fuel CHRYSLER VOYAGER 1996 Service Manual

(20) Remove rear transmission mount and bracket.
(21) Remove power steering pump and bracket
assembly.
(22) Remove wiring harness and connectors from
front of engine.
(23) Remove bending braces and install tool num-
ber 6912 on engine.
(24) Remove transmission inspection cover and
mark flexplate to torque converter.
(25) Remove driveplate to torque converter bolts.
(26) Lower the vehicle.
(27) Remove ground straps to body.
(28) 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. 28).
(29) 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.
(30) Lower vehicle so the weight ofONLY THE
ENGINE AND TRANSMISSIONis on the cradle.
(31) Remove right engine mount assembly and left
transmission mount through bolt. Refer to Engine
Mounts Section of this Group.
(32) 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 6912 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 Accessory drive Section
Located in group 7 for installation procedure.
(9) Raise vehicle and install axle shafts. Refer to
Group 3, Differential and Driveline for procedure.
(10) Install transmission and engine mount and
bracket assemblies. Refer to Engine Mounts section
of this Group.
(11)(AWD equipped)Install propeller shaft to
power transfer unit. Refer to Group 3, Differential
and Driveline for procedure.
(12) Connect exhaust system to manifold. Refer to
Group 11, Exhaust System and Intake Manifold for
procedure and torque specifications.
(13) Install crossmember cradle plate (Fig. 27).
(14) Install left and right inner splash shields.
(15) Connect automatic transmission shifter link-
age. Refer to Group 21, Transmission for procedures.
(16) Lower vehicle and connect fuel line and
heater hoses. Remove plugs from rear heater hoses
and install, if equipped.
(17) Install ground straps. Connect engine and
throttle body connections and harnesses.
(18) Connect throttle body linkage. Refer to Group
14, Fuel System for procedure.
(19) Install radiator and fan module assembly.
Install radiator hoses. Fill cooling system. See Group
7 for filling procedure.
(20) Install battery tray, battery and cover.
(21) Install air cleaner and hoses.
(22) Install oil filter. Fill engine crankcase with
proper oil to correct level.
(23) Start engine and run until operating temper-
ature is reached.
(24) Adjust transmission linkage, if necessary.
Fig. 28 Positioning Engine Cradle Support Post
MountsÐTypical
NS3.3/3.8L ENGINE 9 - 105
REMOVAL AND INSTALLATION (Continued)

CRANKSHAFT DAMPER
REMOVAL
(1) Disconnect negative cable from battery.
(2) Raise vehicle on hoist.
(3) Remove right wheel and inner splash shield.
(4) Remove drive belt. Refer to Group 7, Cooling
System for procedure.
(5) Remove crankshaft pulley (Fig. 29).
INSTALLATION
(1) Install crankshaft pulley (Fig. 30).
(2) Install drive belt. Refer to Cooling System
Group 7 for installation procedure.
(3) Install inner splash shield and wheel.
(4) Connect negative cable to battery.
ROCKER ARMS AND SHAFT ASSEMBLY
REMOVAL
(1) Remove upper intake manifold assembly. Refer
to Group 11, Intake and Exhaust Manifolds.(2) Disconnect spark plug wires by pulling on the
boot straight out in line with plug.
(3) Disconnect closed ventilation system.
(4) Remove cylinder head cover and gasket.
(5) Remove four rocker shaft bolts and retainers.
(6) Remove rocker arms and shaft assembly.
(7) If rocker arm assemblies are disassembled for
cleaning or replacement. Assemble rocker arms in
their original position. Refer to (Fig. 31) for rocker
arm for positioning on the shaft.
INSTALLATION
(1) Install rocker arm and shaft assemblies with
the stamped steel retainers in the four positions,
tighten to 28 N´m (250 in. lbs.) (Fig. 31).
