2003 CHRYSLER VOYAGER spark plugs replace

Kilometers 120 000 125 000 130 000 134 000 139 000 144 000
(Miles) (75,000) (78,000) (81,000) (84,000) (87,000) (90,000)
Change engine oil and engine
oil filter.XXXXX X
Inspect the brake linings. X X
Inspect the engine air cleaner
filter, replace if necessary. *XXXX
Replace theengine air
cleaner filterXX
Replace thespark plugson
3.3 liter engines.X
Replace theignition cables
on 3.3 liter engines.X
Replace thespark plugson
2.4 liter engines.X
Inspect and adjust the power
steering pump belt tension on
2.4 liter engines.XX
Inspect the generator belt on
2.4 liter engines, replace if
necessary.XX
Inspect the tie rod ends and
boot seals.X
Inspect engine accessory
drive belts on 3.3 liter
engines, replace if necessary.
³XX
Change the manual
transmission fluid.X
Check thePCV valveand
replace if necessary. Not
required if previously
changed.*X
Change the All Wheel Drive
power transfer unit fluid. (See
the note at the end of this
chart.)XX
Change the All Wheel Drive
(AWD) overrunning clutch and
rear carrier fluid. (See note at
the end of this chart)X
Replace theengine timing
belton 2.4 liter engines. *X
Replace the air conditioning
filter.XX
0a - 4 MAINTENANCE SCHEDULESRS
MAINTENANCE SCHEDULES FOR ALL MARKETS EXCEPT U.S., CANADA and MEXICO (Continued)
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Kilometers 173 000 178 000 182 000 187 000 192 000
(Miles) (108,000) (111,000) (114,000) (117,000) (120,000)
Change engine oil and engine oil filter.XXXX X
Inspect the brake linings. X X
Inspect the engine air cleaner filter, replace
if necessary. *XXXX
Replace theengine air cleaner filter.X
Replace thespark plugson 2.4 liter
engines.X
Replace theignition cableson 2.4 liter
engines.X
Inspect and adjust the power steering pump
belt tension on 2.4 liter engines.X
Inspect the generator belt on 2.4 liter
engines, replace if necessary.X
Inspect engine accessory drive belts on 3.3
liter engines, replace if necessary. ³X
Inspect the tie rod ends and boot seals. X
Inspect thePCV valveand replace as
necessary.*X
Change the All Wheel Drive (AWD) power
transfer unit fluid. (See note at the end of
this chart)X
Replace the air conditioning filter.X
* This maintenance is recommended by the manu-
facture to the owner but is not required to maintain
the emissions warranty.
³ This maintenance is not required if previously
replaced.
Inspection and service should also be performed
anytime a malfunction is observed or suspected.
Retain all receipts.NOTE: The AWD power transfer unit fluid and the
AWD overrunning clutch/ rear carrier fluid must be
changed at the more frequent intervals shown in
schedule B if the vehicle is operated under any of
the conditions noted by a diamond at the beginning
of the schedule.
