2005 CHRYSLER VOYAGER oil

ENGINE 3.3/3.8L
TABLE OF CONTENTS
page page
ENGINE 3.3/3.8L
DESCRIPTION.........................78
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION...........78
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - PERFORMANCE...........80
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - MECHANICAL.............82
DIAGNOSIS AND TESTING - ENGINE OIL
LEAK INSPECTION....................84
DIAGNOSIS AND TESTING - CYLINDER
COMPRESSION PRESSURE TEST........85
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE
TEST...............................85
STANDARD PROCEDURE
STANDARD PROCEDURE - MEASURING
BEARING CLEARANCE USING
PLASTIGAGE........................86
FORM-IN-PLACE GASKETS AND SEALERS . 86
STANDARD PROCEDURE - ENGINE
GASKET SURFACE PREPARATION........87
HYDROSTATIC LOCKED ENGINE.........87
STANDARD PROCEDURE - REPAIR OF
DAMAGED OR WORN THREADS.........88
STANDARD PROCEDURE - ENGINE CORE
AND OIL GALLERY PLUGS..............88
REMOVAL - ENGINE ASSEMBLY...........88
INSTALLATION - ENGINE ASSEMBLY........91
SPECIFICATIONS
3.3/3.8L ENGINE......................93
SPECIFICATIONS - TORQUE............97
SPECIAL TOOLS
3.3/3.8L ENGINE......................98
AIR CLEANER ELEMENT
REMOVAL............................101
INSTALLATION........................101
AIR CLEANER HOUSING
REMOVAL............................101
INSTALLATION........................102
CYLINDER HEAD
DESCRIPTION........................102
DIAGNOSIS AND TESTINGÐCYLINDER HEAD
GASKET...........................102
REMOVAL - CYLINDER HEAD............103
CLEANING...........................103
INSPECTION.........................104
INSTALLATION - CYLINDER HEAD.........104CYLINDER HEAD COVER(S)
DESCRIPTION........................105
CYLINDER HEAD COVER - RIGHT
REMOVAL............................106
INSTALLATION........................106
CYLINDER HEAD COVER - LEFT
REMOVAL............................107
INSTALLATION........................107
INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION........................107
OPERATION..........................107
STANDARD PROCEDURE - REFACING
VALVESANDVALVESEATS ............107
REMOVAL............................108
CLEANING...........................108
INSPECTION.........................108
INSTALLATION........................109
VALVE SPRINGS
DESCRIPTION........................109
OPERATION..........................109
REMOVAL
REMOVAL - CYLINDER HEAD OFF.......109
REMOVAL - CYLINDER HEAD ON........111
INSPECTION..........................111
INSTALLATION
INSTALLATION - CYLINDER HEAD OFF . . . 111
INSTALLATION - CYLINDER HEAD ON....111
ROCKER ARMS
DESCRIPTION
DESCRIPTION - ROCKER ARMS.........112
DESCRIPTION - PUSHRODS............112
OPERATION
OPERATION - ROCKER ARMS..........112
OPERATION - PUSHRODS.............112
REMOVAL - ROCKER ARMS AND SHAFT....112
DISASSEMBLY - ROCKER ARMS
AND SHAFT.........................113
ASSEMBLY - ROCKER ARMS AND SHAFT . . . 113
INSTALLATION - ROCKER ARMS
AND SHAFT.........................113
VALVE STEM SEALS
DESCRIPTION........................114
REMOVAL............................115
INSTALLATION........................115
ENGINE BLOCK
DESCRIPTION........................115
STANDARD PROCEDURE - CYLINDER BORE
HONING............................115
CLEANING...........................115
9 - 76 ENGINE 3.3/3.8LRS

