2003 CHRYSLER VOYAGER spark plugs replace

(2) Assemble gasket to cylinder cover by inserting
the fasteners through each bolt hole on cover and
gasket (Fig. 25).
(3) Install the cylinder head cover and bolts (Fig.
26).
(4) Tighten cylinder head cover bolts to 12 N´m
(105 in. lbs.) (Fig. 26).
(5) Connect crankcase vent hose.
(6) Connect spark plug wires to spark plugs.
INTAKE/EXHAUST VALVES &
SEATS
DESCRIPTION
The valves have chrome plated valve stems with
four-bead lock grooves. The valve stem seals are
made of Viton rubber.
OPERATION
The two valves per cylinder are opened using
hydraulic lifters, push rods, and rocker arms.
STANDARD PROCEDURE - REFACING VALVES
AND VALVE SEATS
The intake and exhaust valves and seats are
machined to specific angles (Fig. 27).
VALVES
(1) Inspect the remaining margin after the valves
are refaced (Fig. 28). (Refer to 9 - ENGINE - SPEC-
IFICATIONS)
VALVE SEATS
CAUTION: Remove metal from valve seat only. Do
not remove material from cylinder head (Fig. 29).
(1) When refacing valve seats, it is important that
the correct size valve guide pilot be used for reseat-ing stones. A true and complete surface must be
obtained.
(2) Measure the concentricity of valve seat using
dial indicator (Fig. 30). Total runout should not
exceed 0.051 mm (0.002 in.) total indicator reading.
(3) Inspect the valve seat using Prussian blue to
determine where the valve contacts the seat. To do
this, coat valve seatLIGHTLYwith Prussian blue
then set valve in place. Rotate the valve with light
pressure. If the blue is transferred to the center of
valve face, contact is satisfactory. If the blue is trans-
ferred to top edge of valve face, lower valve seat with
a 15 degree stone. If the blue is transferred to the
bottom edge of valve face raise valve seat with a 65
degrees stone.
NOTE: Valve seats which are worn or burned can
be reworked, provided that correct angle and seat
width are maintained. Otherwise cylinder head must
be replaced.
Fig. 27 Valve Face and Seat
1 - SEAT WIDTH
2 - FACE ANGLE
3 - SEAT ANGLE
4 - SEAT CONTACT AREA
Fig. 28 Valve Margin
1 - VALVE FACE
2 - VALVE MARGIN
Fig. 29 Refacing Valve Seats
1 - REFACING STONE MUST NOT CUT INTO CYLINDER HEAD
2-STONE
3 - PILOT
4 - SEAT
9 - 104 ENGINE 3.3/3.8LRS
CYLINDER HEAD COVER - LEFT (Continued)
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NOTE: Replace cylinder head if stem-to-guide clear-
ance exceeds specifications, or if guide is loose in
cylinder head.
INSTALLATION
(1) Coat valve stems with clean engine oil and
insert them in cylinder head.
(2) Install valve spring seat on head (Fig. 35).
(3) Install new seals on all valve stems and over
valve guides (Fig. 35). Install valve springs and valve
retainers (Fig. 35).
(4) Install the valve springs. (Refer to 9 -
ENGINE/CYLINDER HEAD/VALVE SPRINGS -
INSTALLATION)
VALVE SPRINGS
DESCRIPTION
The valve springs are a bee-hive shaped design
(Fig. 34). The springs are seated on a steel washer on
the cylinder head with retainers and locks retaining
the springs (Fig. 35). The springs are installed with
the smaller diameter against spring retainer (Fig.
34).
OPERATION
The valve spring returns the valve against its seat
for a positive seal of the combustion chamber.
REMOVAL
REMOVAL - CYLINDER HEAD OFF
(1) With the cylinder head on a bench, position
Special Tool C-3422-D with 8464 Adapter on the
valve and spring retainer (Fig. 36).
(2) Compress the spring only enough to remove the
valve retainer locks.
(3) Slowly release the spring tension and remove
the valve spring and retainer.
(4) For removal of the valve stem seal (Refer to 9 -
ENGINE/CYLINDER HEAD/VALVE STEM SEALS -
REMOVAL).
REMOVAL - CYLINDER HEAD ON
(1) Disconnect negative cable from battery.
(2) Remove spark plug wires and all spark plugs.