CAUTION: THE ROCKER ARM SHAFT SHOULD BE
TORQUED DOWN SLOWLY, STARTING WITH THE
CENTER BOLTS. ALLOW 20 MINUTES TAPPET
BLEED DOWN TIME AFTER INSTALLATION OF THE
ROCKER SHAFTS BEFORE ENGINE OPERATION.
(2) Clean cylinder head cover gasket surface.
Inspect cover for distortion and straighten if neces-
sary.
(3) Clean head rail if necessary. Install a new gas-
ket and tighten cylinder head cover fasteners to 12
N´m (105 in. lbs.).
(4) Install closed crankcase ventilation system.
(5) Install spark plug wires.
(6) Install upper intake manifold assembly. Refer
to Group 11, Exhaust Systems and Intake Manifolds.
VALVE STEM SEALS OR SPRINGS, CYLINDER
HEAD NOT REMOVED
(1) Perform fuel system pressure release procedure
before attempting any repairs.
(2) Disconnect negative cable from battery.
(3) Remove air cleaner cover and hose assembly.
Fig. 29 Crankshaft DamperÐRemoval
Fig. 30 Crankshaft DamperÐInstallation
Fig. 31 Rocker Arm Location Left Bank
9 - 106 3.3/3.8L ENGINENS
REMOVAL AND INSTALLATION (Continued)

SPARK PLUG TUBE
(1) Remove valve cover. Refer to procedure out-
lined in this section.
(2) Using locking pliers remove the tube from the
cylinder head (Fig. 11). Discard old tube.
(3) Clean area around spark plug with Mopart
parts cleaner or equivalent.
(4) Apply MopartStud and Bearing Mount or
equivalent to a new tube approximately 1 mm from
theendina3mmwide area.
(5) Install sealer end of tube into the cylinder
head. Then carefully install the tube using a hard-
wood block and mallet until the tube is seated into
the bottom of the bore.
(6) Install valve cover. Refer to procedure outlined
in this section.
SPARK PLUG TUBE SEALS
The spark plug tube seals are located in the cylin-
der head cover (Fig. 12). These seals are pressed into
the cylinder head cover to seal the outside perimeterof the spark plug tubes. If these seals show signs of
hardness and/or cracking they should be replaced.
CAMSHAFT
NOTE: TO REMOVE CAMSHAFT THE CYLINDER
HEAD MUST BE REMOVED.
REMOVAL
(1) Perform fuel system pressure release procedure
before attempting any repairs.Refer to Group 14,
Fuel System
(2) Remove the cylinder head cover. Refer to proce-
dure outlined in this section.
(3) Mark rocker arm shaft assemblies so that they
are installed in their original positions.
(4) Remove rocker arm shaft bolts. Refer to proce-
dure outlined in this section.
(5) Remove timing belt, timing belt tensioner, and
camshaft sprocket. Refer to timing belt service out-
lined in this section.
(6) Remove inner timing belt cover.
(7) Remove cylinder head. Refer to procedure out-
lined in this section.
(8) Remove camshaft sensor and camshaft target
magnet.
(9) Remove camshaft from the rear of cylinder
head.
INSPECT CYLINDER HEAD FOR THE FOLLOWING:
NOTE:
²Check oil feed holes for blockage.
²Inspect cylinder head camshaft bearings for
wear, Refer to Cylinder Head, Inspection and Clean-
ing.
²Check camshaft bearing journals for scratches
and worn areas. If light scratches are present, they
may be removed with 400 grit sand paper. If deep
Fig. 10 Ingition Coil Pack
Fig. 11 Servicing Spark Plug Tubes
Fig. 12 Spark Plug Tube Seals
NS/GSENGINE 9 - 7
REMOVAL AND INSTALLATION (Continued)

HYDRAULIC LASH ADJUSTER NOISE
A tappet-like noise may be produced from several
items. Refer to Lash Adjuster Noise - Diagnosis in
Standard Service Procedures, outlined in this Group.
Lash adjusters are replaced with the rocker
arm as an assembly.
