check engine CHRYSLER VOYAGER 1996 Service Manual

front seal is retained in the oil pump case and the
rear is retained in a block-mounted housing.
PISTONS:Are aluminum alloy with a steel strut,
short height, and thin wall so as to be autothermic
and light weight. The piston head with valve
recesses, in combination with the cylinder head,
forms a compact spherical head with clearance for
total valve lift with pistons at top dead center. The
piston skirt, top and second ring lands are finished to
a tapered roughness for oil retention and high resis-
tance to scuffing. Piston pins, pressed into place, join
the pistons to the connecting rods.
CYLINDER HEAD:The alloy cylinder heads fea-
ture cross-flow type intake and exhaust ports. Valve
guides and inserts are hardened cast iron. Valves of
heat resistance steel are arranged in a V with each
camshaft on center. To improve combustion speed the
chambers are a compact spherical design with a
squish area of approximately 30 percent of the piston
top area. The cylinder heads are common to either
cylinder bank by reversing the direction of installa-
tion.
CAMSHAFTS:Two overhead camshafts provide
valve actuation, one front (radiator side of cylinder
bank) and one rear. The front camshaft is provided
with a distributor drive and is longer. Both cam-
shafts are supported by four bearing journals, thrust
for the front camshaft is taken at journal two and
the rear at journal three. Front and rear camshaft
driving sprockets are interchangeable. The sprockets
and the engine water pump are driven by a single
notched timing belt.
ROCKER ARM SHAFTS:The shafts are retained
by the camshaft bearing journal caps. Four shafts are
used, one for each intake and exhaust rocker arm
assembly on each cylinder head. The hollow shafts
provide a duct for lubricating oil flow from the cylin-
der head to the valve mechanisms.
ROCKER ARMS:Are of light weight die-cast with
roller type follower operating against the cam shaft.
The valve actuating end of the rocker arms are
machined to retain hydraulic lash adjusters, elimi-
nating valve lash adjustment.
VALVES:Are made of heat resistant steel, valve
springs are especially designed to be short. The valve
spring wire cross-section is oval shaped and provides
the same spring tension as longer springs. Valve
spring retainers, locks and seals are conventional.
INTAKE MANIFOLD:The aluminum alloy mani-
fold is a cross type with long runners to improve
inertia. The runners, attaching below at the cylinder
head, also attach above and support an air plenum.
The air plenum chamber absorbs air pulsations cre-
ated during the suction phase of each cylinder.
EXHAUST MANIFOLDS:Both manifolds are a
log style made of ductile cast iron. Exhaust gasses,collected from the front cylinder bank, leave the front
manifold through an end outlet and are fed through
an upper crossover tube to the rear manifold. The
collected exhaust from both manifolds are combined,
and exit to the exhaust pipe through an articulated
joint.
DIAGNOSIS AND TESTING
CHECKING ENGINE OIL PRESSURE
Check oil pressure using gauge at oil pressure
switch location. Oil pressure should be 41 kPa ( 6
psi.) at idle or 241 to 517 kPa (35 to 75 psi.) at 3000
RPM.
(1) Remove pressure sending unit and install oil
pressure gauge. (Fig. 2).
CAUTION: If oil pressure is 0 at idle, Do Not Run
engine at 3000 RPM.
(2) Warm engine at high idle until thermostat
opens.
SERVICE PROCEDURES
AUTO LASH ADJUSTER
The automatic lash adjusters are precision units
installed in machined openings in the valve actuating
ends of the rocker arms. Do not disassemble the auto
lash adjuster.
FUNCTION CHECK
Check auto adjusters for free play by inserting a
small wire through the air bleed hole in the rocker
arm andvery lightlypushing the auto adjuster ball
check down (Fig. 3). While lightly holding the check
ball down move the rocker up and down to check for
free play. If there is no play replace the adjuster.
Fig. 2 Checking Engine Oil Pressure
9 - 62 3.0L ENGINENS
DESCRIPTION AND OPERATION (Continued)