Fig. 32 Intake and Exhaust Valves
1 - MARGIN
2-FACE
3 - STEM
4 - VALVE SPRING RETAINER LOCK GROOVES
Fig. 33 Measuring Valve Guide Wear - Typical
Fig. 34 Valve Spring
1 - VALVE SPRING (TOP - SMALLER DIAMETER)
9 - 106 ENGINE 3.3/3.8LRS
INTAKE/EXHAUST VALVES & SEATS (Continued)
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(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. 38).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
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-D with 8464 Adapter
(Fig. 36), compress the spring only enough to install
the valve retainer locks. Install 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 Forceseal against top
of guide. When installing the valve retainer locks,
compress 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.
Fig. 37 VALVE SPRING - REMOVE/INSTALL (HEAD
ON)
1 - SPECIAL TOOL 8453
2 - BOLTS - SPECIAL TOOL ATTACHING
3 - AIR SUPPLY HOSE ADAPTER
Fig. 38 TESTING VALVE SPRING
1 - SPECIAL TOOL C-647
9 - 108 ENGINE 3.3/3.8LRS
VALVE SPRINGS (Continued)
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The combustion reaction caused by the catalyst
releases additional heat in the exhaust system, caus-
ing temperature increases in the area of the reactor
under severe operating conditions. Such conditions
can exist when the engine misfires or otherwise does
not operate at peak efficiency.Do notremove spark
plug wires from plugs or by any other means short
out cylinders, if exhaust system is equipped with a
catalytic converter. Failure of the catalytic converter
can occur due to temperature increases caused by
unburned fuel passing through the converter. This
deterioration of the catalyst core can result in exces-
sively high emission levels, noise complaints, and
exhaust restrictions.
Unleaded gasoline must be used to avoid ruining
the catalyst core. Do not allow engine to operate
above 1200 RPM in neutral for extended periods over
5 minutes. This condition may result in excessive
exhaust system/floor pan temperatures because of no
air movement under the vehicle.
The flex joint allows flexing as the engine moves,
preventing breakage that could occur from the back-
and-forth motion of a transverse mounted engine.
CAUTION: Due to exterior physical similarities of
some catalytic converters with pipe assemblies,
extreme care should be taken with replacement
parts. There are internal converter differences
required in some parts of the country (particularly
vehicles built for States with strict emission
requirements) and between model years.
REMOVAL
(1) Loosen clamp and disconnect the muffler/reso-
nator assembly from catalytic converter pipe.
(2) Disconnect downstream oxygen sensor electri-
cal connector (Fig. 4). For removal of downstream
oxygen sensor, (Refer to 14 - FUEL SYSTEM/FUEL
INJECTION/O2 SENSOR - REMOVAL).
(3) Remove catalytic converter to exhaust manifold
attaching fasteners (Fig. 5).
(4) Remove catalytic converter and gasket (Fig. 5).
INSPECTION
WARNING: THE NORMAL OPERATING TEMPERA-
TURE OF THE EXHAUST SYSTEM IS VERY HIGH.
THEREFORE, NEVER ATTEMPT TO SERVICE ANY
PART OF THE EXHAUST SYSTEM UNTIL IT IS
COOLED. SPECIAL CARE SHOULD BE TAKEN
WHEN WORKING NEAR THE CATALYTIC CON-
VERTER. THE TEMPERATURE OF THE CONVERTER
RISES TO A HIGH LEVEL AFTER A SHORT PERIOD
OF ENGINE OPERATION TIME.Check catalytic converter for a flow restriction.
(Refer to 11 - EXHAUST SYSTEM - DIAGNOSIS
AND TESTING) Exhaust System Restriction Check
for procedure.
