Chrysler RG Voyager. Manual — part 951
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. 37), 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 (Fig. 40).
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 Force seal against top
of guide. When installing the valve retainer locks,
compress the spring only enough to install the locks
(Fig. 40).
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.
ROCKER ARMS
DESCRIPTION
DESCRIPTION - ROCKER ARMS
The rocker arms are installed on the rocker arm
shaft. The rocker arms and shaft assembly is
attached to the cylinder head with seven billeted
bolts and retainers. The rocker arms are made of
stamped steel.
DESCRIPTION - PUSHRODS
The pushrods are made of steel and are a hollow
design. The pushrods are positioned between the
hydraulic lifter and the rocker arm.
OPERATION
OPERATION - ROCKER ARMS
The rocker arm pivots on the rocker shaft. Rocker
arms are used to translate up and down motions pro-
vided by the camshaft, hydraulic lifter, and pushrod
Fig. 39 TESTING VALVE SPRING
1 - SPECIAL TOOL C-647
Fig. 40 VALVE SPRING INSTALLED
1 - VALVE SPRING RETAINER
2 - VALVE INSTALLED HEIGHT
3 - CYLINDER HEAD SURFACE
4 - VALVE SPRING SEAT SURFACE
5 - VALVE SPRING INSTALLED HEIGHT
RS
ENGINE 3.3/3.8L
9 - 113
VALVE SPRINGS (Continued)
on one end, into a down and up motions on the valve
stem on the opposing end.
OPERATION - PUSHRODS
The pushrod is a solid link between the hydraulic
lifter and the rocker arm. Also, the pushrod supplies
engine oil from the hydraulic lifter to the rocker arm.
REMOVAL - ROCKER ARMS AND SHAFT
(1) Remove the cylinder head cover(s). (Refer to 9 -
ENGINE/CYLINDER
HEAD/CYLINDER
HEAD
COVER(S) - REMOVAL)
NOTE: Rocker arm shaft bolts are captured to the
shaft.
(2) Loosen the rocker shaft bolts (Fig. 41), rotating
one turn each, until all valve spring pressure is
relieved.
(3) Remove the rocker arms and shaft assembly
(Fig. 41).
(4) For rocker arm disassembly procedures, (Refer
to 9 - ENGINE/CYLINDER HEAD/ROCKER ARMS -
DISASSEMBLY).
DISASSEMBLY - ROCKER ARMS AND SHAFT
CAUTION: Do not attempt to drive the billeted bolt
from the rocker shaft. This can damage the rocker
arm retainer and bolt assembly.
(1) Remove the rocker arm retainer and bolt by
performing the following procedure:
(a) Using adjustable pliers, grip the edges of the
retainer (Fig. 42).
(b) Apply an upward force with a slight rocking
motion until the retainer disengages from shaft
(Fig. 42).
(2) Remove rocker arms (Fig. 43). Identify the
component locations for reassembly in original loca-
tions.
Fig. 41 ROCKER ARMS AND SHAFT
1 - ROCKER ARMS AND SHAFT ASSEMBLY
2 - ROCKER SHAFT BOLTS
Fig. 42 ROCKER ARM RETAINER - REMOVAL
1 - ADJUSTABLE PLIERS
3 - ROCKER ARM RETAINER
2 - BILLETED ROCKER SHAFT BOLT
9 - 114
ENGINE 3.3/3.8L
RS
ROCKER ARMS (Continued)
ASSEMBLY - ROCKER ARMS AND SHAFT
(1) Install rocker arms on the shaft (Fig. 43).
Install in the orginal positions if re-used. Ensure the
rocker shaft, all the retainers and washers are prop-
erly positioned and installed in the correct locations
(Fig. 43).
(2) Install rocker arms and shaft to the cylinder
head. (Refer to 9 - ENGINE/CYLINDER HEAD/
ROCKER ARMS - INSTALLATION)
INSTALLATION - ROCKER ARMS AND SHAFT
CAUTION: Ensure the longer shaft retaining bolt is
installed in the proper location on the rocker shaft.
