check engine CHRYSLER VOYAGER 1996 Service Manual

(13) Remove pistons and connecting rods from
block.
(14) Remove vibration damper. Refer to procedure
in this section.
(15) Remove front cover. Refer to procedure in this
section.
(16) Remove oil pump drive gear.
(17) Install special tool VM-1004 onto crankshaft
over gear (Fig. 41).
(18) Remove main bearing oil feed and carrier
locators from block.
(19) Remove flywheel and adaptor plate from
engine block.
(20) Remove thrust bearings from rear main bear-
ing carrier (Fig. 42).
(21) Slide crankshaft and bearing carriers rear-
ward to rear of block. If you encounter difficulty in
removing the complete assembly as previously
described, slide the assembly rearward sufficiently to
gain access to the main bearing carrier bolts. Mark
the carriers for assembly and remove the bolts, two
for each carrier (Fig. 43).
(22) Separate the two halves of each carrier,
remove from the crankshaft and temporarily re-as-
semble the carriers (Fig. 44). Withdraw the crank-
shaft through the rear of the crankcase.
INSTALLATION
NOTE: Assemble engine according to sequence
described, thus saving time and preventing dam-
ages to engine components. Clean parts with a suit-
able solvent and dry them with compressed airbefore assembly. Use new gaskets where applicable
and torque wrenches for correct tightening of com-
ponents.
(1) Thoroughly clean crankcase and oil passages,
and blow dry with compressed air.
(2) Install new main bearing shells in each of the
carrier halves. Assemble the carriers to the crank-
shaft journals, ensuring that the carriers are
installed in their original locations. Secure each car-
rier with the two bolts tightening evenly to 42 N´m
(31 ft. lbs.) (Fig. 44).
(3) Slide special tool (VM-1002) over the crank-
shaft gear and, insert the crankshaft and carrier
assembly into the crankcase in the same manner
used for removal.
(4) Align the holes in the lower carriers, with the
center of the crankcase webs (Fig. 45).
(5) Secure each carrier assembly to the crankcase
with the main bearing oil feed and carrier locators
and tighten them to 54 N´m (40 ft. lbs).
(6) Install rear main bearing carrier onto crank-
shaft ensuring arrow on bearing carrier aligns with
vertical web in center of crankcase.
(7) Install rear oil seal.
(8) Install new O-rings in adaptor plate.
(9) Install adaptor plate and tighten bolts to 47
N´m (35 ft. lbs.).
(10) Install bolts to main bearing carrier and
tighten to 26.5 N´m (20 ft. lbs.).
(11) Position flywheel and O-ring on crankshaft
and align bolt holes.
NOTE: For purposes of checking crankshaft end
play used flywheel bolts may be used. Final assem-
bly requires new flywheel bolts.
(12) Install 2 flywheel bolts, 180É apart, and
tighten bolts to 20 N´m plus 60É (15 ft. lbs.) plus 60É.
(13) Attach dial indicator to engine block.
(14) Move crankshaft toward front of engine and
zero indicator.
(15) Move crankshaft toward the rear of engine
and record measurement.
(16) Subtract specified crankshaft end play from
figure obtained. Crankshaft end play 0.08 to 0.21 mm
(0.0032 to 0.0083 in.).
(17) Select thrust washers which will give correct
end play.
(18) Remove tools and flywheel.
(19) Lubricate thrust washer halves and fit them
into the rear main bearing carrier.
(20) To verify correct end play, install 2 flywheel
bolts 180É apart, and tighten bolts to 20 N´m plus 60É
(15 ft. lbs. plus 60É).
(21) Measure crankshaft end play with a dial
gauge. Crankshaft end play should not exceed 0.08-
Fig. 41 Crankshaft Special Tool VM.1004
9 - 64 ENGINENS/GS
REMOVAL AND INSTALLATION (Continued)

CAUTION: The vacuum pump must be centered in
the block and tighten with two bolts. Ensure that
the pump spins freely. If vacuum pump drags ordoes not spin freely loosen bolts and perform pro-
cedures again.
(28) Before installing oil pump check pump bore
depth in block (A) and pump body height (B) (Fig.
47). Difference between A and B should be
0.020-0.082 mm (.0007 to 0032 in.).
(29) Install oil pump and tighten retaining screws
to 27 N´m (20 ft. lbs.). Check for normal backlash
between pump and crankshaft gears.
(30) Install oil pump drive Gear.
(31) Install front cover. Refer to procedure in this
section.
(32) Install vibration damper. Refer to procedure
in this section.
(33) Install cylinder heads. Refer to procedure in
this section.
(34) Install rocker arms and push rods. Refer to
procedure in this section.
(35) Install cylinder head cover. Refer to procedure
in this section.
(36) Install accessary drive system.
(37) Install engine in vehicle. Refer to procedure in
this section.
(38) Fill engine with the correct amount of fluids
specified.
(39) Connect battery cable.OIL PAN
REMOVAL
(1) Disconnect battery cable.
(2) Raise vehicle on hoist.
Fig. 45 Main Bearing Carrier Alignment
Fig. 46 Measuring Crankshaft End Play
Fig. 47 Oil Pump Bore Depth
9 - 66 ENGINENS/GS
REMOVAL AND INSTALLATION (Continued)