Fig. 4 Downstream Oxygen Sensor
1 - OXYGEN SENSOR CONNECTOR
2 - CATALYTIC CONVERTER
3 - DOWNSTREAM OXYGEN SENSOR
4 - ENGINE HARNESS CONNECTOR
Fig. 5 Catalytic Converter to Exhaust Manifold
1 - FLAG NUT
2 - GASKET
3 - BOLT
4 - CATALYTIC CONVERTER
RSEXHAUST SYSTEM11-5
CATALYTIC CONVERTER (Continued)
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PARKING BRAKE CABLES -
ADJUSTMENT........................5-64
PARKING BRAKE LEVER AND FRONT
CABLE - INSTALLATION................5-66
PARKING BRAKE LEVER AND FRONT
CABLE - REMOVAL....................5-65
PARKING BRAKE SHOES - ADJUSTMENT . . . 5-73
PARK/TURN SIGNAL LAMP - EXPORT -
INSTALLATION.......................8L-22
PARK/TURN SIGNAL LAMP - EXPORT -
REMOVAL..........................8L-22
PARK/TURN SIGNAL LAMP -
INSTALLATION.......................8L-21
PARK/TURN SIGNAL LAMP - REMOVAL . . . 8L-21
PARTS - DESCRIPTION, FFV
REPLACEMENT.......................14-2
PASSENGER AIRBAG - DESCRIPTION.....8O-7
PASSENGER AIRBAG - INSTALLATION.....8O-9
PASSENGER AIRBAG - OPERATION.......8O-8
PASSENGER AIRBAG - REMOVAL........8O-8
PASSENGER BENCH - INSTALLATION,
SEAT BELT BUCKLE - SECOND ROW -
THREE.............................8O-14
PASSENGER BENCH - REMOVAL, SEAT
BELT BUCKLE - SECOND ROW - THREE . . . 8O-14
PASSENGER HEATED SEAT SWITCH -
DESCRIPTION.......................8G-12
PASSENGER HEATED SEAT SWITCH -
DIAGNOSIS AND TESTING.............8G-13
PASSENGER HEATED SEAT SWITCH -
INSTALLATION......................8G-14
PASSENGER HEATED SEAT SWITCH -
OPERATION.........................8G-12
PASSENGER HEATED SEAT SWITCH -
REMOVAL..........................8G-14
PASSENGER POWER SEAT TRACK -
DESCRIPTION.......................8N-59
PASSENGER POWER SEAT TRACK -
INSTALLATION......................8N-61
PASSENGER POWER SEAT TRACK -
OPERATION.........................8N-60
PASSENGER POWER SEAT TRACK -
REMOVAL..........................8N-61
PASSENGER SEAT SWITCH -
DESCRIPTION.......................8N-56
PASSENGER SEAT SWITCH - DIAGNOSIS
AND TESTING.......................8N-57
PASSENGER SEAT SWITCH -
INSTALLATION......................8N-57
PASSENGER SEAT SWITCH - OPERATION . 8N-56
PASSENGER SEAT SWITCH - REMOVAL . . . 8N-57
PATTERNS - DIAGNOSIS AND TESTING,
TIRE WEAR.........................22-16
PCM GROUND - OPERATION...........8E-15
PCM INPUT - OPERATION, DATA BUS
COMMUNICATION RECEIVE.............8E-15
PCM INPUT - OPERATION, IGNITION
SENSE.............................8E-15
PCM INPUT - OPERATION, SENSOR
RETURN............................8E-15
PCM OUTPUT - OPERATION, 5 VOLT
SUPPLY............................8E-15
PCM OUTPUT - SBEC CONTROLLER -
OPERATION, 8-VOLT SUPPLY...........8E-15
PCM/SKIM PROGRAMMING - STANDARD
PROCEDURE.........................8E-2
PCV SYSTEM - DIAGNOSIS AND
TESTING...........................25-17
PCV VALVE - DESCRIPTION............25-16
PCV VALVE - OPERATION..............25-16
PEDAL - INSTALLATION, ACCELERATOR . . . 14-24
PEDAL - REMOVAL, ACCELERATOR......14-23
PEDAL INTERLOCK SWITCH -
INSTALLATION, CLUTCH................6-14
PEDAL INTERLOCK SWITCH - REMOVAL,
CLUTCH.............................6-13
PEDAL TORQUE SHAFT - RHD -
INSTALLATION........................5-39
PEDAL TORQUE SHAFT - RHD -
REMOVAL
...........................5-39
PEDAL UPSTOP SWITCH -
INSTALLATION, CLUTCH
................6-16
PEDAL UPSTOP SWITCH - REMOVAL,
