CHRYSLER VOYAGER 1996 Service Manual

INSTALLATION
(1) Install camshaft seal flush with cylinder head
using Special Tool MD 998306 (Fig. 27).
(2) Install camshaft sprocket retaining bolt. Hold
camshaft sprocket with Special Tool C-4687-1 (Fig.
25) and tighten bolt to 115 N´m (85 ft. lbs.).
TIMING BELT SYSTEM
CHECKING BELT TIMINGÐCOVER INSTALLED
²Remove number one spark plug.
²Using a dial indicator, set number one cylinder
to TDC on the compression stroke.²Remove the access plug from the outer timing
belt cover (Fig. 28).
²Check the timing mark on the camshaft
sprocket, it should align with the arrow on the rear
belt cover (Fig. 29).
REMOVALÐTIMING BELT
(1) Remove accessory drive belts. Refer to Group 7,
Cooling System for procedure outlined in that sec-
tion.
(2) Remove crankshaft damper bolt. Remove
damper using the large side of Special Tool 1026 and
insert 6827-A (Fig. 30).
Fig. 27 Installing Camshaft Seal
Fig. 28 Timing Belt System
Fig. 29 Camshaft Timing Marks
NS/GSENGINE 9 - 13
REMOVAL AND INSTALLATION (Continued)

(3) Remove front timing belt cover (Fig. 31).
CAUTION: Align camshaft and crankshaft timing
marks before removing the timing belt.
(4) Loosen timing belt tensioner fasteners (Fig. 33)
and remove timing belt and tensioner.
CAUTION: Do not loosen, tighten, or remove the
tensioner pivot bolt (Fig. 32).
CAMSHAFT AND CRANKSHAFT TIMING
PROCEDURE AND BELT INSTALLATION
ÐSOHC ENGINE
(1) When tensioner is removed from the engine it
is necessary to compress the plunger into the ten-
sioner body.(2) Place the tensioner into a vise equipped with
soft jaws and slowly compress the plunger (Fig. 34).
CAUTION: Index the tensioner in the vise the same
way it is installed on the engine. This is to ensure
proper pin orientation when tensioner is installed
on the engine.
(3) When plunger is compressed into the tensioner
body install a 1.9 mm (5/64) allen wrench or pin
through the body and plunger to retain plunger in
place until tensioner is installed.
(4) Set crankshaft sprocket to TDC by aligning the
sprocket with the arrow on the oil pump housing,
then back off to 3 notches before TDC (Fig. 35).
Fig. 30 Crankshaft DamperÐRemoval
Fig. 31 Timing Belt Cover
Fig. 32 Tensioner Pulley Assembly
Fig. 33 Remove Timing Belt
9 - 14 ENGINENS/GS
REMOVAL AND INSTALLATION (Continued)

(5) Set camshaft to TDC by aligning mark on
sprocket with the arrow on the rear of timing belt
cover (Fig. 36).
(6) Move crankshaft to 1/2 mark before TDC (Fig.
37) for belt installation.
(7) Install timing belt. Starting at the crankshaft,
go around the water pump sprocket and then around
the camshaft sprocket.(8) Move crankshaft sprocket to TDC to take up
belt slack. Install tensioner to block but do not
tighten fasteners.
(9) Using a torque wrench on the tensioner pulley
apply 28 N´m (250 in. lbs.) of torque (Fig. 38).
(10) With torque being applied to the tensioner
pulley move the tensioner up against the tensioner
pulley bracket and tighten fasteners to 31 N´m (275
in. lbs.) (Fig. 38).
(11) Pull tensioner plunger pin. Pretension is cor-
rect when pin can be removed and installed.
(12) Rotate crankshaft 2 revolutions and check the
alignment of the timing marks (Fig. 38).
(13) Install front half of timing cover.
Fig. 34 Compressing Timing Belt Tensioner
Fig. 35 Crankshaft Sprocket Timing
Fig. 36 Camshaft Timing Mark
Fig. 37 Adjusting Crankshaft Sprocket for Timing
Belt Installation
Fig. 38 Adjusting Timing Belt Tension
NS/GSENGINE 9 - 15
REMOVAL AND INSTALLATION (Continued)