VALVE SEALS AND SPRINGS IN VEHICLE
REMOVAL
(1) Remove rocker arm shafts assemblies as previ-
ously outlined in this section.
(2) Rotate crankshaft until piston is at TDC on
compression.
(3) With air hose attached to adapter tool installed
in spark plug hole, apply 90-120 psi air pressure.
(4) Using Special Tool MD-998772A with adapter
6779 (Fig. 19) compress valve springs and remove
valve locks.
(5) Remove valve spring.
(6) Remove valve stem seal by using a valve stem
seal tool (Fig. 20).
INSTALLATION
(1) Install valve seal/valve spring seat assembly
as outlined in the Valve Installation procedure in this
section.
(2) Using Special Tool MD-998772A compress valve
springs only enough to install locks. Correct align-
ment of tool is necessary to avoid nicking valve stems
(air pressure required), piston at TDC.
(3) Install rocker arm shaft assemblies as previ-
ously outlined in this section.
(4) Install valve cover as previously outlined in
this section.
CYLINDER HEAD
REMOVAL
(1) Perform fuel system pressure release procedure
before attempting any repairs.Refer to Group 14,
Fuel System
(2) Disconnect negative battery cable. Drain cool-
ing system. Refer to Group 7, Cooling System.
(3) Disconnect all vacuum lines, electrical wiring
and fuel lines from throttle body.
(4) Remove throttle linkage.
(5) Remove accessory drive belts. Refer to Group 7,
Cooling System for procedure.
(6) Remove power brake vacuum hose from intake
manifold.
(7) Raise vehicle and remove exhaust pipe from
manifold.
(8) Remove power steering pump assembly and set
aside.
(9) Disconnect coil pack wiring connector and
remove coil pack and bracket from engine.
(10) Remove cylinder head cover.
(11) Remove cam sensor and fuel injectors wiring
connectors.
(12) Remove intake manifold. Removal procedure
outline in Group 11.
Fig. 19 Removing and Installing Valve Spring
Fig. 20 Valve Stem Oil Seal Tool
Fig. 21 Valve Spring Assembly
9 - 10 ENGINENS/GS
REMOVAL AND INSTALLATION (Continued)

2.5L VM DIESEL
INDEX
page page
GENERAL INFORMATION
ENGINE IDENTIFICATION................ 41
GENERAL SPECIFICATION............... 40
DESCRIPTION AND OPERATION
LUBRICATION SYSTEM.................. 41
DIAGNOSIS AND TESTING
ENGINE DIAGNOSISÐMECHANICAL....... 44
ENGINE DIAGNOSISÐPERFORMANCE..... 43
HYDRAULIC TAPPETS................... 47
SERVICE PROCEDURES
CHANGING ENGINE OIL AND FILTER....... 47
CHECKING OIL LEVEL................... 47
CRANKSHAFT END PLAY................ 50
FITTING PISTON RING.................. 50
TIMING PROCEDURE................... 49
VALVE AND SEAT REFACING............. 49
REMOVAL AND INSTALLATION
CAMSHAFT........................... 62
CAMSHAFT BEARINGS.................. 63
CRANKSHAFT MAIN BEARINGS........... 63
CRANKSHAFTÐREMOVAL............... 72
CYLINDER HEAD....................... 55
CYLINDER HEAD COVER................ 54
CYLINDER LINER...................... 72
ENGINE ASSEMBLY..................... 53
ENGINE MOUNTÐFRONT................ 51
ENGINE MOUNTÐREAR................. 52
ENGINE MOUNTÐRIGHT................ 51
HYDRAULIC TAPPETS................... 60
INJECTION PUMP...................... 61
MOUNTÐLEFT SIDE.................... 51
OIL FILTER ADAPTER AND OIL COOLER.... 68
OILPAN .............................. 66OIL PUMP............................ 67
OIL PUMP PRESSURE RELIEF VALVE...... 67
PISTONS AND CONNECTING ROD......... 68
REAR CRANKSHAFT OIL SEAL............ 72
ROCKER ARMS AND PUSH RODS......... 54