(3) Drain oil.
(4) Remove oil pan bolts (Fig. 48).
(5) Remove oil pan.
INSTALLATION
(1) Install oil pan. Apply a continuous 3 mm bead
of Silicone Sealer to oil pan, install within 10 min-
utes.
(2) Install oil pan bolts and torque bolts to 11 N´m
(8 ft. lbs.).
(3) Install oil drain plug tighten to 79 N´m (58 ft.
lbs).
(4) Lower vehicle.
(5) Fill engine with proper amount of oil.
(6) Connect battery cable.
OIL PUMP
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove right splash shield.
(3) Remove both accessory drive belts. Refer to
Group 7, Cooling.
(4) Remove pump shaft support bracket assembly.
(5) Remove vibration damper. Refer to Vibration
Damper Removal in this section.
NOTE: Crankshaft damper nut is left handed
thread.
(6) Remove front cover. Refer to Timing Gear
Cover Removal in this section.
(7) Remove oil pump.
INSTALLATION
(1) Install new O-ring and lubricate with clean
engine oil.
(2) Install oil pump and tighten retaining screws
to 27.5 N´m (240 in. lbs.).(3) Install front cover. Refer to Timing Gear Cover
Installation in this section.
(4) Install pump shaft support bracket assembly.
CAUTION: Correct torque on the vibration damper
nut is important or engine damage can occur.
(5) Install vibration damper. Torque nut to 441
N´m (325 ft. lbs.)
(6) Install both accessory drive belts. Refer to
Group 7, Cooling.
(7) Install right splash shield.
OIL PUMP PRESSURE RELIEF VALVE
REMOVAL
(1) Remove oil pan.
(2) Remove clip retaining relief valve.
(3) Remove relief valve cap, spring, and plunger
(Fig. 50).
(4) Check relief valve spring length. Relief valve
spring free length is 57.5mm (2.263 in.). If spring
length is less or spring is distorted it must be
replaced.
(5) Check plunger for scoring, replace if necessary.
INSTALLATION
(1) Thoroughly clean all components and relief
valve pocket in cylinder block.
(2) Fit plunger, spring and cap into block.
(3) Compress spring and install retaining clip.
Ensure clip is completely seated in groove.
Fig. 48 Oil Pan
Fig. 49 Oil Pump Drive Gear
NS/GSENGINE 9 - 67
REMOVAL AND INSTALLATION (Continued)

PISTON RINGÐREMOVAL
(1) Identification (ID) mark on face of upper and
intermediate piston rings must point toward piston
crown.
(2) Using a suitable ring expander, remove upper
and intermediate piston rings (Fig. 58).
(3) Remove the upper oil ring side rail, lower oil
ring side rail and then oil ring expander from piston.
(4) Carefully clean carbon from piston crowns,
skirts and ring grooves ensuring the 4 oil holes in
the oil control ring groove are clear.
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 12 mm (0.50 in.) from bottom of
cylinder bore. Check gap with feeler gauge (Fig. 59).
Top compression ring gap .25 to .50 mm (.0098 to
.0196 in.). Second compression ring gap .25 to .35
mm (.0098 to .0137 in.). Oil control ring gap .25 to
.58 mm (.0098 to .0228 in.).
(2) If ring gaps exceed dimension given, new rings
or cylinder liners must be fitted. Keep piston rings in
piston sets.
(3) Check piston ring to groove clearance (Fig. 60).
Top compression ring gap .08 to .130 mm (.0031 to.0051 in.). Second compression ring gap .070 to .102
mm (.0027 to .0040 in.). Oil control ring gap .040 to
.072 mm (.0015 to .0028 in.).
PISTON RINGSÐINSTALLATION
(1) Install rings on the pistons using a suitable
ring expander (Fig. 58).
(2) Top compression ring is tapered and chromium
plated. The second ring is of the scraper type and
must be installed with scraping edge facing bottom of
the piston. The third is an oil control ring (Fig. 61).
Ring gaps must be positioned, before inserting piston
into the liners, as follows (Fig. 62).
(3) Top ring gap must be positioned at 30 degrees
to the right of the combustion chamber recess (look-
ing at the piston crown from above).
(4) Second piston ring gap should be positioned on
the opposite side of the combustion chamber recess.
(5) Oil control ring gap to be located 30 degrees to
the left of combustion chamber recess.
(6) When assembling pistons check that compo-
nents are installed in the same position as before dis-
Fig. 57 Piston Assembly
Fig. 58 Piston RingsÐRemoving and Installing
Fig. 59 Ring Gap Measurement
9 - 70 ENGINENS/GS
REMOVAL AND INSTALLATION (Continued)

