torque CHRYSLER VOYAGER 1996 Service Manual

(2) Before installing the ring compressor, make
sure the oil ring expander ends are butted and the
rail gaps located as shown in (Fig. 92). As viewed
from top.
(3) Immerse the piston head and rings in clean
engine oil, slide the ring compressor, over the piston
(Fig. 93).Be sure position of rings does not
change during this operation.
(4) The directional stamp on the piston should
face toward the front of the engine (Fig. 90).
(5) Rotate crankshaft so that the connecting rod
journal is on the center of the cylinder bore. Insert
rod and piston assembly into cylinder bore and guide
rod over the crankshaft journal.
(6) Tap the piston down in cylinder bore, using a
hammer handle. At the same time, guide connecting
rod into position on connecting rod journal.
NOTE: The rod bearing bolts should not be reused.
(7) Before installing theNEWbolts the threads
should be coated with clean engine oil.(8) Install each bolt finger tight than alternately
torque each bolt to assemble the cap properly.
CAUTION: Do not use a torque wrench for second
part of last step.
(9) Tighten the bolts to 27 N´m PLUS 1/4 turn (20
ft. lbs. PLUS 1/4 turn).
(10) Using a feeler gauge, check connecting rod
side clearance (Fig. 94).
DISASSEMBLY AND ASSEMBLY
OIL PUMP
DISASSEMBLY
(1) To remove the relief valve, proceed as follows:
(a) Remove the threaded plug and gasket from
the oil pump (Fig. 95).
(b) Remove spring and relief valve.
(2) Remove oil pump cover screws, and lift off
cover.
(3) Remove pump rotors.
Fig. 92 Piston Ring End Gap Position
Fig. 93 PistonÐInstallation
Fig. 94 Checking Connecting Rod Side Clearance
Fig. 95 Oil Pressure Relief Valve
9 - 50 2.4L ENGINENS
REMOVAL AND INSTALLATION (Continued)

TORQUE CHART 2.4L
DESCRIPTION TORQUE
Balance Shaft Carrier to Block
Bolts.....................54N´m(40ft.lbs.)
Balance Shaft Gear Cover
Double Ended Fastener......12N´m(105 in. lbs.)
Balance Shaft Sprockets
Bolts....................28N´m(250 in. lbs.)
Balance Shaft Chain Tensioner
Bolts....................12N´m(105 in. lbs.)
Balance Shaft Carrier Cover
Fasteners................12N´m(105 in. lbs.)
Camshaft Sensor Pick Up
Bolts.....................27N´m(20ft.lbs.)
Timing Belt Cover
Outer to Inner Attaching Bolts M6.......4.5 N´m
(40 in. lbs.)
Inner Cover to Head/Oil Pump Bolts M6 . . .12 N´m
(105 in. lbs.)
Camshaft Sprocket
Bolt.....................101 N´m (75 ft. lbs.)
Connecting Rod Cap
Bolts..............................27N´m
(20 ft. lbs.) Plus 1/4 Turn
Crankshaft Main Bearing Cap/Bedplate
M8 Bedplate Bolts.........34N´m(250 in. lbs.)
Main Cap Bolts M11..................41N´m
(30 ft. lbs.) Plus 1/4 Turn
Crankshaft Damper
Bolt....................135 N´m (100 ft. lbs.)
Cylinder Head
Bolts........Refer To Cylinder Head Installation
Cylinder Head Cover
Bolts....................12N´m(105 in. lbs.)DESCRIPTION TORQUE
Engine Mount Bracket
Bolts.....................61N´m(45ft.lbs.)
Engine MountÐFront and Rear
Through Bolt...............61N´m(45ft.lbs.)
Exhaust Manifold to Cylinder Head
Bolts....................23N´m(200 in. lbs.)
Exhaust Manifold Heat Shield
Bolts....................12N´m(105 in. lbs.)
Front Torque BracketÐ2.0/2.4L Engine
Bolts.....................33N´m(24ft.lbs.)
Front Torque Bracket StrutÐ2.0/2.4L Engine
Long Bolts................110N´m(80ft.lbs.)
Short Bolt.................61N´m(45ft.lbs.)
Intake Manifold
Bolts.....................27N´m(20ft.lbs.)
Oil Filter
Filter.....................20N´m(15ft.lbs.)
Oil Pan
Oil Pan Bolts.............12N´m(105 in. lbs.)
Drain Plug.................27N´m(20ft.lbs.)
Oil Pump Attaching
Bolts....................28N´m(250 in. lbs.)
Oil Pump Cover Fastener. . . .12 N´m (105 in. lbs.)
Oil Pump Pick-up Tube Bolt . .28 N´m (250 in. lbs.)
Oil Pump Relief Valve Cap. . . .41 N´m (30 ft. lbs.)
Rear Torque Bracket
Bolts....................110N´m(80ft.lbs.)
Spark Plugs
Plugs.....................28N´m(20ft.lbs.)
Thermostat Housing
Bolts....................23N´m(200 in lbs.)
Timing Belt Tensioner Assembly
Bolts.....................61N´m(45ft.lbs.)
Water Pump Mounting
Bolts....................12N´m(105 in. lbs.)
NS2.4L ENGINE 9 - 57
SPECIFICATIONS (Continued)