FITTING CONNECTING ROD BEARINGS
CONNECTING ROD CLEARANCE
(1) Following procedures specified in the Standard
Service Procedures Section for Measuring Main Bear-
ing Clearance and Connecting Rod Bearing Clear-
ance (Fig. 4). Refer to Connecting Rod Specification
Chart.
(2) Tighten nuts to 52 N´m (38 ft. lbs.).
(3) Remove connecting rod cap and measure Plas-
tigage (Fig. 4).
CAUTION: Do not rotate crankshaft or the Plasti-
gage may be smeared.
CONNECTING ROD SIDE CLEARANCE
Using a feeler gauge, check connecting rod side
clearance (Fig. 5). Refer to Connecting Rod Specifica-
tion Chart.
FITTING MAIN BEARING
INSPECTION
Visually check the main and connecting rod bear-
ing journals for wear, scuffs or scoring and replace if
necessary.
CRANKSHAFT OIL CLEARANCEÐ
MECHANICAL MEASUREMENT
Measure the journal outside diameter and the
main bearing inside diameter (Fig. 6) & (Fig. 7). If
the clearance exceeds the specifications limit, replace
the main bearing(s) and if necessary replace the
crankshaft. Refer to Crankshaft Clearance Specifica-
tion Chart.
PLASTIGAGE MEASUREMENT
(1) Remove oil from journal and bearing shell.
(2) Install crankshaft.
(3) Cut plastigage to same length as width of the
bearing and place it in parallel with the journal axis
(Fig. 8).
Fig. 3 Auto Lash AdjusterÐFunction Check
Fig. 4 Connecting RodÐChecking Bearing
Clearance
Fig. 5 Checking Connecting Rod Side Clearance
CONNECTING ROD SPECIFICATION CHART
Connecting Rod Bearing Oil Clearance
New Part: 0.018 - 0.036 mm
(0.0007 - 0.0014 in.)
Connecting Rod Side Clearance
New Part: 0.10 - 0.25 mm
(0.004 - 0.010 in.)
Wear Limit: 0.4 mm (0.015 in.)
NS3.0L ENGINE 9 - 63
SERVICE PROCEDURES (Continued)

CHECKING CRANKSHAFT END PLAY
(1) Mount a dial indicator to front of engine, locat-
ing probe on nose of crankshaft (Fig. 11).
(2) Move crankshaft all the way to the rear of its
travel.
(3) Zero the dial indicator.
(4) Move crankshaft all the way to the front and
read the dial indicator. Refer to Crankshaft Specifi-
cation Chart.
CRANKSHAFT SIZE CLASSIFICATION CHART
SIZE NEW CURRENT
MAIN JOURNAL
59.982 - 59.988 mm
(2.3615 - 2.3617 in.)2 WHITE
ENAMEL
59.988 - 59.994 mm
(2.3617 - 2.3620 in.)1 NONE
59.994 - 60.000 mm
(2.3620 - 2.3622 in.)0 YELLOW
ENAMEL
CONNECTING ROD JOURNAL
49.980 - 49.985 mm
(1.9677 - 1.9679 in.)III WHITE
ENAMEL
49.985 - 49.995 mm
(1.9679 - 1.9683 in.)II NONE
49.995 - 50.000 mm
(1.9683 - 1.9685 in.)I YELLOW
ENAMEL
Fig. 10 Bearing Identification
Fig. 11 Checking Crankshaft End Play
CRANKSHAFT SPECIFICATION CHART
Crankshaft End-Play
New Part: 0.05 - 0.25 mm
0.002 - 0.001 in.)
Wear Limit: 0.30 mm (0.012 in.)
Main Bearing Oil Clearance
New Part: 0.018 - 0.036 mm
(0.0007 - 0.0014 in.)
Wear Part: 0.10 mm (0.0039 in.)
Crankshaft Main Bearing Journal
Standard Diameter: 59.980 mm (2.361 in.)
Crankshaft Connecting Rod Journal
Standard Diameter: 50.00 mm (1.968 in.)
NS3.0L ENGINE 9 - 65
SERVICE PROCEDURES (Continued)