(4) Face chamber recess side of piston towards
camshaft.
(5) Install connecting rod bolt protectors on rod
bolts.
(6) Rotate crankshaft so that the connecting rod
journal is on the center of the cylinder bore. Insert
rod and piston into cylinder bore and guide rod over
the crankshaft journal.
CAUTION: During piston and rod installation. DO
NOT rotate piston and connecting rod or damage to
the oil jets extending out into the cylinder bore will
occur (Fig. 56).
(7) Tap the piston down in cylinder bore, using a
hammer handle. At the same time, guide connecting
rod into position on connecting rod journal.
(8) Install rod caps. Install nuts on cleaned and
oiled rod bolts and tighten nuts to 29.5 N´m (22 ft.
lb.) plus 60É.
CYLINDER LINER
REMOVAL
(1) Remove cylinder heads (refer to cylinder head
removal in this section).
(2) Remove Oil pan (refer to oil pan removal in
this section).
(3) Remove pistons (refer to piston removal in this
section).
(4) Use tool VM-1001 to remove liners (Fig. 64).
(5) Remove shims from cylinder liner or cylinder
block recess. Keep shims with each cylinder liner.
INSTALLATION
(1) Carefully clean residualsealerfrom liner and
crankcase, and degrease the crankcase where it
comes into contact with the liners. Referring to (Fig.
65), install the liners in the crankcase as shown (A),
rotating them back and forth by 45É in order to guar-
antee correct positioning.
(2) Measure the liner recess relative to block deck
with a dial indicator mounted on a special tool
VM-1010 A.All the measurements must be taken
on camshaft side. Zero dial gauge on block deck.
(3) Move dial gauge to cylinder liner record read-
ing on dial gauge.
(4) Remove liner and special tool.
(5) Then select the correct shim thickness to give
proper protrusion (0.01 - 0.06 mm).
(6) Fit the shim and the O-rings onto the liner.
(7) Lubricate the lower liner location in the block.
Apply LOCTITE 275 to the corner of the liner seat.
Apply LOCTITE 275 uniformly to the upper part of
the liner at area.
(8) Fit the liners in the crankcase making sure
that the shim is positioned correctly in the seat. Lockthe liners in position using special tool (VM-1016)
and bolts (Fig. 66). Clean the residual LOCTITE on
the upper surface of the block deck.
(9) Recheck the liner protrusion. It should be 0.01
- 0.06 mm.
NOTE: A period of six hours must elapse between
the liners being installed and engine start-up. If
engine assembly is not continued after liner instal-
lation, the liners need to be clamped for twelve
hours minimum.
(10) Refer to Cylinder Head Removal and Installa-
tion procedure in this section. To measure piston pro-
trusion for installation of proper head gasket
thickness.
CRANKSHAFTÐREMOVAL
Refer to CRANKSHAFT MAIN BEARING
REMOVAL in this section.
REAR CRANKSHAFT OIL SEAL
REMOVAL
(1) Remove transmission. Refer to Group 21,
Transmission for removal procedure.
(2) Remove flywheel.
Fig. 64 Cylinder LinerÐRemoval
9 - 72 ENGINENS/GS
REMOVAL AND INSTALLATION (Continued)