CLUTCH
.............................6-15
PERFORMANCE - DIAGNOSIS AND
TESTING, ENGINE DIAGNOSIS
........9-4,9-78
PERFORMANCE TEST - DIAGNOSIS AND
TESTING, A/C
........................24-5PERFORMANCE TEST - DIAGNOSIS AND
TESTING, HEATER.....................24-6
PIN BUSHINGS (DISC/DISC BRAKES) -
ASSEMBLY, CALIPER GUIDE.............5-25
PIN BUSHINGS (DISC/DISC BRAKES) -
DISASSEMBLY, CALIPER GUIDE..........5-24
PINCH SENSOR - DESCRIPTION.........8N-17
PINCH SENSOR - INSTALLATION........8N-17
PINCH SENSOR - OPERATION..........8N-17
PINCH SENSOR - REMOVAL............8N-17
PINION FACTOR SETTING - STANDARD
PROCEDURE...................8E-15,8E-23
PINS (DISC/DRUM BRAKES) -
INSTALLATION, DISC BRAKE CALIPER
GUIDE..............................5-31
PINS (DISC/DRUM BRAKES) - REMOVAL,
DISC BRAKE CALIPER GUIDE............5-31
PIPE - 3.3/3.8L - INSTALLATION,
CROSS-OVER........................11-6
PIPE - 3.3/3.8L - REMOVAL, CROSS-
OVER...............................11-6
PIPE - INSTALLATION, AIR INTAKE......24-113
PIPE - REMOVAL, AIR INTAKE.........24-112
PISTON & CONNECTING ROD -
DESCRIPTION...................9-116,9-42
PISTON & CONNECTING ROD -
INSTALLATION........................9-44
PISTON & CONNECTING ROD -
REMOVAL...........................9-43
PISTON AND SEAL - ASSEMBLY,
CALIPER........................5-26,5-29
PISTON AND SEAL - DISASSEMBLY,
CALIPER........................5-24,5-28
PISTON RING, FITTING.................9-45
PISTON RING FITTING - STANDARD
PROCEDURE........................9-121
PISTON RINGS - INSTALLATION.........9-121
PISTON RINGS - REMOVAL............9-121
PISTON TO CYLINDER BORE FITTING -
STANDARD PROCEDURE................9-42
PISTONS - STANDARD PROCEDURE,
FITTING............................9-117
PLANETARY GEARTRAIN - DESCRIPTION . 21-232
PLANETARY GEARTRAIN - OPERATION . . 21-232
PLASTIC BODY PANEL REPAIR -
STANDARD PROCEDURE................23-3
PLASTIC GROCERY BAG RETAINER -
INSTALLATION......................23-103
PLASTIC GROCERY BAG RETAINER -
REMOVAL.........................23-103
PLASTIGAGE - STANDARD PROCEDURE,
MEASURING BEARING CLEARANCE
USING..........................9-12,9-84
PLATE - 2.5L TD - INSTALLATION,
CLUTCH DISC AND PRESSURE...........6-12
PLATE - 2.5L TD - REMOVAL, CLUTCH
DISC AND PRESSURE..................6-11
PLATE - DESCRIPTION, BODY CODE....Intro.-1
PLATE - DESCRIPTION, MANUFACTURER . Intro.-11
PLATE - DRUM BRAKE - INSTALLATION,
SUPPORT...........................5-56
PLATE - DRUM BRAKE - REMOVAL,
SUPPORT...........................5-56
PLATE - INSTALLATION, DOOR SILL
TRIM..............................23-76
PLATE - INSTALLATION, FLEX...........9-131
PLATE - INSTALLATION, LIFTGATE SILL
. . . 23-77
PLATE - INSTALLATION, SLIDING DOOR
SILL
...............................23-80
PLATE - INSTALLATION, STEERING
COLUMN COVER BACKING
.............23-69
PLATE - REMOVAL, DOOR SILL TRIM
....23-76
PLATE - REMOVAL, FLEX
..............9-131
PLATE - REMOVAL, LIFTGATE SILL
.......23-77
PLATE - REMOVAL, SLIDING DOOR SILL
. . 23-80
PLATE - REMOVAL, STEERING COLUMN
COVER BACKING
.....................23-69
PLATE BATTERY CHARGING -
STANDARD PROCEDURE, SPIRAL
........8F-10
PLATE MISALIGNMENT - DIAGNOSIS
AND TESTING, DRIVE
...................6-6
PLATES - ADHESIVE ATTACHED -
INSTALLATION, EXTERIOR NAME
........23-50
PLATES - ADHESIVE ATTACHED -
REMOVAL, EXTERIOR NAME