(Refer to 9 - ENGINE/CYLINDER HEAD/ROCKER
ARMS - ASSEMBLY)
(1) Position the rocker arm and shaft assemblies
on the pedestal mounts.
CAUTION: Ensure all pushrods are properly located
on the lifter and the rocker arm socket.
(2) Align each rocker arm socket with each push-
rod end.
CAUTION: The rocker arm shaft should be tight-
ened down slowly, starting with the center bolts.
Allow 20 minutes lifter bleed down time after instal-
lation of the rocker shafts before engine operation.
(3) Slowly tighten rocker shaft bolts evenly until
shaft is seated. Tighten bolts to 23 N·m (200 in. lbs.)
(Fig. 44).
Fig. 43 ROCKER ARMS AND SHAFT
1 - BOLT (ROCKER SHAFT OIL FEED - LONGER LENGTH)
5 - ROCKER ARM - EXHAUST
2 - SHAFT RETAINER/SPACER - 21.5 mm (0.84 in.)
6 - WASHER
3 -SHAFT RETAINER/SPACER - 37.5 mm (1.47 in.)
7 - ROCKER ARM - INTAKE (LARGER OFFSET)
4 - SHAFT RETAINER/SPACER - 40.9 mm (1.61 in.)
8 - ROCKER ARMS LUBRICATION FEED HOLE (POSITION
UPWARD & TOWARD VALVE SPRING)
Fig. 44 ROCKER ARMS AND SHAFT
1 - ROCKER ARMS AND SHAFT ASSEMBLY
2 - ROCKER SHAFT BOLTS
RS
ENGINE 3.3/3.8L
9 - 115
ROCKER ARMS (Continued)
(4) Install the cylinder head cover(s). (Refer to 9 -
ENGINE/CYLINDER
HEAD/CYLINDER
HEAD
COVER(S) - INSTALLATION)
VALVE STEM SEALS
DESCRIPTION
The valve stem seals are made of Viton rubber. The
seals are positioned over the valve stem and seated
on the valve guide (Fig. 45).
REMOVAL
(1) Remove the valve springs. (Refer to 9 -
ENGINE/CYLINDER
HEAD/VALVE
SPRINGS
-
REMOVAL)
(2) Remove the valve stem seal (Fig. 45).
INSTALLATION
(1) Install the valve stem seal squarely over the
valve guide, using the valve stem as a guide (Fig.
45). Do not force the seal against top of the valve
guide.
(2) Install the valve spring. (Refer to 9 - ENGINE/
CYLINDER HEAD/VALVE SPRINGS - INSTALLA-
TION)
ENGINE BLOCK
DESCRIPTION
The cylinder block is made of cast iron and is a
deep skirt design.
STANDARD PROCEDURE
CYLINDER BORE HONING
(1) Used carefully, the cylinder bore resizing hone,
recommended tool C-823 or equivalent, equipped
with 220 grit stones, is the best tool for this honing
procedure. In addition to deglazing, it will reduce
taper and out-of-round as well as removing light
scuffing, scoring or scratches. Usually a few strokes
will clean up a bore and maintain the required lim-
its.
(2) Deglazing of the cylinder walls may be done
using a cylinder surfacing hone, recommended tool
C-3501 or equivalent, equipped with 280 grit stones,
if the cylinder bore is straight and round. 20–60
strokes depending on the bore condition, will be suf-
ficient to provide a satisfactory surface. Use a light
honing oil. Do not use engine or transmission oil,
mineral spirits or kerosene. Inspect cylinder walls
after each 20 strokes.
(3) Honing should be done by moving the hone up
and down fast enough to get a cross-hatch pattern.
When hone marks intersect at 40-60 degrees, the
cross hatch angle is most satisfactory for proper seat-
ing of rings (Fig. 46).
Fig. 45 Valve Stem Seal
Fig. 46 Cylinder Bore Cross-Hatch Pattern
1 - CROSS-HATCH PATTERN
2 - 40°–60°
9 - 116
ENGINE 3.3/3.8L
RS
ROCKER ARMS (Continued)
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