INSPECTION..........................115
HYDRAULIC LIFTERS (CAM IN BLOCK)
DESCRIPTION........................116
DIAGNOSIS AND TESTING - HYDRAULIC
LIFTERS...........................116
REMOVAL............................117
INSTALLATION........................117
CAMSHAFT & BEARINGS (IN BLOCK)
DESCRIPTION........................118
OPERATION..........................118
REMOVAL............................118
INSPECTION..........................118
INSTALLATION........................118
PISTON & CONNECTING ROD
DESCRIPTION........................119
STANDARD PROCEDURE
STANDARD PROCEDURE - FITTING
CONNECTING RODS..................119
STANDARD PROCEDURE - FITTING
PISTONS...........................120
REMOVAL............................120
INSTALLATION........................121
CONNECTING ROD BEARINGS
STANDARD PROCEDURE - MEASURING
CONNECTING ROD BEARING
CLEARANCE........................123
PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING............................124
REMOVAL............................124
INSTALLATION........................124
CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDURE - MAIN BEARING
FITTING............................125
REMOVAL - CRANKSHAFT MAIN BEARINGS . 127
INSTALLATION - CRANKSHAFT MAIN
BEARINGS..........................127
CRANKSHAFT
DESCRIPTION
DESCRIPTION - 3.3L..................128
DESCRIPTION - 3.8L..................128
STANDARD PROCEDURE - MEASURING
CRANKSHAFT END PLAY..............128
REMOVAL............................128
INSTALLATION........................129
CRANKSHAFT OIL SEAL - FRONT
REMOVAL............................130
INSTALLATION........................130
CRANKSHAFT OIL SEAL - REAR
REMOVAL............................131
INSTALLATION........................131
CRANKSHAFT REAR OIL SEAL RETAINER
REMOVAL............................132
INSTALLATION........................132
VIBRATION DAMPER
REMOVAL............................132
INSTALLATION........................132FLEX PLATE
REMOVAL............................133
INSTALLATION........................133
ENGINE MOUNTING
DESCRIPTION........................134
FRONT MOUNT
REMOVAL............................134
INSTALLATION........................134
LEFT MOUNT
REMOVAL............................136
INSTALLATION........................136
REAR MOUNT
REMOVAL............................136
INSTALLATION........................137
RIGHT MOUNT
REMOVAL............................138
INSTALLATION........................138
LUBRICATION
DESCRIPTION........................138
OPERATION..........................138
DIAGNOSIS AND TESTING - ENGINE OIL
PRESSURE.........................138
OIL
STANDARD PROCEDURE
STANDARD PROCEDURE - ENGINE OIL
AND FILTER CHANGE.................139
STANDARD PROCEDURE - ENGINE OIL
LEVEL CHECK.......................140
OIL COOLER & LINES
DESCRIPTION........................141
OPERATION..........................141
REMOVAL............................141
INSTALLATION........................141
OIL FILTER
REMOVAL............................141
INSTALLATION........................141
OIL FILTER ADAPTER
REMOVAL............................142
INSTALLATION........................142
OIL PAN
REMOVAL............................142
CLEANING...........................142
INSPECTION.........................143
INSTALLATION........................143
OIL PRESSURE RELIEF VALVE
REMOVAL............................143
INSTALLATION........................144
OIL PRESSURE SWITCH
DESCRIPTION........................144
OPERATION..........................144
REMOVAL............................144
INSTALLATION........................144
OIL PUMP
DESCRIPTION........................144
REMOVAL............................144
DISASSEMBLY........................145
CLEANING...........................145
RSENGINE 3.3/3.8L9-77

