2001 CHRYSLER VOYAGER service

INSTALLATION
(1) Clean cylinder head and cover mating surfaces.
Inspect cylinder head cover surface for flatness.
Replace gasket as necessary.
(2) Inspect seal on the cover bolt for wear or dam-
age (Fig. 24). Replace bolt assembly as necessary.
NOTE: The cylinder head cover bolts contain a
torque limiter sleeve and a seal (Fig. 24). The seal
and torque sleeve is replaced with the bolt.
(3) Assemble gasket to cylinder cover by inserting
the bolt assemblies through each bolt hole on the
cover and gasket (Fig. 24).
(4) Install cylinder head cover and bolts (Fig. 25).
(5) Tighten cylinder head cover bolts to 12 N´m
(105 in. lbs.) (Fig. 25).
(6) Connect PCV hose to cylinder head cover.
(7) Connect power steering pump supply hose sup-
port clip to cylinder head cover (Fig. 22).
(8) Connect spark plug wires to spark plugs.
(9) Install wiper module. (Refer to 8 - ELECTRI-
CAL/WIPERS/WASHERS/WIPER MODULE -
INSTALLATION)
(10) Connect negative cable to battery.
CYLINDER HEAD COVER -
LEFT
REMOVAL
(1) Disconnect spark plug wires from spark plugs.
(2) Disconnect crankcase vent hose from cylinder
head cover.
(3) Remove cylinder head cover bolts.
(4) Remove cylinder head cover and gasket.
Fig. 23 PCV Hose
1 - HOSE - PCV
2 - P C V VA LV E
Fig. 24 CYLINDER HEAD COVER GASKET
1 - CYLINDER HEAD COVER
2 - BOLT
3 - SEAL (SERVICED WITH BOLT)
4 - GASKET
Fig. 25 Cylinder Head Cover
1 - CYLINDER HEAD COVER
2 - BOLT
9 - 98 ENGINE 3.3/3.8LRS
CYLINDER HEAD COVER - RIGHT (Continued)

CLEANING
Clean cylinder block thoroughly using a suitable
cleaning solvent.
INSPECTION
ENGINE BLOCK
(1) Clean cylinder block thoroughly and check all
core hole plugs for evidence of leaking.
(2) If new core plugs are to be installed, refer to
Engine Core Plugs for procedures (Refer to 9 -
ENGINE - STANDARD PROCEDURE).
(3) Examine block and cylinder bores for cracks or
fractures.
(4) Check block deck surfaces for flatness. Deck
surface must be within service limit of 0.1 mm (0.004
in.).
CYLINDER BORE
NOTE: The cylinder bores should be measured at
normal room temperature, 21ÉC (70ÉF).
The cylinder walls should be checked for out-of-
round and taper with Tool C119 or equivalent (Fig.
44). (Refer to 9 - ENGINE - SPECIFICATIONS) If
the cylinder walls are badly scuffed or scored, the
cylinder block should be replaced, and new pistons
and rings fitted.
Measure the cylinder bore at three levels in direc-
tions A and B (Fig. 44). Top measurement should be
10 mm (3/8 in.) down and bottom measurement
should be 10 mm (3/8 in.) up from bottom of bore.Refer to Engine Specifications (Refer to 9 - ENGINE
- SPECIFICATIONS).
CAMSHAFT & BEARINGS (IN
BLOCK)
DESCRIPTION
The nodular iron camshaft is mounted in the
engine block and supported with four steel backed
aluminum bearings (Fig. 45). A thrust plate, located
in front of the first bearing, is bolted to the block and
controls the camshaft end play (Fig. 45). To distin-
guish camshafts between the 3.3L and 3.8L engines,
a cast-in ring is located between the rear bearing
journal and rear lobe (Fig. 46). The 3.3L engine
application is as-cast only. The 3.8L engine applica-
tion the cast ring is machined off.
OPERATION
The camshaft is driven by the crankshaft through
a timing chain and sprockets. The camshaft has pre-
cisely machined (egg-shaped) lobes to provide accu-
rate valve timing and duration.
REMOVAL
(1) Remove the engine assembly from vehicle.
(Refer to 9 - ENGINE - REMOVAL)
Remove the cylinder heads. (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL)
(2) Remove the timing chain and camshaft
sprocket. (Refer to 9 - ENGINE/VALVE TIMING/
Fig. 43 Cylinder Bore Cross-Hatch Pattern
1 - CROSS-HATCH PATTERN
2 - 40ɱ60É
Fig. 44 Checking Cylinder Bore Size
RSENGINE 3.3/3.8L9 - 107
ENGINE BLOCK (Continued)