NOTE: Inspect O-ring in flywheel (Fig. 67).
(3) Remove rear crankshaft oil seal from retainer
(Fig. 68).
CAUTION: When removing seal from retainer take
care not to damage retainer.
INSTALLATION
(1) Install crankshaft oil seal.
CAUTION: Use NEW flywheel bolt for the following
procedure.
(2) Install new O-ring on flywheel. Install fly-
wheel. The 6 flywheel bolts must be tightened as fol-
lows:
a. Torque the 6 flywheel bolts to 60 N´m (44 ft.
lbs.).b. Loosen 2 of the 6 bolts, 180É apart. Torque the 2
bolts to 20 N´m (180 in. lbs.). Then using a torque
angle gauge rotate the 2 bolts 65É additional.
c. Loosen the next 2 bolts, 180É apart and follow
the same procedure.
d. Loosen the last 2 bolts, 180É apart and follow
the same procedure.
(3) Install Transmission. Refer to procedure in
Group 21, Transmission.
DISASSEMBLY AND ASSEMBLY
HYDRAULIC TAPPETS
DISASSEMBLE AND ASSEMBLE
(1) Pry out plunger retainer spring clip.
(2) Clean varnish deposits from inside of tappet
body above plunger cap.
(3) Invert tappet body and remove plunger cap,
plunger, check valve, check valve spring, check valve
Fig. 65 Cylinder LinerÐInstallation
NS/GSENGINE 9 - 73
REMOVAL AND INSTALLATION (Continued)

retainer and plunger spring. Check valve could be
flat or ball.
Assemble tappets in reverse order.
CLEANING AND INSPECTION
CYLINDER HEAD COVERS
Remove any original sealer from the cover sealing
surface of the engine cylinder head.
Remove all residue from the sealing surface using
a clean, dry cloth.
ROCKER ARMS AND PUSH RODS
CLEANING
Clean all the components (Fig. 69) with cleaning
solvent.
Use compressed air to blow out the oil passages in
the rocker arms and push rods.
INSPECTION
Inspect the pivot surface area of each rocker arm.
Replace any that are scuffed, pitted, cracked or
excessively worn.
Inspect the valve stem tip contact surface of each
rocker arm and replace any rocker arm that is deeply
pitted.
Inspect each push rod end for excessive wear and
replace as required. If any push rod is excessively
worn because of lack of oil, replace it and inspect the
corresponding hydraulic tappet for excessive wear.
Inspect the push rods for straightness by rolling
them on a flat surface or by shining a light between
the push rod and the flat surface.
A wear pattern along the length of the push rod is
not normal. Inspect the engine cylinder head for
obstruction if this condition exists.
Fig. 66 Liner Clamp Location
Fig. 67 Flywheel
Fig. 68 Crankshaft Seal
9 - 74 ENGINENS/GS
DISASSEMBLY AND ASSEMBLY (Continued)

CYLINDER HEAD
CLEANING
Thoroughly clean the engine cylinder head and cyl-
inder block mating surfaces. Clean the intake and
exhaust manifold and engine cylinder head mating
surfaces. Remove all gasket material and carbon.
Check to ensure that no coolant or foreign material
has fallen into the tappet bore area.
Remove the carbon deposits from the combustion
chambers and top of the pistons.
INSPECTION
Use a straightedge and feeler gauge to check the
flatness of the engine cylinder head and block mating
surfaces (Fig. 70).
Minimum cylinder head thickness 89.95mm (3.541
in.)
CAUTION: If only one cylinder head is found to be
distorted and requires machining, it will also be
necessary to machine the remaining cylinders
heads and end plates by a corresponding amount
to maintain correct cylinder alignment.
VALVE GUIDE HEIGHT
(1) Valve Guides height requirement.
(2) Measurement A (Fig. 71): 13.50 - 14.00 mm.
VALVE STEM-TO-GUIDE CLEARANCE
MEASUREMENT
(1) Measure and record internal diameter of valve
guides. Valve guide internal diameter is 8.0 to 8.015
mm (.3149 to .3155 in.).
(2) Measure valve stems and record diameters.
Intake valve stem diameter 7.94 to 7.96 mm (.3125 to
.3133 in). Exhaust valve stem diameter 7.92 to 7.94
mm (.3118 to .31215 in).
(3) Subtract diameter of valve stem from internal
diameter of its respective valve guide to obtain valve
stem clearance in valve guide. Clearance of inlet
valve stem in valve guide is .040 to .075 mm (.0015
to .0029 in). Clearance of exhaust valve stem in valve
guide is .060 to .095 mm (.0023 to .0037 in).
(4) If valve stem clearance in valve guide exceeds
tolerances, new valve guides must be installed.
TIMING GEAR COVER
Be sure mating surfaces of timing gear cover and
cylinder block are clean and free from burrs.
Fig. 69 Rocker Arm Components
Fig. 70 Checking Cylinder Head Flatness
Fig. 71 Valve Guide Height
NS/GSENGINE 9 - 75
CLEANING AND INSPECTION (Continued)