............23-50
PLATES - TAPE ATTACHED -
INSTALLATION, EXTERIOR NAME
........23-50PLATES - TAPE ATTACHED - REMOVAL,
EXTERIOR NAME.....................23-50
PLATINUM PLUGS - DESCRIPTION........8I-9
PLAY - ADJUSTMENT, DIFFERENTIAL
SIDE GEAR END.....................21-70
PLAY - STANDARD PROCEDURE,
CRANKSHAFT END....................9-36
PLAY - STANDARD PROCEDURE,
MEASURING CAMSHAFT END............9-29
PLAY - STANDARD PROCEDURE,
MEASURING CRANKSHAFT END.........9-125
PLAYER - DESCRIPTION, DVD...........8A-8
PLAYER - INSTALLATION, DVD...........8A-8
PLAYER - OPERATION, DVD.............8A-8
PLAYER - REMOVAL, DVD..............8A-8
PLUG CABLE - DESCRIPTION, SPARK.....8I-10
PLUG CABLE RESISTANCE,
SPECIFICATIONS - SPARK...............8I-2
PLUG, SPECIFICATIONS - SPARK.........8I-2
PLUGS - DESCRIPTION, PLATINUM........8I-9
PLUGS - STANDARD PROCEDURE,
ENGINE CORE AND OIL GALLERY....9-10,9-86
PLUMBING - CAUTION, A/C............24-61
PLUMBING - WARNING, A/C............24-61
POINTS - DESCRIPTION, LUBRICATION.....0-7
POLISHING - DESCRIPTION, FINESSE
SANDING/BUFFING...................23-84
PORT REPAIR - STANDARD
PROCEDURE, INTAKE MANIFOLD
VACUUM...........................9-145
PORTS - INSTALLATION, SERVICE.......24-93
PORTS - REMOVAL, SERVICE...........24-92
POSITION LAMP - EXPORT -
INSTALLATION, FRONT................8L-10
POSITION LAMP - EXPORT - REMOVAL,
FRONT.............................8L-10
POSITION SENSOR - DESCRIPTION,
CAMSHAFT...........................8I-3
POSITION SENSOR - DESCRIPTION,
CRANKSHAFT.......................14-24
POSITION SENSOR - DESCRIPTION,
THROTTLE..........................14-36
POSITION SENSOR - OPERATION,
CAMSHAFT...........................8I-3
POSITION SENSOR - OPERATION,
CRANKSHAFT.......................14-24
POSITION SENSOR - OPERATION,
THROTTLE..........................14-36
POSITION SENSOR - REMOVAL,
CRANKSHAFT.......................14-25
POTENTIAL - STANDARD PROCEDURE,
TESTING OF VOLTAGE..............8W-01-9
POWER - INSTALLATION, WINDOW
REGULATOR........................23-22
POWER - REMOVAL, WINDOW
REGULATOR........................23-22
POWER ADJUSTER - INSTALLATION,
FRONT SEAT TRACK..................23-94
POWER ADJUSTER - REMOVAL, FRONT
SEAT TRACK........................23-94
POWER BRAKE BOOSTER -
DESCRIPTION........................5-40
POWER BRAKE BOOSTER - DIAGNOSIS
AND TESTING
........................5-41
POWER BRAKE BOOSTER - OPERATION
. . . 5-41
POWER DISTRIBUTION SYSTEM -
DESCRIPTION
.....................8W-97-1
POWER DISTRIBUTION SYSTEM -
OPERATION
.......................8W-97-1
POWER DISTRIBUTION SYSTEMS,
SPECIAL TOOLS
...................8W-97-2
POWER DOOR LEARN CYCLE -
STANDARD PROCEDURE
..............8N-28
POWER FOLDAWAY MIRROR SWITCH -
EXPORT - DESCRIPTION
...............8N-48
POWER FOLDAWAY MIRROR SWITCH -
EXPORT - INSTALLATION
..............8N-49
POWER FOLDAWAY MIRROR SWITCH -
EXPORT - OPERATION
................8N-48
POWER FOLDAWAY MIRROR SWITCH -
EXPORT - REMOVAL
..................8N-48
POWER LIFTGATE CONTROL MODULE -
DESCRIPTION
.......................8E-10
POWER LIFTGATE CONTROL MODULE -
INSTALLATION
.......................8E-11
POWER LIFTGATE CONTROL MODULE -
OPERATION
.........................8E-11
RSINDEX23
Description Group-Page Description Group-Page Description Group-Page
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