3.0L ENGINE
INDEX
page page
DESCRIPTION AND OPERATION
ENGINE COMPONENTS.................. 61
ENGINE IDENTIFICATION NUMBER......... 61
ENGINE LUBRICATION................... 61
DIAGNOSIS AND TESTING
CHECKING ENGINE OIL PRESSURE......... 62
SERVICE PROCEDURES
AUTO LASH ADJUSTER................... 62
CHECKING CRANKSHAFT END PLAY........ 65
FITTING CONNECTING ROD BEARINGS...... 63
FITTING MAIN BEARING.................. 63
VALVE SERVICE RECONDITION............ 66
REMOVAL AND INSTALLATION
CAMSHAFT SEAL....................... 72
CAMSHAFT............................ 71
CRANKSHAFT.......................... 81
CYLINDER HEAD COVER................. 70
CYLINDER HEAD........................ 73
ENGINE ASSEMBLY...................... 69
ENGINE MOUNTS....................... 68
FRONT CRANKSHAFT OIL SEAL............ 83OIL FILTER AND ADAPTOR................ 84
OILPAN ............................... 77
OIL PUMP............................. 84
PISTON AND CONNECTING ROD........... 78
REAR CRANKSHAFT SEAL................ 83
ROCKER ARMS......................... 72
TIMING BELT........................... 75
DISASSEMBLY AND ASSEMBLY
ROCKER ARMS AND SHAFTS.............. 85
CLEANING AND INSPECTION
CYLINDER BORE........................ 87
CYLINDER HEAD........................ 86
OIL PUMP............................. 87
TIMING BELT........................... 86
ADJUSTMENTS
ENGINE MOUNTS....................... 88
SPECIFICATIONS
3.0L ENGINE........................... 89
TORQUE CHART 3.0L.................... 90
SPECIAL TOOLS
3.0L ENGINE........................... 91
DESCRIPTION AND OPERATION
ENGINE IDENTIFICATION NUMBER
The engine identification number is located on the
rear of the cylinder block just below the cylinder
head (Fig. 1).
ENGINE LUBRICATION
System is a full flow filtration, pressure feed type.
The oil pump is mounted behind the timing belt
cover. The pump inner rotor is driven by the crank-
shaft. The engine oil pan contains a baffle plate to
control oil level fluctuation during engine operation.
ENGINE COMPONENTS
BLOCK:The cylinder block is a light weight
design created by reducing thickness in many parts
and a short 10 mm (3/8 in.) block skirt. High rigidity
is provided with ribs cast in the outer wall, a full
length water jacket, and a mono-block or beam type,
main bearing cap. This single unit four bearing cap
is designed to control vibration of the cylinder block
partition walls.
CRANKSHAFT:A six throw, five weight crank-
shaft is supported by four main bearings with num-
ber three being the thrust bearing. The six separate
connecting rod throws pins reduce torque fluctua-tions while a torsional vibration damper is used to
control torsion caused vibration of the crankshaft.
Rubber lipped seals are used at front and rear. The
Fig. 1 Engine Identification
NS3.0L ENGINE 9 - 61