(14) Install crankshaft damper using M12-1.75 x
150 mm bolt, washer, thrust bearing and nut from
Special Tool 6792. Install crankshaft damper bolt and
tighten to 142 N´m (105 ft. lbs.) (Fig. 39).
(15) Install accessory drive belts. Refer to Group 7,
Cooling System Accessory Drive section for proce-
dure.
(16) Perform camshaft and crankshaft timing
relearn. Refer to Group 25, Emission Control Sys-
tems for procedure.
TIMING BELTÐw/AUTO TENSIONERÐIF
EQUIPPED
CHECKING BELT TIMINGÐCOVER INSTALLED
²Remove number one spark plug.
²Using a dial indicator, set number one cylinder
to TDC on the compression stroke.
²Remove the access plug from the outer timing
belt cover (Fig. 28).
²Check the timing mark on the camshaft
sprocket, it should align with the arrow on the rear
belt cover (Fig. 29).
REMOVALÐTIMING BELT
(1) Remove accessory drive belts. Refer to Group 7,
Cooling System for procedure outlined in that sec-
tion.
(2) Raise vehicle on a hoist and remove right inner
splash shield (Fig. 42).
(3) Remove crankshaft damper bolt. Remove
damper using the large side of Special Tool 1026 and
insert 6827-A (Fig. 30).
(4) Lower vehicle and place a jack under engine.
(5) Remove right engine mount. Refer to procedure
outlined in this section.
(6) Remove right engine mount bracket (Fig. 44).
(7) Remove front timing belt cover (Fig. 31).CAUTION: Align camshaft and crankshaft timing
marks before removing the timing belt by rotating
the engine with the crankshaft.
(8) Inserta8mmAllen wrench into the belt ten-
sioner. Before rotating the tensioner insert the long
end of a 1/8º or 3 mm Allen wrench into the pin hole
on the front of the tensioner (Fig. 33). Rotate the ten-
sioner counterclockwise with the Allen wrench, while
pushing in lightly on the 1/8 in. or 3 mm Allen
wrench, until it slides into the locking hole.
(9) Remove timing belt.
CAUTION: Do not rotate the camshafts once the
timing belt has been removed or damage to valve
components may occur.
CAMSHAFT AND CRANKSHAFT TIMING PROCEDURE AND
BELT INSTALLATION ÐSOHC ENGINE
(1) Set crankshaft sprocket to TDC by aligning the
sprocket with the arrow on the oil pump housing,
then back off to 3 notches before TDC (Fig. 35).
(2) Set camshaft to TDC by aligning mark on
sprocket with the arrow on the rear of timing belt
cover (Fig. 36).
(3) Move crankshaft to 1/2 mark before TDC (Fig.
37) for belt installation.
(4) Install timing belt. Starting at the crankshaft,
go around the water pump sprocket and then around
the camshaft sprocket.
(5) Move crankshaft sprocket to TDC to take up
belt slack.
(6) Remove the pin or 1/8º or 3 mm Allen wrench
from belt tensioner.
(7) Rotate crankshaft 2 revolutions and check the
alignment of the timing marks (Fig. 50).
(8) Install front half of timing cover.
(9) Install engine mount bracket.
(10) Install Right engine mount. Refer to proce-
dure outlined in this section.
(11) Remove jack from under engine.
(12) Install crankshaft damper using M12-1.75 x
150 mm bolt, washer, thrust bearing and nut from
Special Tool 6792. Install crankshaft damper bolt and
tighten to 142 N´m (105 ft. lbs.) (Fig. 39).
(13) Install accessory drive belts. Refer to Group 7,
Cooling System Accessory Drive section for proce-
dure.
(14) Raise vehicle on hoist and install right inner
splash shield.
(15) Perform camshaft and crankshaft timing
relearn procedure as follows:
²Connect the DRB scan tool to the data link
(diagnostic) connector. This connector is located in
the passenger compartment; at the lower edge of
instrument panel; near the steering column.
Fig. 39 Crankshaft DamperÐInstallation
9 - 16 ENGINENS/GS
REMOVAL AND INSTALLATION (Continued)