VALVE SERVICE RECONDITION
(1) With suitable valve spring compressor, remove
spring retainer locks, retainer, valve spring, spring
seat and valve (Fig. 12).
(2) Remove valve stem seals with suitable tool
(Fig. 13). Do not reuse valve stem seals.
VALVES
(1) Check valve stem tip for pitting or depression
at point A (Fig. 14).
(2) Check for wear and ridge wear at Point B.
(3) Check for even contact (at face center) with
valve seat, Point C.
(4) Check margin (Fig. 14). Replace valve if mar-
gin is out of specification. Refer to Valve Specification
Chart.
(5) Check valve guide height (Fig. 15).
(6) Measure valve stem to guide clearance. Refer
to Valve Specification Chart.
(7) Measure Valve spring free length and square-
ness (Fig. 16). Refer to Valve Specification Chart.
Fig. 12 Remove Valves
Fig. 13 Remove Valve Stem Seals
Fig. 14 Valve Inspection
Fig. 15 Valve Guide Height
9 - 66 3.0L ENGINENS
SERVICE PROCEDURES (Continued)

(2) Tighten mount to transmission bolts to 55 N´m
(40 ft. lbs.) (Fig. 22).
Tighten through bolt to 75 N´m (55 ft. lbs.)
(3) Engine mount adjustment, Refer to Engine
Mount Insulator Adjustment of this section.
REAR MOUNT
(1) Raise vehicle on hoist.
(2) Support the transmission with a transmission
jack so it will not rotate.
(3) Remove the insulator through bolt from the
mount and rear suspension crossmember.
(4) Remove the four transmission mount fasteners
and remove the mount.
(5) Reverse the removal procedure for installation.
Refer to (Fig. 23).
ENGINE MOUNT RUBBER INSULATORS
Insulator location on (right side) is adjustable to
allow right/left drive train adjustment in relation to
driveshaft assembly length. See Engine Mount
Adjustments in this section.
Check and reposition right engine mount insulator.
Adjust drive train position, if required, for the follow-
ing conditions:
²Driveshaft distress: See Group 2, Suspension
and Driveshafts.
²Any front end structural damage (after repair).
²Insulator replacement.
ENGINE ASSEMBLY
REMOVAL
(1) Perform fuel pressure release procedure. Refer
to Group 14, Fuel System for procedure. Remove fuel
line to fuel rail.
(2) Disconnect battery.
(3) Remove Air cleaner and hoses.
(4) Remove battery cover, battery and battery tray,
with integral vacuum reservoir, from vehicle.
(5) Block off heater hoses to rear heater assembly,
if equipped.
(6) Drain cooling system. Refer to Group 7, Cooling
System for procedure.
(7) Disconnect heater hoses.
(8) Remove fan module and radiator. Refer to
Group 7, Cooling System for procedure.
(9) Disconnect transmission shift linkage.
(10) Disconnect throttle body linkage and vacuum
hoses from throttle body.
(11) Remove accessory drive belts. Refer to Acces-
sory Drive System located in Group 7, Cooling Sys-
tem for procedure.
(12) Remove air conditioning compressor from
engine and set it aside.
(13) Disconnect generator wiring harness and
remove generator.
(14) Hoist vehicle and remove axle shafts. Refer to
Group 2, Driveshaft for procedure.
(15) Remove right and left inner splash shields.
(16) Disconnect exhaust pipe from manifold.
(17) Remove front engine mount and bracket as an
assembly.
(18) Remove rear transmission mount and bracket.
(19) Remove power steering pump and bracket
assembly.
(20) Remove wiring harness and connectors from
front of engine.
(21) Remove bending braces and install tool num-
ber 6910 on engine.
(22) Remove trans inspection cover and mark flex-
plate to torque converter.
(23) Remove driveplate to torque converter bolts.
(24) Lower the vehicle.
Fig. 22 Engine MountÐLeft
Fig. 23 Engine MountÐRear
NS3.0L ENGINE 9 - 69
REMOVAL AND INSTALLATION (Continued)