INSPECTION.........................145
ASSEMBLY...........................146
INSTALLATION........................146
INTAKE MANIFOLD
DESCRIPTION........................147
DIAGNOSIS AND TESTING - INTAKE
MANIFOLD LEAKS....................147
INTAKE MANIFOLD - UPPER
STANDARD PROCEDURE
STANDARD PROCEDURE - MANIFOLD
STRIPPED THREAD REPAIR............147
STANDARD PROCEDURE - INTAKE
MANIFOLD VACUUM PORT REPAIR......148
REMOVAL - UPPER INTAKE MANIFOLD.....148
CLEANING...........................148
INSPECTION.........................149
INSTALLATION - UPPER INTAKE MANIFOLD . 149
INTAKE MANIFOLD - LOWER
REMOVAL - LOWER INTAKE MANIFOLD....150
CLEANING...........................151
INSPECTION.........................151
INSTALLATION - LOWER INTAKE MANIFOLD . 151
EXHAUST MANIFOLD - RIGHT
REMOVAL............................152
CLEANING...........................153
INSPECTION.........................153INSTALLATION........................153
EXHAUST MANIFOLD - LEFT
REMOVAL............................154
CLEANING...........................154
INSPECTION.........................155
INSTALLATION........................155
VALVE TIMING
STANDARD PROCEDURE
STANDARD PROCEDURE - VALVE TIMING
VERIFICATION.......................155
STANDARD PROCEDURE - MEASURING
TIMING CHAIN WEAR.................155
TIMING CHAIN COVER
REMOVAL............................156
INSTALLATION........................157
TIMING CHAIN AND SPROCKETS
REMOVAL
REMOVAL - TIMING CHAIN AND
CAMSHAFT SPROCKET...............159
REMOVAL - CRANKSHAFT SPROCKET . . . 159
INSTALLATION
INSTALLATION - CRANKSHAFT
SPROCKET.........................160
INSTALLATION - TIMING CHAIN AND
CAMSHAFT SPROCKET...............160
ENGINE 3.3/3.8L
DESCRIPTION
The 3.3 Liter (201 cu. in.) and 3.8 Liter (231 cu.
in.) engines are 60É V-6 engines with cast iron cylin-
der blocks and aluminum cylinder heads (Fig. 1). The
engine uses a single, block mounted camshaft with
pushrods to actuate the valves. These engines do not
have provisions for a free wheeling valve train.
The firing order is 1±2±3±4±5±6. The cylinders are
numbered from the front of the engine to the rear.
The front cylinder bank is numbered 2, 4, and 6. The
rear cylinder bank is numbered 1, 3, and 5.
The engine identification number is located on the
rear of the cylinder block just below the cylinder
head (Fig. 2).
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION
Engine diagnosis is helpful in determining the
causes of malfunctions not detected and remedied by
routine maintenance.These malfunctions may be classified as either
mechanical (e.g., a strange noise), or performance
(e.g., engine idles rough and stalls).
Refer to the Engine Mechanical and the Engine
Performance diagnostic charts, for possible causes
and corrections of malfunctions (Refer to 9 - ENGINE
- DIAGNOSIS AND TESTING - MECHANICAL)
(Refer to 9 - ENGINE - DIAGNOSIS AND TESTING
- PERFORMANCE).
For fuel system diagnosis, (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY - DIAGNOSIS AND
TESTING).
Additional tests and diagnostic procedures may be
necessary for specific engine malfunctions that can-
not be isolated with the Service Diagnosis charts.
Information concerning additional tests and diagno-
sis is provided within the following:
²Cylinder Compression Pressure Test
²Cylinder Combustion Pressure Leakage Test
²Engine Cylinder Head Gasket Failure Diagnosis
²Intake Manifold Leakage Diagnosis
²Hydraulic Lash Adjuster Noise Diagnosis
²Engine Oil Leak Inspection
9 - 78 ENGINE 3.3/3.8LRS

DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE
CONDITION POSSIBLE CAUSE CORRECTION
ENGINE WILL NOT START 1. Weak battery. 1. Test battery. Charge or replace
as necessary. (Refer to 8 -
ELECTRICAL/BATTERY SYSTEM -
DIAGNOSIS AND TESTING)
2. Corroded or loose battery
connections.2. Clean and tighten battery
connections. Apply a coat of light
mineral grease to terminals.
3. Faulty starter. 3. Test starting system. (Refer to 8 -
ELECTRICAL/STARTING -
DIAGNOSIS AND TESTING)
4. Faulty coil(s) or control unit. 4. Test and replace as needed.
(Refer to Appropriate Diagnostic
Information)
5. Incorrect spark plug gap. 5. Set gap. (Refer to 8 -
ELECTRICAL/IGNITION CONTROL
- SPECIFICATIONS)
6. Contamination in fuel system. 6. Clean system and replace fuel
filter.
7. Faulty fuel pump. 7. Test fuel pump and replace as
needed. (Refer to Appropriate
Diagnostic Information)
8. Incorrect engine timing. 8. Check for a skipped timing
belt/chain.
ENGINE STALLS OR IDLES
ROUGH1. Idle speed too low. 1. Test minimum air flow. (Refer to
Appropriate Diagnostic Information)
2. Incorrect fuel mixture. 2. (Refer to Appropriate Diagnostic
Information)
3. Intake manifold leakage. 3. Inspect intake manifold, manifold
gasket, and vacuum hoses.
4. Faulty ignition coil(s). 4. Test and replace as necessary.
(Refer to Appropriate Diagnostic
Information)
9 - 80 ENGINE 3.3/3.8LRS
ENGINE 3.3/3.8L (Continued)