TIMING BELT/CHAIN AND SPROCKETS -
REMOVAL)
(3) Remove the hydraulic lifters. (Refer to 9 -
ENGINE/ENGINE BLOCK/HYDRAULIC LIFTERS
(CAM IN BLOCK) - REMOVAL). Identify each tappet
for reinstallation in original location.
(4) Remove camshaft thrust plate (Fig. 45).
(5) Install a long bolt into front of camshaft to
facilitate removal of the camshaft.
(6) Remove the camshaft (Fig. 45), being careful
not to damage cam bearings with the cam lobes.
NOTE: The camshaft bearings are serviced with the
engine block.
INSPECTION
(1) Check the cam lobes and bearing surfaces for
abnormal wear and damage (Fig. 47). Replace cam-
shaft as required.
NOTE: If camshaft is replaced due to lobe wear or
damage, always replace the lifters.
(2) Measure the lobe actual wear (unworn area -
wear zone = actual wear) (Fig. 47) and replace cam-
shaft if out of limit. Standard value is 0.0254 mm
(0.001 in.), wearlimitis 0.254 mm (0.010 in.).
INSTALLATION
(1) Lubricate camshaft lobes and camshaft bearing
journals with engine oil.
(2) Install a long bolt into the camshaft to assist in
the installation of the camshaft.
(3) Carefully install the camshaft in engine block.
(4) Install camshaft thrust plate and bolts (Fig.
45). Tighten to 12 N´m (105 in. lbs.) torque.
(5) Measure camshaft end play. (Refer to 9 -
ENGINE - SPECIFICATIONS) If not within specifi-
cations, replace thrust plate.
(6) Install the timing chain and sprockets. (Refer
to 9 - ENGINE/VALVE TIMING/TIMING BELT/
CHAIN AND SPROCKETS - INSTALLATION)
NOTE: When camshaft is replaced, all of the
hydraulic lifters must be replaced also.
(7) Install the hydraulic lifters (Refer to 9 -
ENGINE/ENGINE BLOCK/HYDRAULIC LIFTERS
(CAM IN BLOCK) - INSTALLATION). Each lifter
Fig. 45 CAMSHAFT AND BEARINGS
1 - CAMSHAFT
2 - THRUST PLATE
3 - BOLT
4 - CAMSHAFT BEARINGS (SERVICED WITH BLOCK)
Fig. 46 CAMSHAFT IDENTIFICATION
1 - CAMSHAFT - 3.3L ENGINE
2 - CAST-IN RING
3 - CAMSHAFT - 3.8L ENGINE
4 - MACHINED CAST-IN RING
Fig. 47 Checking Camshaft for Wear (Typical)
1 - UNWORN AREA
2 - ACTUAL WEAR
3 - BEARING JOURNAL
4 - LOBE
5 - WEAR ZONE
9 - 108 ENGINE 3.3/3.8LRS
CAMSHAFT & BEARINGS (IN BLOCK) (Continued)