CAUTION: Do not rotate crankshaft or the plasti-
gage will be smeared.
(4) Install the main bearing cap carefully and
tighten the bolts to specified torque.(5) Carefully remove the bearing cap and measure
the width of the plastigage at the widest part using
the scale on the plastigage package (Fig. 9). Refer to
Crankshaft Clearance Specification Chart for proper
clearances. Also see Measuring Main and Connecting
Rod Bearing Clearance in Standard Service Proce-
dures.
CRANKSHAFT BEARING INSTALLATION
When the bearings need replacing, select and
install the proper bearing by the following procedure.
(1) Measure the crankshaft journal diameter and
confirm its classification from the following. In the
case of a bearing supplied as a service part, its iden-
tification color is painted at the position show in (Fig.
10).
NOTE: Service replacement parts have identifica-
tion marks, but factory-assembled parts have no
identification marks. Service crankshaft identifica-
tion may have marks or paint at counterweights.
Refer to Crankshaft Size Classification Chart.
Fig. 6 Measure Crankshaft Journal O.D.
Fig. 7 Measure Main Bearing I.D.
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.)
Fig. 8 Measure Oil Clearance with Plastigage
Fig. 9 Measuring Clearance
9 - 64 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)

(25) Remove ground straps to body.
(26) Raise vehicle enough to allow engine dolly
Special Tool 6135 and cradle Special Tool 6710 with
post Special Tool 6848 and adaptor Special Tool 6909
to be installed under vehicle (Fig. 24).
(27) Loosen cradle engine mounts to allow move-
ment for positioning onto engine locating holes on the
engine. Lower vehicle and position cradle mounts
until the engine is resting on mounts. Tighten
mounts to cradle frame. This will keep mounts from
moving when removing or installing engine and
transmission.
(28) Lower vehicle so the weight ofONLY THE
ENGINE AND TRANSMISSIONis on the cradle.
(29) Remove right engine mount assembly and left
transmission mount through bolt. Refer to Engine
Mounts Section of this Group.
(30) Raise vehicle slowly. It may be necessary to
move the engine/transmission assembly on the cradle
to allow for removal around body flanges.
INSTALLATION
(1) Position engine and transmission assembly
under vehicle and slowly lower the vehicle over the
engine and transmission. It may be necessary to
move the engine/transmission assembly with the cra-
dle for clearance around body flanges.
(2) Align engine and transmission mounts to
attaching points. Install mounting bolts at the right
engine and left transmission mounts. Refer to proce-
dures outlined in this section.(3) Slowly raise vehicle enough to remove the
engine dolly and cradle Special Tools 6135, 6710,
6848 and 6909.
(4) Remove Special tools 6910 and install bending
braces.
(5) Lower vehicle. Install generator and wiring
harness.
(6) Connect wiring harness on the front of the
engine.
(7) Install Air Conditioning Compressor.
(8) Install power steering pump and bracket and
accessory drive belt. Refer to Group 7. Accessory
Drive Belts Section for installation procedure.
(9) Raise vehicle and install axle shafts. Refer to
Group 2, Driveshafts for procedure.
(10) Install transmission and engine mount and
bracket assemblies. Refer to Engine Mounts in this
section for procedure.
(11) Connect exhaust system to manifold. Refer to
Group 11, Exhaust System and Intake Manifold for
procedure and torque specifications.
(12) Install left and right inner splash shields.
(13) Connect automatic transmission shifter link-
age. Refer to Group 21, Transmission for procedures.
(14) Lower vehicle and connect fuel line and
heater hoses. Remove plugs from rear heater hoses
and install, if equipped.
(15) Install ground straps. Connect engine and
throttle body connections and harnesses.
(16) Connect throttle body linkage. Refer to Group
14, Fuel System for procedure.
(17) Install radiator and fan module assembly.
Install radiator hoses. Fill cooling system. Refer to
Group 7, Cooling for procedures.
(18) Install battery tray, battery and cover.
(19) Install air cleaner and hoses.
(20) Install oil filter. Fill engine crankcase with
proper oil to correct level.
(21) Start engine and run until operating temper-
ature is reached.
(22) Adjust transmission linkage, if necessary.
CYLINDER HEAD COVER
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove air inlet resonator when removing left
head cover.
(3) When Removing left cylinder head cover,
remove dipstick tube.
(4) When removing right cylinder head cover
remove wiper unit. Refer to Wiper Unit Removal in
Group 8K.
(5) When removing right cylinder head cover,
remove accessory drive belt. Refer to Accessory Drive
Belt Removal in Group 7.
Fig. 24 Positioning Engine Cradle Support Post
MountsÐTypical
9 - 70 3.0L ENGINENS
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)

