(7) Disconnect the fuel injector wire harness.
(8) Remove the fuel injectors and rail assembly
(Fig. 135).
(9) Remove radiator upper hose.
(10) Remove the intake manifold bolts.
(11) Remove lower intake manifold (Fig. 137).
WARNING: INTAKE MANIFOLD GASKET IS MADE
OF VERY THIN METAL AND MAY CAUSE PER-
SONAL INJURY, HANDLE WITH CARE.
(12) Remove intake manifold seal retainers screws
(Fig. 137). Remove intake manifold gasket.
(13) Inspect and clean manifold. (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSPECTION) (Refer to 9 - ENGINE/MANIFOLDS/
INTAKE MANIFOLD - CLEANING)
CLEANING
(1) Discard gasket(s).
(2) Clean all sealing surfaces.
INSPECTION
Check for:
²Damage and cracks of each section.
²Clogged water passages in end cross-overs (if
equipped).
²Check for cylinder head mounting surface distor-
tion using a straightedge and thickness gauge. (Refer
to 9 - ENGINE/CYLINDER HEAD - INSPECTION)
Fig. 135 FUEL RAIL AND IGNITION COIL &
BRACKET
1 - FUEL RAIL
2 - BOLT - FUEL RAIL
3 - NUT - IGNITION COIL
4 - BOLT - IGNITION COIL
5 - IGNITION COIL
6 - BRACKET - IGNITION COIL
7 - STUD - IGNITION COIL
8 - SEPARATOR - SPARK PLUG CABLE
9 - BRACKET - SPARK PLUG CABLE SEPARATOR
10 - BOLT - SEPARATOR BRACKET
11 - BRACKET - SPARK PLUG CABLE SEPARATOR
9 - 148 ENGINE 3.3/3.8LRS
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)