(6) When removing right cylinder head cover, dis-
connect generator wiring and remove generator.
(7) Relocate spark plug wires.
(8) Remove vacuum connections.
(9) Remove rocker cover screws and remove cover
(Fig. 25).
INSTALLATION
(1) Clean cylinder head and cover mating surfaces.
Install new gasket.
(2) See (Fig. 25) and apply sealant such as Mopar
Silicone Rubber Adhesive Sealant to cover ends.
(3) Install cover and tighten cover bolt washer and
gasket assembly to 10 N´m (88 in. lbs.).
(4) Reverse removal procedures for installation.
CAMSHAFT
REMOVAL
NOTE: SEE AUTO LASH ADJUSTER FUNCTION
CHECK BEFORE DISASSEMBLY
(1) Install auto lash adjuster retainers (Fig. 26).
(2) Remove distributor adaptor (Fig. 27).
(3) When removing camshaft bearing caps do not
remove the bolts from the bearing caps. Remove the
rocker arm, rocker shafts and bearing cap as an
assembly.
CAMSHAFT INSPECTION
(1) Inspect camshaft bearing journals for damage
and binding (Fig. 28). If journals are binding, also
check the cylinder head for damage. Also check cyl-
inder head oil holes for clogging.
(2) Front cylinder head camshaft check the tooth
surface of the distributor drive gear teeth of the cam-
shaft and replace if abnormal wear is evident (Fig.
28).
(3) Check the cam surface for abnormal wear and
damage and replace if defective. Also measure the
cam height (Fig. 28) and replace if out of limit, stan-
dard value is 41.25 mm (1.624 in.), wearlimitis
40.75 mm (1.604 in.).
CAMSHAFT INSTALL
Lubricate camshaft journals and cams with engine
oil and install camshaft on cylinder head.
Fig. 25 Rocker Cover
Fig. 26 Auto Lash Adjuster Retainers
NS3.0L ENGINE 9 - 71
REMOVAL AND INSTALLATION (Continued)

ROCKER ARMS
INSTALL ROCKER ARM SHAFT ASSEMBLY
(1) Apply Mopar Silicone Rubber Adhesive Sealant
at bearing cap ends as shown in (Fig. 29).
(2) Install the rocker arm shaft assembly making
sure that the arrow mark on the bearing cap and the
arrow mark on the cylinder head are in the same
direction (Fig. 29).
NOTE: The direction of arrow marks on the front
and rear assemblies are opposite to each other.
(3) Tighten bearing cap bolts in the following order
to 10 N´m (85 in. lbs.). First #3, then #2, #1 and #4.
(4) Repeat step 3 increasing the torque to 20 N´m
(180 in.lbs.).
(5) Install distributor drive adaptor assembly (Fig.
30).
CAMSHAFT SEAL
CAMSHAFT END SEAL (PLUG)Ð IN VEHICLE
SERVICE
(1) Remove air cleaner assembly from engine.
(2) Use a small punch and a hammer, carefully
remove cam plug from cylinder head.
Fig. 27 Cylinder Heads and Camshafts
Fig. 28 Checking Camshafts
9 - 72 3.0L ENGINENS
REMOVAL AND INSTALLATION (Continued)

CAMSHAFT SPROCKETS
To remove camshaft sprockets
1. Hold camshaft sprocket with Spanner Tool
MB-990775 loosen and remove bolt and washer (Fig.
39).
2. Remove camshaft sprocket from camshaft.
To install camshaft sprockets
3. Place camshaft sprocket on camshaft.
4. Install bolt and washer to camshaft. Using
Spanner Tool MB-990775 hold camshaft sprocket and
torque bolt to 95 N´m (70 ft. lbs.) (Fig. 39).
TIMING BELT TENSIONER
(1) Install timing belt tensioner and tensioner
spring.
(2) Hook spring upper end to water pump pin and
lower end to tensioner bracket with hook out (Fig.
40).
(3) Turn timing belt tensioner counterclockwise
full travel in adjustment slot and tighten bolt to tem-
porarily hold this position (Fig. 41).
INSTALLATIONÐTIMING BELT
(1) Install timing belt on crankshaft sprocket and
keep belt tight on tension side (Fig. 38). Install belt
on the front (radiator side) camshaft sprocket. Installbelt on the water pump pulley, rear camshaft
sprocket and finally on the timing belt tensioner.
(2) Rotate the front camshaft sprocket in opposite
direction to take up belt slack. Check that all timing
marks are aligned (Fig. 38).
(3) Install crankshaft sprocket flange (Fig. 36).
(4) Loosen tensioner bolt and allow spring to ten-
sion timing belt.
Fig. 38 Timing Belt Engine Sprocket Timing
Fig. 39 Camshaft Sprockets
9 - 76 3.0L ENGINENS
REMOVAL AND INSTALLATION (Continued)