0a - 6 MAINTENANCE SCHEDULESRS
MAINTENANCE SCHEDULES FOR ALL MARKETS EXCEPT U.S., CANADA and MEXICO (Continued)
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SCHEDULE ªAº
Kilometers 12 000 24 000 36 000 48 000 60 000 72 000
(Miles) (7,500) (15,000) (22,500 (30,000) (37,500) (45,000)
[Months] [6] [12] [18] [24] [30] [36]
Change engine oil and engine oil
filter.XXXXX X
Inspect the brake linings. X X
Inspect the engine air cleaner filter,
replace if necessary. *XXX X X
Replace theengine air cleaner
filter.X
Replace thespark plugson 2.4 liter
engines.X
Inspect the tie rod ends and boot
seals.X
Replace the air conditioning filter. X X X
Kilometers 84 000 96 000 108 000 120 000 132 000 144 000
(Miles) (52,500) (60,000) (67,500) (75,000) (82,500) (90,000)
[Months] [42] [48] [54] [60] [66] [72]
Change engine oil and engine oil filter.XXXXX X
Inspect the brake linings. X X
Inspect the engine air cleaner filter,
replace if necessary. *X XXX
Replace theengine air cleaner filter.XX
Replace thespark plugson 2.4 liter
engines.XX
Replace theignition cableson 2.4 liter
engines.X
Inspect and adjust the power steering
pump belt tension on 2.4 liter engines.XX
Inspect the tie rod ends and boot seals. X X
Inspect the generator belt on 2.4 liter
engines, replace if necessary.XX
Check thePCV valveand replace, if
necessary.*XX
Inspect the serpentine drive belt on 3.3
liter engines, replace if necessary. ³XX X
Flush and replace the engine coolant at
60 months, regardless of mileage.X
Replace the air conditioning filter. X X X
RSMAINTENANCE SCHEDULES0a-7
MAINTENANCE SCHEDULES FOR ALL MARKETS EXCEPT U.S., CANADA and MEXICO (Continued)
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Kilometers 156 000 160 000 168 000 180 000 192 000
(Miles) (97,500) (100,000) (105,000) (112,500) (120,000)
[Months] [78] [84] [90] [96]
Change engine oil and engine oil filter. X X X X
Inspect the brake linings. X
Inspect the engine air cleaner filter, replace
if necessary. *XXXX
Replace theengine air cleaner filter.X
Replace thespark plugson 2.4 liter
engines.X
Replace theignition cableson 2.4 liter
engines.X
Inspect the tie rod ends and boot seals. X
Inspect and adjust the power steering pump
belt tension on 2.4 liter engines.XX
Inspect the generator belt on 2.4 liter
engines, replace if necessary.XX
Check and replace thePCV valve,if
necessary.*X
Inspect the serpentine drive belt on 3.3 liter
engines, replace if necessary. ³XX
Replace thespark plugs3.3 liter engines. X
Replace theignition cables3.3 liter
engines.X
Flush and replace the engine coolant at
100,000 miles, if not done at 60 months.X
Replace theengine timing belton 2.4 liter
engines only.X
Replace the air conditioning filter. X
* This maintenance is recommended by the manu-
facture to the owner but is not required to maintain
the emissions warranty.
³ This maintenance is not required if previously
replaced.
Inspection and service should also be performed
anytime a malfunction is observed or suspected.
Retain all receipts.WARNING: You can be badly injured working on or
around a motor vehicle. Do only that service work
for which you have the knowledge and the right
equipment. If you have any doubt about your ability
to perform a service job, take your vehicle to a
competent mechanic.
0a - 8 MAINTENANCE SCHEDULESRS
MAINTENANCE SCHEDULES FOR ALL MARKETS EXCEPT U.S., CANADA and MEXICO (Continued)
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(1) Install target magnet in end of camshaft.
Tighten mounting screw to 3 N´m (30 in. lbs.) torque.
Over torqueing could cause cracks in magnet. If mag-
net cracks replace it.
(2) Install camshaft position sensor. Tighten sensor
mounting screws to 12.9 N´m (115 in. lbs.) torque.
(3) Carefully attach electrical connector to cam-
shaft position sensor.
(4) Connect the negative battery cable.
INSTALLATION - 3.3/3.8L
If the removed sensor is reinstalled, clean off
the old spacer on the sensor face. A NEW
SPACER must be attached to the face before
installation.Inspect O-ring for damage, replace if
necessary. If the sensor is being replaced, confirm
that the paper spacer is attached to the face and
O-ring is positioned in groove of the new sensor (Fig.
8).
(1) Apply a couple drops of clean engine oil to the
O-ring prior to installation.
(2) Install sensor in the chain case cover and
rotate into position.
(3) Push sensor down until contact is made with
the camshaft gear. While holding the sensor in this
position, install and tighten the retaining bolt 14
N´m (125 in. lbs.) torque.
(4) Connect camshaft position sensor electrical
connector to harness connector.
(5) Install the air box cover and inlet hose (Fig. 5).
(6) Connect the negative battery cable.
IGNITION COIL
DESCRIPTION
The ignition coil assembly consists of 2 or 3 inde-
pendent coils molded together (Fig. 9) or (Fig. 10).