²Turn the ignition switch on and access the ªmis-
cellaneousº screen.
²Select ªre-learn cam/crankº option and follow
directions on DRB screen.
OIL PAN
REMOVAL
(1) Drain engine oil.
(2) Remove transmission inspection cover.
(3) If equipped with air conditioning remove oil fil-
ter and adaptor. Refer to Oil Filter Adapter Removal
and Installation in this section.
(4) Remove oil pan.(5) Clean oil pan and all gasket surfaces.
Fig. 40 Timing Belt System
Fig. 41 Camshaft Timing Marks
Fig. 42 Right Inner Splash Shield
NS/GSENGINE 9 - 17
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Apply Mopar Silicone Rubber Adhesive Sealant
or equivalent at the oil pump to engine block parting
line (Fig. 52).
(2) Install a new oil pan gasket to pan.
(3) Install pan and tighten screws to 12 N´m (105
in. lbs.).
(4) Install oil filter and adaptor.
(5) Install proper amount of oil. With oil filter 4.25
Liters (4.5 Qts.). Without oil filter 3.8 Liters (4.0
Qts.)
FRONT CRANKSHAFT OIL SEAL
REMOVAL
(1) Using Special Tool 1026 and Insert 6827±A,
remove crankshaft damper (Fig. 53).
(2) Remove outer timing belt cover and timing
belt. Refer to Timing Belt System outlined in this
section.(3) Remove crankshaft sprocket using Special Tool
6793 and insert C-4685-C2 (Fig. 54).
CAUTION: Do not nick shaft seal surface or seal
bore.
Fig. 43 Crankshaft DamperÐRemoval
Fig. 44 Right Engine Mount Bracket
Fig. 45 Timing Belt Cover
Fig. 46 Timing Belt Removal
9 - 18 ENGINENS/GS
REMOVAL AND INSTALLATION (Continued)

(4) Using Tool 6771 to remove front crankshaft oil
seal (Fig. 55). Do not damage the seal contact area
on the crankshaft.
INSTALLATION
(1) Install new seal by using Tool 6780±1 (Fig. 56).(2) Place seal into opening with seal spring
towards the inside of engine. Install seal until flush
with cover.
(3) Install crankshaft sprocket (Fig. 57). Using
Special Tool 6792.
NOTE: Make sure the word ªfrontº on the sprocket
is facing you.
(4) Install timing belt and covers. Refer to Timing
Belt System in this section for installation.
(5) Install crankshaft damper (Fig. 58). Use thrust
bearing/washer and 12M-1.75 x 150 mm bolt from
Fig. 47 Crankshaft Sprocket Timing
Fig. 48 Camshaft Timing Mark
Fig. 49 Adjusting Crankshaft Sprocket for Timing
Belt Installation
Fig. 50 Crankshaft and Camshaft Timing
Fig. 51 Crankshaft DamperÐInstallation
NS/GSENGINE 9 - 19
REMOVAL AND INSTALLATION (Continued)

Special Tool 6792. Install crankshaft damper bolt and
tighten to 142 N´m (105 ft. lbs.)
CRANKSHAFT OIL SEALÐREAR
REMOVAL
(1) Insert a 3/16 flat bladed screwdriver between
the dust lip and the metal case of the crankshaftseal. Angle the screwdriver (Fig. 59) through the dust
lip against metal case of the seal. Pry out seal.
CAUTION: Do not permit the screwdriver blade to
contact crankshaft seal surface. Contact of the
screwdriver blade against crankshaft edge (cham-
fer) is permitted.
INSTALLATION
CAUTION: If burr or scratch is present on the
crankshaft edge (chamfer), cleanup with 400 grit
sand paper to prevent seal damage during installa-
tion of new seal.
Fig. 52 Oil Pan Sealing
Fig. 53 Crankshaft DamperÐRemoval
Fig. 54 Crankshaft SprocketÐRemoval
Fig. 55 Front Crankshaft Oil SealÐRemoval
Fig. 56 Front Crankshaft Oil SealÐInstallation
9 - 20 ENGINENS/GS
REMOVAL AND INSTALLATION (Continued)