TIMING GEAR COVER................... 61
TIMING GEAR COVER OIL SEAL........... 61
VACUUM PUMP........................ 68
VALVE SPRINGSÐCYLINDER HEAD NOT
REMOVED.......................... 55
VALVES AND VALVE SPRINGSÐHEAD OFF . . 60
VIBRATION DAMPER.................... 61
DISASSEMBLY AND ASSEMBLY
HYDRAULIC TAPPETS................... 73
CLEANING AND INSPECTION
CRANKSHAFT......................... 77
CRANKSHAFT MAIN BEARING............ 77
CYLINDER HEAD....................... 75
CYLINDER HEAD COVERS............... 74
CYLINDER LINER...................... 78
HYDRAULIC TAPPETS................... 76
OILPAN .............................. 78
OIL PUMP............................ 76
PISTON AND CONNECTING ROD.......... 76
ROCKER ARMS AND PUSH RODS......... 74
TIMING GEAR COVER................... 75
VALVES AND VALVE SPRINGS............ 76
SPECIFICATIONS
2.5L VM DIESEL........................ 78
TORQUE............................. 80
SPECIAL TOOLS
2.5L VM DIESEL........................ 81
GENERAL INFORMATION
GENERAL SPECIFICATION
Type ........................425CLIEE (36B)
Displacement...................2.5L (2499 cc)
Bore.............................92.00 mm
Stroke............................94.00 mm
Compression Ratio....................20.95:1
Vacuum at Idle..........600mm/Hg (23.6 In/Hg)
Thermostat Opening................80ÉC62ÉC
Generator Rating............Bosch 50/120 Amp
Cooling System Capacity..............9.5Liter
Power Steering Capacity.............0.75 LiterType ........................425CLIEE (36B)
Engine Oil Capacity.....6.5Liters With Oil Filter
Change
Timing System . Pushrod Operated Overhead valves,
With Gear-Driven Camshaft.
Air Intake........................DryFilter
Fuel Feed...........Vacuum Pump Incorporated
in Injection Pump.
Fuel System.............Indirect Fuel Injection
(Precombustion Chamber)
Combustion Cycle....................4Stroke
Cooling System..................Water Cooled
Injection Pump.......Rotary Pump Electronically
Controlled.
9 - 40 ENGINENS/GS

DIAGNOSIS AND TESTING
ENGINE DIAGNOSISÐPERFORMANCE
CONDITION POSSIBLE CAUSES CORRECTION
ENGINE WILL NOT
CRANK OR CRANKS
SLOWLY1. Starting motor operating, but not cranking the
engine.1. Remove the starter motor. Check for broken
flywheel teeth or a broken starter motor spring.
2. Crankshaft rotation restricted. 2. Rotate the engine to check for rotational
resistance.
3. Starting circuit connections loose or corroded. 3. Clean and tighten connections.
4. Neutral safety or starter relay inoperative. 4. Check starter relay supply voltage and proper
operation of neutral safety switch (if equipped).
Replace defective parts.
5. Battery charge low. 5. Check Battery voltage. Replace battery if a
charge cannot be held.
6. No voltage to starter solenoid. 6. Check voltage to solenoid. If necessary, replace
the solenoid.
7. Solenoid or starter motor inoperative. 7. Replace starter motor.
ENGINE CRANKS, BUT
WILL NOT START, NO
SMOKE1. No fuel in supply tank. 1. Fill fuel supply.
2. Electrical fuel shutdown solenoid not operating. 2. Check for loose wires and verify that the fuel
shutdown solenoid is functioning. Check for fault
codes in the ECU.
3. Fuel injection system defective: Cranking speed
sensor. Loose connection between ECU and
harness. No power supply to the ECU. Loose
connection between injection pump and harness.3. Check for fault codes at ECU. Refer to Group 14,
Fuel System for repairs procedures.
