2002 CHRYSLER VOYAGER Service Manual

tires clock trailer lug pattern drain bolt charging

Page 1417 of 2399

CHRYSLER VOYAGER 2002 Service Manual (3) Install balance shaft assembly and retaining
bolts (Fig. 89). Torque bolts to 32.4N´m.
(4) Install oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION).
(5) Refill engine oil to pro

(3) Install balance shaft assembly and retaining
bolts (Fig. 89). Torque bolts to 32.4N´m.
(4) Install oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION).
(5) Refill engine oil to proper level.
(6) Connect negative battery cable.
TIMING BELT / CHAIN
COVER(S)
REMOVAL
REMOVAL - TIMING BELT OUTER COVER
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(3) Remove air cleaner housing.
(4) Support engine and remove right engine mount
and bracket.
(5) Remove power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(6) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(7) Remove vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(8) Remove timing belt outer cover retaining bolts
and remove cover (Fig. 92).
REMOVAL - TIMING BELT INNER COVER
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(3) Remove air cleaner housing.
(4) Support engine and remove right engine mount
and bracket.
(5) Remove power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(6) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(7) Remove vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(8) Remove timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(9) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL).(10) Remove timing belt idler pulleys (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT IDLER
PULLEY - REMOVAL).
(11) Using special tool VM.1055, remove camshaft
sprockets (Fig. 93).
(12) Remove timing belt tensioner (Refer to 9 -
ENGINE/VALVE TIMING/TMNG BELT/CHAIN
TENSIONER&PULLEY - REMOVAL) .
(13) Remove injection pump sprocket (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL INJEC-
TION PUMP - REMOVAL).
(14) Remove timing belt inner cover retaining bolts
and remove cover (Fig. 94).
INSTALLATION
INSTALLATION - TIMING BELT OUTER COVER
(1) Install timing belt outer cover seal and cover
(Fig. 92). Torque 3mm bolts to 10.8N´m and 8mm
bolts to 10.8N´m.
(2) Install vibration damper (Refer to 9 - ENGINE/
ENGINE BLOCK/VIBRATION DAMPER - INSTAL-
LATION).
Fig. 92 TIMING BELT COVER (OUTER)
1 - SEAL
2 - TIMING BELT OUTER COVER
3 - RETAINING BOLTS
9a - 56 ENGINERG
BALANCE SHAFT (Continued)
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Page 1418 of 2399

CHRYSLER VOYAGER 2002 Service Manual (3) Install accessory drive belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(4) Install power steering belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LA

Page 1419 of 2399

CHRYSLER VOYAGER 2002 Service Manual (9) Install vibration damper (Refer to 9 - ENGINE/
ENGINE BLOCK/VIBRATION DAMPER - INSTAL-
LATION).
(10) Install accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).

(9) Install vibration damper (Refer to 9 - ENGINE/
ENGINE BLOCK/VIBRATION DAMPER - INSTAL-
LATION).
(10) Install accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(11) Install power steering belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(12) Install right engine mount assembly.
(13) Install air cleaner housing.
(14) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
(15) Connect negative battery cable.
TIMING BELT IDLER PULLEY
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(3) Remove air cleaner housing.
(4) Support engine and remove right engine
mount.
(5) Remove power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(6) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(7) Remove vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(8) Remove timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(9) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL).
NOTE: Idler pulley retaining bolts are LHD thread.
(10) Remove timing belt idler pulleys (Fig. 95).
INSTALLATION
(1) Install timing belt idler pulleys (Fig. 95).
Torque bolts to 47.1N´m.
(2) Install timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION) .
(3) Install timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(4) Install vibration damper (Refer to 9 - ENGINE/
ENGINE BLOCK/VIBRATION DAMPER - INSTAL-
LATION).(5) Install accessory drive belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(6) Install power steering belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(7) Install right engine mount.
(8) Install air cleaner housing.
(9) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
(10) Connect negative battery cable.
Fig. 95 TIMING BELT AND SPROCKETS
1 -CAMSHAFT SPROCKETS
2 - INJECTION PUMP SPROCKET
3 - INJECTION PUMP SPROCKET RETAINING NUT
4 - TIMING BELT
5 - TIMING BELT TENSIONER RETAINING BOLT
6 - TIMING BELT TENSIONER
7 - TENSIONER ALIGNMENT PIN
8 - IDLER PULLEY
9 - CAMSHAFT SPROCKET RETAINING BOLT
9a - 58 ENGINERG
TIMING BELT / CHAIN COVER(S) (Continued)
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Page 1420 of 2399