CRANKSHAFT MAIN
BEARINGS
STANDARD PROCEDURE - MAIN BEARING
FITTING
Bearing caps are not interchangeable and should
be marked at removal to insure correct assembly
(Fig. 56). Upper and lower bearing halves are NOT
interchangeable. Lower main bearing halves of 1, 3
and 4 are interchangeable. Upper main bearing
halves of 1, 3 and 4 are interchangeable.
Upper and lower number 2 bearing halves are
flanged to carry the crankshaft thrust loads and are
NOT interchangeable with any other bearing halves
in the engine (Fig. 57). All bearing cap bolts removed
during service procedures are to be cleaned and
lubricated with engine oil before installation. Bearing
shells are available in standard and the following
undersizes: 0.025 mm (0.001 in.) and 0.254 mm
(0.010 in). Never install an undersize bearing that
will reduce clearance below specifications.
CRANKSHAFT BEARING OIL CLEARANCE
Inspect the crankshaft bearing journals. (Refer to 9
- ENGINE/ENGINE BLOCK/CRANKSHAFT -
INSPECTION)
Engine crankshaft bearing clearances can be deter-
mined by use of Plastigage or the equivalent. The fol-
lowing is the recommended procedures for the use of
Plastigage with the engine in the vehicle or engine
on a repair stand.PLASTIGAGE METHODÐENGINE IN-VEHICLE
NOTE: The total clearance of the main bearings can
only be determined with the engine in the vehicle
by removing the weight of the crankshaft. This can
be accomplished by either of two following meth-
ods:
(1) Preferred method:
²Shim the bearings adjacent to the bearing to be
checked in order to remove the clearance between
upper bearing shell and the crankshaft. This can be
accomplished by placing a minimum of 0.254 mm
(0.010 in.) shim (e. g. cardboard, matchbook cover,
etc.) between the bearing shell and the bearing cap
on the adjacent bearings and tightening bolts to
14±20 N´m (10±15 ft. lbs.).
²When checking #1 main bearing shim #2 main
bearing.
²When checking #2 main bearing shim #1 & #3
main bearing.
²When checking #3 main bearing shim #2 & #4
main bearing.
²When checking #4 main bearing shim #3 main
bearing.
NOTE: Remove all shims before reassembling
engine.
Fig. 56 Main Bearing Cap Identification
Fig. 57 Main Bearing Identification
1 - OIL GROOVES
2 - OIL HOLES
3 - UPPER BEARINGS
4 - LOWER BEARINGS
RSENGINE 3.3/3.8L9 - 113

ENGINE 2.5L TURBO DIESEL
TABLE OF CONTENTS
page page
ENGINE 2.5L TURBO DIESEL
DESCRIPTION............................2
REMOVAL...............................3
INSTALLATION............................6
SPECIFICATIONS.........................7
SPECIAL TOOLS.........................12
CYLINDER HEAD
STANDARD PROCEDURE..................18
VALVE SERVICE.......................18
MEASURING PISTON PROTRUSION........19
REMOVAL..............................20
CLEANING..............................21
INSPECTION............................22
INSTALLATION...........................22
CAMSHAFT(S)
DESCRIPTION...........................23
OPERATION.............................23
REMOVAL..............................23
INSTALLATION...........................24
CYLINDER HEAD COVER(S)
DESCRIPTION...........................24
REMOVAL..............................24
INSTALLATION...........................26
CAMSHAFT OIL SEAL(S)
REMOVAL..............................28
INSTALLATION...........................28
ROCKER ARMS
DESCRIPTION...........................28
OPERATION.............................28
REMOVAL..............................28
INSTALLATION...........................29
HYDRAULIC LIFTERS
DESCRIPTION...........................30
REMOVAL..............................30
INSPECTION............................31
INSTALLATION...........................31
ENGINE BLOCK
DESCRIPTION...........................31
CRANKSHAFT
DESCRIPTION...........................31
OPERATION.............................31
STANDARD PROCEDURE..................32
CHECKING CRANKSHAFT END PLAY.......32
REMOVAL..............................32
INSTALLATION...........................33
CYLINDER LINERS
DESCRIPTION...........................34
REMOVAL..............................34
INSPECTION............................34INSTALLATION...........................35
INTERNAL VACUUM PUMP
DESCRIPTION...........................36
REMOVAL..............................36
INSTALLATION...........................36
PISTON & CONNECTING ROD
DESCRIPTION...........................37
STANDARD PROCEDURE..................37
PISTON RING FITTING..................37
REMOVAL..............................38
INSPECTION............................38
INSTALLATION...........................40
CRANKSHAFT OIL SEAL - FRONT
REMOVAL..............................42
INSTALLATION...........................42
VIBRATION DAMPER
REMOVAL..............................43
INSTALLATION...........................44
ENGINE COVER - FRONT
DESCRIPTION...........................44
REMOVAL..............................44
INSTALLATION...........................45
CRANKSHAFT MAIN BEARINGS
REMOVAL..............................45
INSTALLATION...........................46
CRANKSHAFT OIL SEAL - REAR
REMOVAL..............................46
INSTALLATION...........................46
OIL PAN
REMOVAL..............................46
INSTALLATION...........................47
OIL PUMP
REMOVAL..............................47
INSTALLATION...........................48
OIL PRESSURE SENSOR/SWITCH
DESCRIPTION...........................49
REMOVAL..............................49
INSTALLATION...........................50
OIL TEMPERATURE SENSOR
DESCRIPTION...........................50
REMOVAL..............................50
INSTALLATION...........................50
OIL PRESSURE RELIEF VALVE
DESCRIPTION...........................50
REMOVAL..............................51
INSTALLATION...........................51
OIL COOLER & LINES
REMOVAL..............................51
INSTALLATION...........................52
RGENGINE 2.5L TURBO DIESEL9a-1