The coil assembly for the 3.3/3.8L is mounted on the
intake manifold. The coil assembly for the 2.4L is
mounted on the cylinder head cover. Spark plug
cables route to each cylinder from the coil.
OPERATION
The coil fires two spark plugs every power stroke.
One plug is the cylinder under compression, the
other cylinder fires on the exhaust stroke. The Pow-
ertrain Control Module (PCM) determines which of
the coils to charge and fire at the correct time.
The Auto Shutdown (ASD) relay provides battery
voltage to the ignition coil. The PCM provides a
ground contact (circuit) for energizing the coil. When
the PCM breaks the contact, the magnetic energy in
the coil transfers to the secondary causing the spark.
The PCM will de-energize the ASD relay if it does
not receive the crankshaft position sensor and cam-
shaft position sensor inputs. Refer to Auto Shutdown
(ASD) RelayÐPCM Output, in this section for relay
operation.
Fig. 8 Camshaft Position Sensor and Spacer
1 - ELECTRICAL CONNECTOR
2 - O-RING
3 - PAPER SPACER
Fig. 9 IGNITION COIL - 2.4L
8I - 6 IGNITION CONTROLRS
CAMSHAFT POSITION SENSOR (Continued)
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REMOVAL
When replacing the spark plugs and spark plug
cables, route the cables correctly and secure them in
the appropriate retainers. Failure to route the cables
properly can cause the radio to reproduce ignition
noise, cross ignition of the spark plugs orshort cir-
cuit the cables to ground.
Always remove cables by grasping at the boot,
rotating the boot 1/2 turn, and pulling straight back
in a steady motion.
(1) Prior to removing the spark plug, spray com-
pressed air around the spark plug hole and the area
around the spark plug.
(2) Remove the spark plug using a quality socket
with a foam insert.
(3) Inspect the spark plug condition.
INSTALLATION
When replacing the spark plugs and spark plug
cables, route the cables correctly and secure them in
the appropriate retainers. Failure to route the cables
properly can cause the radio to reproduce ignition
noise, cross ignition of the spark plugs orshort cir-
cuit the cables to ground.
(1) Coat threads of spark plug with anti-seize. Be
sure not to get anti-seizeANTWHERE BUT ON
THE THREADS OF THE SPARK PLUG as
shown in (Fig. 13).
(2) To avoid cross threading, start the spark plug
into the cylinder head by hand.
(3) Tighten spark plugs to 17.5 N´m (13 ft. lbs.)
torque.
(4) Install spark plug cables over spark plugs. A
click will be heard and felt when the cable properly
attaches to the spark plug.
SPARK PLUG CABLE
DESCRIPTION
Spark Plug cables are sometimes referred to as
secondary ignition wires. The wires transfer electri-
cal current from the ignition coil pack to individual
spark plugs at each cylinder. The resistive spark plug
cables are of nonmetallic construction. The cables
provide suppression of radio frequency emissions
from the ignition system.
Check the spark plug cable connections for good
contact at the coil, and spark plugs. Terminals should
be fully seated. The insulators should be in good con-
dition and should fit tightly on the coil, and spark
plugs. Spark plug cables with insulators that are
cracked or torn must be replaced.
Clean Spark Plug cables with a cloth moistened
with a non-flammable solvent. Wipe the cables dry.
Check for brittle or cracked insulation. The spark
plug cables and spark plug boots are made from high
temperature materials.
REMOVAL - 2.0/2.4L
Failure to route the cables properly could cause the
radio to reproduce ignition noise, cross ignition of the
spark plugs or short circuit the cables to ground.
Remove spark plug cable from coil first.
Always remove the spark plug cable by grasping
the top of the spark plug insulator, turning the boot
1/2 turn and pulling straight up in a steady motion.
INSTALLATION - 2.0/2.4L
Failure to route the cables properly could cause the
radio to reproduce ignition noise, cross ignition of the
spark plugs or short circuit the cables to ground.
Install spark plug insulators over spark plugs.
Ensure the top of the spark plug insulator covers the
upper end of the spark plug tube, then connect the
other end to coil pack.