CHRYSLER VOYAGER 2002 Service Manual TMNG BELT/CHAIN
TENSIONER
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(3) Remove air cleaner housing.
(4) Support engine and remove right en

Page 1421 of 2399

CHRYSLER VOYAGER 2002 Service Manual ADJUSTMENTS
ADJUSTMENT - TIMING BELT TENSIONER
(1) With timing belt outer cover removed and tim-
ing belt installed.
(2) Loosen timing belt tensioner (Fig. 97).
(3) Align timing belt tensioner spring

Page 1422 of 2399

CHRYSLER VOYAGER 2002 Service Manual (8) Remove timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(9) Loosen timing belt tensioner and remove tim-
ing belt (Fig. 99).
INSTALLATION
(1) With

Page 1423 of 2399

CHRYSLER VOYAGER 2002 Service Manual ProCarManuals.com

Page 1424 of 2399

CHRYSLER VOYAGER 2002 Service Manual EXHAUST SYSTEM
TABLE OF CONTENTS
page page
EXHAUST SYSTEM
DESCRIPTION..........................1
OPERATION............................2
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - EXCESSIVE
EXHAUST

EXHAUST SYSTEM
TABLE OF CONTENTS
page page
EXHAUST SYSTEM
DESCRIPTION..........................1
OPERATION............................2
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - EXCESSIVE
EXHAUST SYSTEM NOISE...............2
DIAGNOSIS AND TESTING - EXHAUST
SYSTEM RESTRICTION CHECK...........2
INSPECTION...........................3
ADJUSTMENTS.........................3
SPECIFICATIONS
TORQUE.............................3
SPECIAL TOOLS
EXHAUST SYSTEM.....................4
CATALYTIC CONVERTER
DESCRIPTION..........................4
OPERATION............................4REMOVAL.............................5
INSPECTION...........................6
INSTALLATION..........................6
CROSS-OVER PIPE - 3.3/3.8L
REMOVAL.............................6
INSTALLATION..........................6
HEAT SHIELDS
DESCRIPTION..........................6
OPERATION............................7
REMOVAL.............................7
INSTALLATION..........................7
MUFFLER
REMOVAL.............................7
INSTALLATION..........................8
RESONATOR
REMOVAL.............................9
INSTALLATION..........................9
EXHAUST SYSTEM
DESCRIPTION
The exhaust system consists of a catalytic converter,
muffler, and a resonator with connecting pipes in-be-
tween (Fig. 1). The system is serviced in two sections;
the catalytic converter and pipe, and the muffler and
resonator with connecting pipe. A band clamp is usedto connect the joint between the two components.
Three support hanger rods with rubber isolators are
used to support and isolate the exhaust system. A flex-
ible joint, integral to the catalytic converter, allows for
engine movement. On vehicles equipped with AWD, an
additional heat shield is mounted to the catalytic con-
verter. The exhaust system is tuned for each vehicle/
powertrain combination.
Fig. 1 Exhaust System - Typical (All Vehicles)
1 - CATALYTIC CONVERTER 4 - SUPPORT - RESONATOR
2 - BAND CLAMP 5 - RESONATOR
3 - SUPPORTS - MUFFLER 6 - MUFFLER
RSEXHAUST SYSTEM11-1
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