FITTING PISTON RINGS
(1) Wipe cylinder bore clean. Insert ring and push
down with piston to ensure it is square in bore. The
ring gap measurement must be made with the ring
positioning at least 16 mm (0.63 in.) from bottom of
cylinder bore. Check gap with feeler gauge (Fig. 49).
Refer to Piston Ring Specification Chart.
(2) Check piston ring to groove clearance (Fig. 50).
Refer to Piston Ring Specification Chart.PISTON RINGSÐINSTALLATION
(1) The No. 1 and No. 2 piston rings have a differ-
ent cross section. Install rings with manufacturers
mark and size mark facing up, to the top of the pis-
ton (Fig. 51).
CAUTION: Install piston rings in the following
order:
a. Oil ring expander.
b. Upper oil ring side rail.
PISTON RING SPECIFICATION CHART
Ring Position Ring Gap Ring Gap Wear
LimitGroove Clearance Maximum Groove
Clearance
Upper Ring 0.30 - 0.45 mm
(0.012 - 0.018 in.)0.8 mm (0.031 in.) 0.05 - 0.09 mm
(0.002 - 0.0035 in.)0.10 mm (0.004 in.)
Intermediate Ring 0.25 - 0.40 mm
(0.010 - 0.016 in.)0.8 mm (0.031 in.) 0.02 - 0.06 mm
(0.0007 - 0.002 in.)0.10 mm (0.004 in.)
Oil Control Ring 0.30 - 0.90 mm
(0.012 - 0.035 in.)1.0 mm (0.039 in.) Oil Ring Side Rails Must Be Free To Rotate
After Assembly
Fig. 48 Piston Clearance and Wear
Fig. 49 Check Gap on Piston Rings
Fig. 50 Piston Ring Clearance
Fig. 51 Piston RingÐInstallation
NS3.0L ENGINE 9 - 79
REMOVAL AND INSTALLATION (Continued)

c. Lower oil ring side rail.
d. No. 2 Intermediate piston ring.
e. No. 1 Upper piston ring.
(2) Install the side rail by placing one end between
the piston ring groove and the expander. Hold end
firmly and press down the portion to be installed
until side rail is in position.Do not use a piston
ring expander(Fig. 52).
(3) Install upper side rail first and then the lower
side rail.
(4) Install No. 2 piston ring and then No. 1 piston
ring (Fig. 53).
(5)
Position piston ring end gaps as shown in (Fig. 54).
(6) Position oil ring expander gap at least 45É from
the side rail gaps butnoton the piston pin center or
on the thrust direction.
(7) Connecting rod front mark 72 must always face
forward, toward timing belt end. (Fig. 55)
(8) Install the piston and connecting rod assembly
into there respective bore from the cylinder block top.
CAUTION: Piston assemblies are not to be inter-
changed from bank to bank.(9) Check alignment marks made during disassem-
bly and that bearing position notches new or used
are on the same side as shown in (Fig. 56).
Fig. 52 Side RailÐInstallation
Fig. 53 Installing Upper and Intermediate Rings
Fig. 54 Piston Ring End Gap Position
Fig. 55 Identify Piston and Rod Assembly for
Cylinder Installation
Fig. 56 Connecting Rod and Cap
9 - 80 3.0L ENGINENS
REMOVAL AND INSTALLATION (Continued)