4. Air intake or exhaust plugged. 4. Remove the obstruction.
5. Fuel filter plugged. 5. Drain fuel/water separator and replace fuel filter.
6. Excessive fuel inlet restriction. 6. Check for restriction. Correct cause.
7. Injection pump not getting fuel or fuel is aerated. 7. Check fuel flow/bleed fuel system.
8. One or more injectors worn or not operating
properly.8. Check/replace bad or improperly operating
injectors.
9. Camshaft out of time. 9. Check/correct timing chain sprocket alignment.
ENGINE HARD TO
START, OR WILL NOT
START, SMOKE FROM
EXHAUST1. Incorrect starting procedure. 1. The fuel shutoff solenoid control must be in the
run position. Ensure the proper procedure is being
used.
2. Cranking speed to slow. 2. Check the battery, starter motor and look for
loose or corroded wiring connections.
3. Cylinder head heater plugs defective. 3. Verify system is working. Verify connection
between heater plug relay and ECU. Repair/replace
inoperative parts.
4. Insufficient intake air 4. Inspect or replace air filter and check for
obstruction in air supply.
5. Air in fuel system or the fuel supply is
inadequate.5. Check the fuel flow through the filter and bleed
system. Locate and eliminate the air source.
6. Contaminated fuel. 6. Verify by operating the engine with clean fuel
from a temporary tank. Check for the presence of
gasoline. Drain and flush fuel supply tank. Replace
fuel/water separator filter.
7. Fuel screen plugged. 7. Check fuel screen.
8. One or more injectors worn or not operating
properly.8. Check/replace improperly operating injectors.
9. Injector pump out of time. 9. Check pump timing. Refer to Group 14, Fuel
System for procedure.
10. Engine compression low. 10. Check compression to identify the problem.
11. Fuel injection system defective. 11. Vacuum modulator defective causing EGR to
open in cold condition. Check for fault codes in the
ECU.
NS/GSENGINE 9 - 43

ENGINE DIAGNOSISÐMECHANICAL
CONDITION POSSIBLE CAUSES CORRECTION
LUBRICATING OIL PRESSURE
LOW1. Low oil level. 1a. Check and fill with clean engine
oil.
1b. Check for severe external oil
leaks that could reduce the
pressure.
2. Oil viscosity thin, diluted, or
wrong specification.2. Verify the correct oil is being
used. Check for oil dilution.
3. Improperly operating pressure
switch/gauge3. Verify the pressure switch is
functioning correctly. If not, replace
switch/gauge.
4. Relief valve stuck open. 4. Check/replace valve.
5. Plugged oil filter. 5. Change oil filter. Oil filter change
interval may need to be revised.
6. Oil cooler was replaced, shipping
plugs left in cooler.6. Check/removed shipping plugs.
7. Worn oil pump. 7. Check/replace oil pump.
8. Suction tube loose or seal
leaking.8. Check and replace seal.
9. Worn bearing or wrong bearing
installed.9. Inspect and replace connecting
rod or main bearings. check and
replace piston cooling oil jet.
10. Oil jets under piston loose or
bad fit.10. Check oil jets position.
LUBRICATING OIL LOSS 1. External oil leaks. 1. Visually inspect for oil leaks.
Repair as required.
2. Crankcase being overfilled. 2. Verify that the correct dipstick is
being used.
3. Incorrect oil specification or
viscosity.3a. Make sure the correct oil is
being used.
3b. Look for reduced viscosity from
dilution with fuel.
3c. Review/reduce the oil change
intervals.
4. Oil cooler leak. 4. Check and replace the oil cooler.
5. High blow-by forcing oil out the
breather.5. Check the breather tube area for
signs of oil loss.
9 - 44 ENGINENS/GS
DIAGNOSIS AND TESTING (Continued)

ENGINE DIAGNOSISÐMECHANICAL CONT.