NOTE: When installing seal, no lube on seal is
needed.
(1) Place Special Tool 6926-1 on crankshaft. This is
a pilot tool with a magnetic base (Fig. 60).
(2) Position seal over pilot tool. Make sure you can
read the wordsTHIS SIDE OUTon seal (Fig. 60).
Pilot tool should remain on crankshaft during instal-
lation of seal. Ensure that the lip of the seal is facing
towards the crankcase during installation.
CAUTION: If the seal is driven into the block past
flush, this may cause an oil leak.
(3) Drive the seal into the block using Special Tool
6926-2 and handle C-4171 (Fig. 61) until the tool bot-
toms out against the block (Fig. 62).
CRANKSHAFT
REMOVAL
(1) Remove oil filter and adapter from bedplate.(2) Remove collar from oil pan to transmission
housing.
(3) Remove oil pan.
(4) Remove crankshaft sprocket and oil pump both
procedures outlined in this section.
(5) Remove all main bearing cap and bedplate
bolts from the engine block (Fig. 63).
(6) Using a mallet tap the bedplate loose from the
engine block dowel pins.
Fig. 57 Crankshaft SprocketÐInstallation
Fig. 58 Crankshaft DamperÐInstallation
Fig. 59 Rear Crankshaft Oil SealÐRemoval
Fig. 60 Rear Crankshaft Seal and Special Tool
6926-1
NS/GSENGINE 9 - 21
REMOVAL AND INSTALLATION (Continued)

CAUTION: Do not pry up on one side of the bed-
plate. Damage may occur to cylinder block and bed-
plate alignment.(7) Bedplate should be removed evenly from the
cylinder block dowel pins.
(8) Lift out crankshaft from cylinder block. Be sure
not to damage the main bearings or journals when
removing the crankshaft.
CRANKSHAFT MAIN BEARINGS LOCATION
The crankshaft is supported in five main bearings.
All upper bearing shells in the crankcase have oil
grooves. All lower bearing shells installed in the (bed-
plate) main bearing cap are plain. Crankshaft end
play is controlled by a flanged bearing on the number
three main bearing journal (Fig. 64).
NOTE: The upper and lower main Bearing shells
are Not interchangeable. The lower shells have a
revised tab to prevent improper installation.
CRANKSHAFT MAIN JOURNALS INSPECTION
The crankshaft journals should be checked for
excessive wear, taper and scoring. Limits of taper or
out-of-round on any crankshaft journals should be
held to .025 mm (.001 inch). Journal grinding should
not exceed .305 mm (.012 inch) under the standard
journal diameter. DO NOT grind thrust faces of
Number 3 main bearing. DO NOT nick crank pin or
bearing fillets. After grinding, remove rough edges
from crankshaft oil holes and clean out all passages.
CAUTION: With the nodular cast iron crankshafts
used it is important that the final paper or cloth pol-
ish after any journal regrind be in the same direc-
tion as normal rotation in the engine.
Upper and lower Number 3 bearing halves are
flanged to carry the crankshaft thrust loads and are
NOT interchangeable with any other bearing halves
in the engine (Fig. 64). All bearing cap bolts removed
during service procedures are to be cleaned and oiled
before installation. Bearing shells are available in
standard and the following undersized: 0.016 mm
(.0006 inch), .032 mm (.0012 inch), .250 mm (.010
inch). Never install an undersize bearing that will
reduce clearance below specifications.
INSTALLATION
(1) Install the main bearing shells with the lubri-
cation groove in the cylinder block. Install O-ring
into recess in the block (Fig. 65).
(2) Make certain oil holes in block line up with oil
hole in bearings and bearing tabs seat in the block
tab slots.
CAUTION: Do Not get oil on the bedplate mating
surface. It will affect the sealer ability to seal the
bedplate to cylinder block.
Fig. 61 Crankshaft Seal Special Tool 6926-2
Fig. 62 Rear Crankshaft SealÐInstallation
9 - 22 ENGINENS/GS
REMOVAL AND INSTALLATION (Continued)