SPECIFICATIONS - TORQUE
2.5L DIESEL TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Oil Pump Bolts 10.8 8 96
Vacuum Pump Bolts 10.8 8 96
Crankshaft Gear Bolts 10.8 8 96
Crankshaft Position
Sensor Bolts10.8 8 96
Flywheel Bolts - Refer to the Service Procedure
Cylinder Head Bolts - Refer to the Service Procedure
Reluctor Wheel Bolts 14.6 11 130
Rear Main Bearing
Support Bolts27.5 21 240
Oil Cooler to Engine Block
Bolt47.1 35 Ð
Oil Cooler Mounting Stud 50 37 Ð
Water Pump Housing Nuts 24.4 18 212
Connecting Rod Bolts - Refer to the Service Procedure
Balance Shaft Bolts 32.4 24 Ð
Oil Jet Bolts 10.8 8 96
Oil Pan Bolts 11.8 8 96
Crankshaft Hub Bolt 304 225 Ð
Front Engine Cover Bolts 11.8 8 96
Transmission to Engine
Bolts83.4 62 Ð
Cylinder Head Cover /
Intake Manifold Bolts27.5 20 Ð
Camshaft Access Plugs 80 59 Ð
Oil Separator Bolts 10.8 8 96
Camshaft Position Sensor
Bolt10.8 8 96
Boost Pressure / Intake
Air Temp. Sensor Bolts5.4 Ð 48
Accessory Drive Bracket
Bolts47.1 35 Ð
Vacuum Line Fitting Bolt 56.9 42 Ð
Fuel Pump Nuts 27.5 21 Ð
Fuel Line Fittings at Pump 27.5 21 Ð
Inner Timing Belt Cover Bolts
8mm 10.8 8 96
10mm 47.1 35 Ð
Outer Timing Belt Cover Bolts
3mm 6 Ð 54
8mm 10.8 8 96
9a - 10 ENGINE 2.5L TURBO DIESELRG
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

(6) Remove plug in cylinder head cover/intake
manifold and insert VM.1053 to lock exhaust cam-
shaft in position (Fig. 84).
(7) Remove generator (Refer to 8 - ELECTRICAL/
CHARGING/GENERATOR - REMOVAL).
(8) Remove plug in cylinder head cover/intake
manifold and insert VM.1052 to lock intake camshaft
in position (Fig. 85).
(9) At this point the timing belt can be removed
for service.
(10) After engine service is completed and timing
belt reinstalled, remove both camshaft locking pins
from cylinder head cover/intake manifold.
(11) Install both camshaft access plugs.
(12) Remove 90É after TDC engine locking pin.
(13) Install starter motor (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - INSTALLA-
TION).
(14) Install generator (Refer to 8 - ELECTRICAL/
CHARGING/GENERATOR - INSTALLATION).(15) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
(16) Install front wiper unit (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
INSTALLATION).
(17) Connect negative battery cable.
BALANCE SHAFT
DESCRIPTION
The 2.5L Common Rail Diesel engine is equipped
with two nodular cast iron balance shafts in a cast
aluminum carrier. The balance shaft assembly is
mounted to the engine block (Fig. 86).
Fig. 84 EXHAUST CAMSHAFT LOCKING PIN
VM.1053
1 - EXHAUST MANIFOLD HEAT SHIELD
2 - EXHAUST CAMSHAFT LOCKING PIN VM.1053
3 - COOLANT TUBE FROM THERMOSTAT HOUSING TO UPPER
RADIATOR HOSE
4 - CYLINDER HEAD COVER/INTAKE MANIFOLD
Fig. 85 INTAKE CAMSHAFT LOCKING PIN VM.1052
1 - TIMING BELT INNER COVER
2 - GLOW PLUG ELECTRICAL CONNECTOR
3 - CYLINDER HEAD COVER/INTAKE MANIFOLD
4 - FUEL RAIL
5 - INTAKE CAMSHAFT LOCKING PIN VM.1052
RGENGINE 2.5L TURBO DIESEL9a-55
VALVE TIMING (Continued)