CONDITION POSSIBLE CAUSES CORRECTION
LUBRICATING OIL LOSS
(CONT.)6. Turbocharger leaking oil into the
air intake.6. Inspect air duct for evidence of oil
transfer.
7. Piston rings not sealing (oil being
consumed by the engine).7. Perform blow-by check. Repair as
required.
COMPRESSION KNOCKS 1. Air in fuel system. 1. Bleed the fuel system (refer to
Group 14, Fuel System).
2. Poor quality fuel or water/gasoline
contaminated fuel.2. Verify by operating from a
temporary tank with good fuel. Clean
and flush the fuel supply tank.
Replace fuel/water separator.
3. Engine Overloaded. 3. Verify the engine load rating is not
being exceeded.
4. Improperly operating injectors. 4. Check and replace injectors.
5. Fuel injection system defective. 5a. Instrumented injection. 5b. Timing
solenoid of the fuel pump. 5c. Pre
and post heat time of the glow plugs.
Check the fault codes in the ECU.
EXCESSIVE ENGINE NOISES 1. Drive belt squeal, insufficient
tension or abnormally high loading.1. Inspect the drive belts. Make sure
water pump pulley, generator and
power steering all turn freely.
2. Intake air and exhaust leak. 2. Refer to excessive exhaust smoke.
(Engine Diagnosis and Testing)
3. Excessive valve lash. 3. Make sure the rocker arms are not
bent. Defective hydraulic lash
adjuster.
4. Turbocharger noise. 4. Check turbocharger impeller and
turbine wheel for housing contact.
5. Power function knock. 5. Check and replace rod and main
bearings.
6. Fuel injection system defective. 6a. Instrumented injection. 6b. Timing
solenoid of the fuel pump. 6c. Pre
and post heat time of the glow plugs.
Check the fault codes in the ECU.
NS/GSENGINE 9 - 45
DIAGNOSIS AND TESTING (Continued)

HYDRAULIC TAPPETS
Before disassembling any part of the engine to cor-
rect tappet noise, check the oil pressure. If vehicle
has no oil pressure gauge, install a reliable gauge at
the pressure sending unit. The pressure should be
between 3.5 bars to 5.0 bars at 4000 RPM.
Check the oil level after the engine reaches normal
operating temperature. Allow 5 minutes to stabilize
oil level, check dipstick. The oil level in the pan
should never be above the FULL mark or below the
ADD OIL mark on dipstick. Either of these 2 condi-
tions could be responsible for noisy tappets.
OIL LEVEL HIGH
If oil level is above the FULL mark, it is possible
for the connecting rods to dip into the oil. With the
engine running, this condition could create foam in
the oil pan. Foam in oil pan would be fed to the
hydraulic tappets by the oil pump causing them to
lose length and allow valves to seat noisily.
OIL LEVEL LOW
Low oil level may allow oil pump to take in air.
When air is fed to the tappets, they lose length which
allows valves to seat noisily. Any leaks on intake side
of oil pump through which air can be drawn will cre-
ate the same tappet action. Check the lubrication
system from the intake strainer to the pump cover,
including the relief valve retainer cap. When tappet
noise is due to aeration, it may be intermittent or
constant, and usually more than 1 tappet will be
noisy. When oil level and leaks have been corrected,
operate the engine at fast idle. Run engine for a suf-
ficient time to allow all of the air inside the tappets
to be bled out.
TAPPET NOISE DIAGNOSIS
(1) To determine source of tappet noise, operate
engine at idle with cylinder head covers removed.
(2) Feel each valve spring or rocker arm to detect
noisy tappet. The noisy tappet will cause the affected
spring and/or rocker arm to vibrate or feel rough in
operation.
NOTE: Worn valve guides or cocked springs are
sometimes mistaken for noisy tappets. If such is
the case, noise may be dampened by applying side
thrust on the valve spring. If noise is not apprecia-
bly reduced, it can be assumed the noise is in the
tappet. Inspect the rocker arm push rod sockets
and push rod ends for wear.