CYLINDER HEAD
REMOVAL
(1) Remove timing belt and camshaft sprockets.
See Timing Belt in this section for procedures.
(2) Remove cylinder head covers and rocker arms
and shafts. Refer to procedure outlined in this sec-
tion.
(3) Remove intake manifolds. Refer to Intake and
Exhaust Manifolds, Group 11.
(4) Remove distributor.
(5) Remove exhaust manifolds and cross over Refer
to Intake and Exhaust Manifolds, Group 11.
(6) Remove cylinder head bolts in sequence shown
in (Fig. 33) and remove cylinder head.
INSTALLATION
(1) Clean surfaces of head and block, install head
gasket over locating dowels.
(2) Install head on locating dowels.
(3) Install 10 mm Allen hex head bolts with wash-
ers.CAUTION: Attach the cylinder head bolt washer in
the direction shown in (Fig. 34).
(4) Tighten bolts in the order shown in (Fig. 35).
When tightening the cylinder head bolts, tighten
gradually, working in two or three steps and finally
tighten to specified torque of 108 N´m (80 ft. lbs.).
(5) Install rocker arms and cylinder head covers.
(6) Install camshaft sprockets and timing belt.
(7) Install exhaust manifolds and cross over pipe.
(8) Install distributor.
(9) Install intake manifolds.
Fig. 33 Cylinder Head Bolt Removal Sequence
Fig. 34 Cylinder Head Bolt Washer
Fig. 35 Cylinder Head Bolt Tightening Sequence
9 - 74 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)

(5) Turn crankshaft two full turns in clockwise
direction.Turn smoothly and in clockwise direc-
tion ONLY.
(6) Align the timing marks on the sprockets and
tighten the timing belt tensioner locking bolt to 25
N´m (250 in. lbs.) torque.
(7) Reassembly belt covers, engine bracket, insula-
tor, crankshaft pulleys, accessories and accessory
drive belts in reverse order.
OIL PAN
Oil pan to crankcase sealing is provided with
MopartSilicone Rubber Adhesive Sealant or equiva-
lent gasket material. See Form-In-Place Gaskets in
Standard Service Procedures.
(1) Apply sealant as shown in (Fig. 42).
(2) Install pan and tighten screws to 6 N´m (50 in.
lbs.) in sequence shown in (Fig. 43).
Fig. 41 Positioning Belt Tensioner
Fig. 42 Oil Pan Sealing
Fig. 43 Oil Pan Screw Tightening Sequence
Fig. 40 Timing Belt Tensioner
NS3.0L ENGINE 9 - 77
REMOVAL AND INSTALLATION (Continued)