8I - 10 IGNITION CONTROLRS
SPARK PLUG (Continued)
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CONDITION POSSIBLE CAUSE CORRECTION
ENGINE LOSS OF POWER 1. 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 SPEED 1. 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). 3. Test and replace as necessary.
(Refer to Appropriate Diagnostic
Information)
4. Contamination in fuel system. 4. Clean system and replace fuel
filter.
RSENGINE 2.4L9-5
ENGINE 2.4L (Continued)
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CONDITION POSSIBLE CAUSES CORRECTION
OIL CONSUMPTION OR SPARK
PLUGS FOULED1. PCV system malfunction. 1. Check system and repair as
necessary. (Refer to 25 -
EMISSIONS CONTROL/
EVAPORATIVE EMISSIONS/PCV
VALVE - DIAGNOSIS AND
TESTING)
2. Worn, scuffed or broken rings. 2. Hone cylinder bores. Install new
rings.
3. Carbon in oil ring slots. 3. Install new rings.
4. Rings fitted too tightly in grooves. 4. Remove rings and check
grooves. If groove is not proper
width, replace piston.
5. Worn valve guide(s). 5. Replace cylinder head assembly.
6. Valve stem seal(s) worn or
damaged.6. Replace seal(s).
DIAGNOSIS AND TESTING - ENGINE OIL LEAK
INSPECTION
Begin with a thorough visual inspection of the
engine, particularly at the area of the suspected leak.
If an oil leak source is not readily identifiable, the
following steps should be followed:
(1) Do not clean or degrease the engine at this
time because some solvents may cause rubber to
swell, temporarily stopping the leak.
(2) Add an oil soluble dye (use as recommended by
manufacturer). Start the engine and let idle for
approximately 15 minutes. Check the oil dipstick to
make sure the dye is thoroughly mixed as indicated
with a bright yellow color under a black light.
(3) Using a black light, inspect the entire engine
for fluorescent dye, particularly at the suspected area
of oil leak. If the oil leak is found and identified,
repair as necessary.
(4) If dye is not observed, drive the vehicle at var-
ious speeds for approximately 24 km (15 miles), and
repeat inspection.
(5)If the oil leak source is not positively
identified at this time, proceed with the air leak
detection test method as follows:
²Disconnect the fresh air hose (make-up air) at
the cylinder head cover and plug or cap the nipple on
the cover.
²Remove the PCV valve hose from the cylinder
head cover. Cap or plug the PCV valve nipple on the
cover.
²Attach an air hose with pressure gauge and reg-
ulator to the dipstick tube.
CAUTION: Do not subject the engine assembly to
more than 20.6 kpa (3 PSI) of test pressure.²Gradually apply air pressure from 1 psi to 2.5
psi maximum while applying soapy water at the sus-
pected source. Adjust the regulator to the suitable
test pressure that provides the best bubbles which
will pinpoint the leak source. If the oil leak is
detected and identified, repair per service manual
procedures.
²If the leakage occurs at the crankshaft rear oil
seal area, refer to the section, Inspection for Rear
Seal Area Leak.
(6) If no leaks are detected, turn off the air supply.
Remove the air hose, all plugs, and caps. Install the
PCV valve and fresh air hose (make-up air). Proceed
to next step.
(7) Clean the oil off the suspect oil leak area using
a suitable solvent. Drive the vehicle at various
speeds approximately 24 km (15 miles). Inspect the
engine for signs of an oil leak by using a black light.
NOTE: If oil leakage is observed at the dipstick tube
to block location; remove the tube, clean and reseal
using MoparTStud & Bearing Mount (press fit tube
applications only), and for O-ring style tubes,
remove tube and replace the O-ring seal.
INSPECTION FOR REAR SEAL AREA LEAKS
Since it is sometimes difficult to determine the
source of an oil leak in the rear seal area of the
engine, a more involved inspection is necessary. The
following steps should be followed to help pinpoint
the source of the leak.
If the leakage occurs at the crankshaft rear oil seal
area:
(1) Disconnect the battery.
(2) Raise the vehicle.
9 - 8 ENGINE 2.4LRS
ENGINE 2.4L (Continued)
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