(3) Valve tappet noise ranges from light noise to a
heavy click. A light noise is usually caused by exces-
sive leak down around the unit plunger or by the
plunger partially sticking in the tappet body cylinder.
The tappet should be replaced. A heavy click iscaused by a tappet check valve not seating or by for-
eign particles becoming wedged between the plunger
and the tappet body. This will cause the plunger to
stick in the down position. This heavy click will be
accompanied by excessive clearance between the
valve stem and rocker arm as valve closes. In either
case, tappet assembly should be removed for inspec-
tion and cleaning.
(4) The valve train generates a noise very much
like a light tappet noise during normal operation.
Care must be taken to ensure that tappets are mak-
ing the noise. In general, if more than one tappet
seems to be noisy, its probably not the tappets.
SERVICE PROCEDURES
CHECKING OIL LEVEL
To assure proper engine lubrication, the engine oil
must be maintained at the correct level. Check the
oil level at regular intervals, such as every fuel stop.
The best time to check the oil level is about 5 min-
utes after a fully warmed-up engine is shut off, or
before starting the vehicle after it has sat overnight.
Checking the oil while the vehicle is on level
ground, will improve the accuracy of the oil level
readings (Fig. 4).
CHANGING ENGINE OIL AND FILTER
Change engine oil and filter at mileage and time
intervals described in the Maintenance Schedule.
Fig. 4 Checking Engine Oil
NS/GSENGINE 9 - 47
DIAGNOSIS AND TESTING (Continued)

ENGINE OIL CHANGE
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY. CONTACT YOUR DEALER OR GOVERN-
MENT AGENCY FOR LOCATION OF COLLECTION
CENTER IN YOUR AREA.
Run engine until achieving normal operating tem-
perature.
(1) Position the vehicle on a level surface and turn
engine off.
(2) Remove oil fill cap.
(3) Hoist vehicle. Refer to Hoisting and Jacking
Recommendations.
(4) Place a suitable drain pan under crankcase
drain.
(5) Remove drain plug from crankcase and allow
oil to drain into pan (Fig. 5). Inspect drain plug
threads for stretching or other damage. Replace
drain plug if damaged.
(6) Install drain plug in crankcase.
(7) Lower vehicle and fill crankcase with specified
type and amount of engine oil.
(8) Install oil fill cap.
(9) Start engine and inspect for leaks.
(10) Stop engine and inspect oil level.
ENGINE OIL
ENGINE OIL QUALITY
Use only oils conforming to API (American Petro-
leum Institute) quality SG/CD, or CCMC G4. Use
only Diesel engine oil meeting standardMIL-2104C
or API service classificationSG/CD or CCMM PD1.
OIL VISCOSITY
Grade 15W-40 is recommended for temperatures
between +35ÉC to ±10ÉC (95ÉF to 14ÉF). Low viscosity
oils must have the proper API quality or the CCMC
G5 designation. Low viscosity oils are preferred when
minimum temperatures consistently fall below ±12ÉC
(10ÉF).
ENGINE OIL FILTER CHANGE
(1) Position a drain pan under the oil filter.
(2) Using a suitable oil filter wrench loosen filter.
(3) Rotate the oil filter counterclockwise to remove
it from the oil filter base (Fig. 6).
(4) When filter separates from base, tip gasket end
upward to minimize oil spill. Remove filter from vehi-
cle.
(5) With a cloth, wipe clean the gasket sealing sur-
face of oil and grime.
OIL FILTER INSTALLATION
(1) Lightly lubricate oil filter gasket with engine
oil.
(2) Thread filter onto the base. When gasket
makes contact with sealing surface, hand tighten fil-
ter one full turn, do not over tighten.
Fig. 5 Oil Drain Plug
Fig. 6 Oil Filter
9 - 48 ENGINENS/GS
SERVICE PROCEDURES (Continued)