VALVES AND VALVE SPRINGS
VALVE CLEANING
Clean all carbon deposits from the combustion
chambers, valve ports, valve stems, valve stem
guides and heads.
Clean all grime and gasket material from the
engine cylinder head machined gasket surfaces.
INSPECTION
Inspect for cracks in the combustion chambers and
valve ports.
Inspect for cracks on the exhaust seat.
Inspect for cracks in the gasket surface at each
coolant passage.
Inspect valves for burned, cracked or warped
heads.
Inspect for scuffed or bent valve stems.
Replace valves displaying any damage.
Check valve spring height. (Fig. 72).
HYDRAULIC TAPPETS
(1) Clean all tappet parts in a solvent that will
remove all varnish and carbon.
(2) Replace tappets that are unfit for further ser-
vice with new assemblies.
(3) If plunger shows signs of scoring or wear,
install a new tappet assembly. If valve is pitted, or
valve seat on end of plunger is prevented from seat-
ing, install a new tappet assembly.
OIL PUMP
CLEANING
Wash all parts in a suitable solvent and inspect
carefully for damage or wear (Fig. 74).
INSPECTION
(1) Before installing oil pump check pump bore
depth in block (A) and pump body height (B) (Fig.
73). Difference between A and B should be
0.020-0.082 mm.
(2) Check clearance between rotors (Fig. 75).
PISTON AND CONNECTING ROD
PISTONS
(1) Piston Diameter: Size Group A: 91.93-91.94mm
(3.6191-3.6196 in.) Size Group B: 91.94-91.95mm
Fig. 72 Valve Spring Chart
Fig. 73 Oil Pump Bore Depth
Fig. 74 Oil Pump Inner and Outer Rotors
9 - 76 ENGINENS/GS
CLEANING AND INSPECTION (Continued)

(3.6196-3.6200 in.). Maximum wear limit .05mm
(.0019 in.).
(2) Check piston pin bores in piston for roundness.
Make 3 checks at 120É intervals. Maximum out of
roundness .05mm (.0019in.).
(3) The piston diameter should be measured
approximately 15 mm (.590 in.) up from the base.
(4) Skirt wear should not exceed 0.1 mm (.00039
in.).
(5) The clearance between the cylinder liner and
piston should not exceed 0.25 mm (.0009 in.).
(6) Make sure the weight of the pistons does not
differ by more than 5 g.
CONNECTING ROD
(1) Assemble bearing shells and bearing caps to
their respective connecting rods ensuring that the
serrations on the cap and reference marks are
aligned.
(2) Tighten bearing cap bolts to 29 N´m (21 ft. lbs.)
plus 60É.
(3) Check and record internal diameter of crank
end of connecting rod.
Note: When changing connecting rods, all four
must have the same weight and be stamped with the
same number.Replacement connecting rods will
only be supplied in sets of four.
(4) Connecting rods are supplied in sets of four
since they all must be of the same weight category.
Max allowable weight difference is 18 gr.NOTE:On
one side of the big end of the con-rod there is a two-
digit number which refers to the weight category. On
the other side of the big end there is a four digitnumber on both the rod and the cap. These numbers
must both face the camshaft as well as the recess on
the piston crown (Fig. 76). Lightly heat the piston in
oven. Insert piston pin in position and secure it with
provided snap rings.The Four digit numbers
marked on con rod big end and rod cap must
be on the same side as the camshaft (Fig. 76).
After having coated threads with Molyguard, tighten
con rod bolts to 29 N´m (21 ft. lbs.) plus 60É.
PISTON PIN
(1) Measure the diameter of piston pin in the cen-
ter and both ends (Fig. 77).
(2) Piston pin diameter is 29.990 to 29.996mm
(1.1807 to 1.1809 in.).
CRANKSHAFT
CRANKSHAFT JOURNALS
(1) Using a micrometer, measure and record crank-
shaft connecting rod journals, take reading of each
journal 120É apart. Crankshaft journal diameter is
53.84 to 53.955mm (2.1196 to 2.1242 in.).
(2) Crankshaft journals worn beyond limits or
show signs of out of roundness must be reground or
replaced. Minimum reground diameter is 53.69mm
(2.1137 in.).
BEARING-TO-JOURNAL CLEARANCE
Compare internal diameters of connecting rod with
crankshaft journal diameter. Maximum clearance
between connecting rod and crankshaft journals .022
to .076mm (.0008 to .0029 in.) (Fig. 78).
CRANKSHAFT MAIN BEARING
INSPECTION
(1) Fit main bearing carriers together and torque
to 42 N´m (31 ft. lbs.)
(2) Check internal diameter of bearings.
Fig. 75 Checking Rotor Clearance
Fig. 76 Connecting Rod Identification
NS/GSENGINE 9 - 77
CLEANING AND INSPECTION (Continued)