Changing the spark plugs on a Chrysler Voyager V6

The rear spark plugs on a Chrysler Voyager V6 (2000) at first seem very difficult to change. I have heard of various methods, from gaining access from underneath the car, to lifting the inlet manifold an inch or two.

I decided to take the easiest approach, which might not be the quickest if you have access to a vehicle lift, but is relatively straight forward.

As well as a new set of spark plugs and ignition leads you may need a new inlet manifold gasket as it could break when you remove the manifold

Below is a step by step photo guide on how to replace the spark plugs, which you might find helpful if tackling the job yourself.


Note position of wiper arms

Remove wiper arm spindle cap

Remove wiper arm spindle nut

Remove wiper arm and wiper top panel screws

Panel clips

Remove flat nuts from wiper top panel studs

Disconnect screen washer tubing

Disconnect screen washer tubing on jets

Remove wiper box top bracket nuts

Remove main wiper box bolts

Remove main wiper box bolts

Remove wiper motor multiplug

Disconnect wiper box drain pipes

Lift out wiper box assembly for easy access to inlet manifold

Remove 3 alternator bracket bolts and rotate plate upwards

Remove distributor bolts

Remove air box and vacuum pipes, breather pipes, multiplugs, throttle cables on throttle body

Remove exhaust recirculation pipe bolts (a bit tricky)

Remove inlet manifold support bracket bolt from engine block

Remove cable mounting bracket bolt on back of manifold(left side) (a bit tricky)

Remove cable mounting bracket bolt (right side) (also a bit tricky)

View of cable bracket/bolts on back of manifold(may assist in removal)

Remove earth wires on bulkhead stud

Remove inlet manifold nuts and bolts

Remove inlet manifold and cover engine inlet ports

Remove ignition leads and Remove and replace rear spark plugs

Remove ignition leads and Remove and replace front spark plugs

Check wiring and multiplug cable mounting bracket

Fit new inlet manifold gasket

Fit new air filter at this stage if necessary and rebuild Refit rear ignition leads; rebuild inlet manifold assembly, electrics and wiper box.

Parts used

voyager

This entry was posted by Steve on 13 June 2008 at 4:47 pm, and is filed under Cars. Follow any responses to this post through RSS 2.0. You can leave a response or trackback from your own site.

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Comments (14)

#1 written by Steve
about 3 years ago

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Very useful with the photos.
Beats a Haynes Manual
#2 written by gary
about 3 years ago

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hi very helpful plugs are done water pump has gone now i have found one on an american website (rockauto) wi this fit uk version i would be grateful if you could help
#3 written by Steve
about 3 years ago

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Hi Gary. I usually buy car spares (brakes parts and filters etc.) for my Voyager from Bristol Motor Parts (01179553311). But on checking with them today, they tell me Chrysler Voyager water pumps are only available through the main dealer. I haven’t checked the price with Dick Lovett, but I bet it will be advisable to be sitting down when they tell you! I haven’t tried purchasing any spares from the U.S
#4 written by Art
about 3 years ago

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Well, my garage got the water pump from normal parts shop.
£160 including labour
#5 written by dave allan
about 3 years ago

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many thanks doing engine change .engine and box out through the top split .change engine .forgot some of the item ie wear they go pic have helped .its also got lpg .many thanks again dave
#6 written by Jochen from Germany
about 2 years ago

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Hallo Gary, same problem here in Germany with the 6 spare plug. We try from below with some short tool. Hard work and take some time.

Thank you for this phantastic instruction. I should find this earlier.

Make a good day Jochen
#7 written by mike burr
about 2 years ago

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great step by step by your pictures and expertise I think I’ll have a professional change my plugs , thank you
#8 written by David Baas
about 2 years ago

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Excelent material. Professional quality. Very useful. Many thanks
#9 written by Alex Nava
about 2 years ago

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Thankyou from Mexico City. Very clear explanation. (Quite different of change spark plugs on my chysler aspen 1984!)
#10 written by anders flodin
about 2 years ago

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Good Stuff!
I just want to confirm that I did exactly what you explained here, tried various methods used by others like reaching from underneath etc, none worked except this method, took me 2 long evenings the first time, second time you know there are no shortcuts so much faster.
Thanks,
Anders
#11 written by Baldboab
about 1 year ago

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Hi,

Thanks for doing this I found it really helpful. I was going to give it to a garage, but might give this a go myself over a weekend. Can I ask do you think I could get the rear exhaust manifold out this way too? I think mine is cracked. The spark plugs neeed changing but thought if I was going to do the plugs this way, if possible I would do the manifold this way at the same time.

Thanks.
#12 written by Mr.O
about 1 year ago

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Thanks for this I found it really helpful.

Is it possible to replace the rear exhaust manifold out this way too? It is cracked.

Any help appreciated
#13 written by Bruce
about 5 months ago

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Just what was looking for. Thank you
#14 written by Bruce
about 3 months ago

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Successfully completed the job using this tutorial. And additional peice of advice, disconnect the pcv hose that runs horizontally under the inlet manifold before attempting to remove it. I snapped the hose when lifting up the manifold. Even if it didn’t brake, the pcv tube needed to be replaced anyway. It had hardened from all the heat. Autozone part # 46033, pcv tube connects to the cylinder head crank case vent.