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 3.3/3.8L9-81
ENGINE 3.3/3.8L (Continued)

DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL
CONDITION POSSIBLE CAUSES CORRECTION
NOISY VALVES 1. High or low oil level in
crankcase.1. Check and correct engine oil
level.
2. Thin or diluted oil. 2. Change oil to correct viscosity.
3. Thick oil 3. (a) Change engine oil and filter.
(b) Run engine to operating
temperature.
(c) Change engine oil and filter
again.
4. Low oil pressure. 4. Check and correct engine oil
pressure problem.
5. Dirt in hydraulic lifters/lash
adjusters.5. Replace hydraulic lifters/lash
adjusters.
6. Worn rocker arms. 6. Inspect oil supply to rocker arms.
7. Worn hydraulic lifters/lash
adjusters.7. Replace hydraulic lifters/lash
adjusters.
8. Worn valve guides. 8. Replace cylinder head assembly.
9. Excessive runout of valve seats
on valve faces.9. Grind valve seats and valves.
CONNECTING ROD NOISE 1. Insufficient oil supply. 1. Check engine oil level.
2. Low oil pressure. 2. Check engine oil level. Inspect oil
pump relief valve and spring.
3. Thin or diluted oil. 3. Change oil to correct viscosity.
4. Thick oil 4. (a) Change engine oil and filter.
(b) Run engine to operating
temperature.
(c) Change engine oil and filter
again.
5. Excessive bearing clearance. 5. Measure bearings for correct
clearance. Repair as necessary.
6. Connecting rod journal
out-of-round.6. Replace crankshaft or grind
surface.
7. Misaligned connecting rods. 7. Replace bent connecting rods.
9 - 82 ENGINE 3.3/3.8LRS
ENGINE 3.3/3.8L (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
MAIN BEARING NOISE 1. Insufficient oil supply. 1. Check engine oil level.
2. Low oil pressure. 2. Check engine oil level. Inspect oil
pump relief valve and spring.
3. Thin or diluted oil. 3. Change oil to correct viscosity.
4. Thick oil 4. (a) Change engine oil and filter.
(b) Run engine to operating
temperature.
(c) Change engine oil and filter
again.
5. Excessive bearing clearance. 5. Measure bearings for correct
clearance. Repair as necessary.
6. Excessive end play. 6. Check thrust bearing for wear on
flanges.
7. Crankshaft journal out-of-round
or worn.7. Replace crankshaft or grind
journals.
8. Loose flywheel or torque
converter.8. Tighten to correct torque.
OIL PRESSURE DROP 1. Low oil level. 1. Check engine oil level.
2. Faulty oil pressure sensor/switch. 2. Replace oil pressure sensor/
switch.
3. Low oil pressure. 3. Check oil pressure sensor/switch
and main bearing oil clearance.
4. Clogged oil filter. 4. Install new oil filter.
5. Worn parts in oil pump. 5. Replace worn parts or pump.
6. Thin or diluted oil. 6. Change oil to correct viscosity.
7. Oil pump relief valve stuck. 7. Remove valve and inspect, clean,
or replace.
8. Oil pump suction tube loose. 8. Remove oil pan and install new
tube or clean, if necessary.
9. Oil pump cover warped or
cracked.9. Install new oil pump.
10. Excessive bearing clearance. 10. Measure bearings for correct
clearance.
OIL LEAKS 1. Misaligned or deteriorated
gaskets.1. Replace gasket(s).
2. Loose fastener, broken or porous
metal part.2. Tighten, repair or replace the
part.
3. Misaligned or deteriorated cup or
threaded plug.3. Replace as necessary.
RSENGINE 3.3/3.8L9-83
ENGINE 3.3/3.8L (Continued)

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 outlet on
the cover.
²Remove the PCV valve hose from the cylinder
head cover. Cap or plug the PCV valve outlet 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 - 84 ENGINE 3.3/3.8LRS
ENGINE 3.3/3.8L (Continued)