change time CHRYSLER VOYAGER 1996 User Guide

SERVICE PROCEDURES
AUTOMATIC DOOR LOCKS DISABLE OR ENABLE
The vehicle comes with two options for power door
locks:
²Rolling automatic lock, ENABLE approximately
at 16 mph.
²No rolling automatic lock, DISABLE.
To change the automatic door lock selection, do the
following:
(1) Close all doors.
(2) Place the ignition key in the OFF position for
20 seconds or more.
(3) Turn ignition key to the run position and to the
OFF position without cranking the engine four times.
The malfunction lamp will come on each time the key
is in the run position.
(4) Press the door lock button to lock the doors.
This procedure reverses the automatic door lock
option, Enable to Disable, or Disable to Enable. If thepresent option is undesirable, repeat to arrive at the
desired option.
REMOVAL AND INSTALLATION
FRONT DOOR LOCK MOTOR/LATCH
Refer to Group 23, Body for proper service proce-
dures.
LIFTGATE LOCK MOTOR
REMOVAL
(1) Remove liftgate trim panel.
(2) Remove bolts holding liftgate lock motor to lift-
gate (Fig. 5).
(3) Disconnect the wire connector from power lock
motor.
(4) Disconnect the liftgate lock motor from outside
handle lock link.
(5) Remove the liftgate lock motor from vehicle.
INSTALLATION
For installation, reverse the above procedures.
SLIDING DOOR LOCK CONTACTS
REMOVAL
(1) Open the sliding door.
(2) Remove screw holding the lock contacts to
B-pillar (Fig. 6).
(3) Disconnect the wire connector from the lock
contacts.
(4) Remove the lock contacts from B-pillar.
INSTALLATION
For installation, reverse the above procedures.
Fig. 3 Lift Gate Release Assembly
Fig. 4 Door Lock Switch
DOOR LOCK SWITCH TEST
SWITCH
POSITIONCONTINUITY
BETWEENRESISTANCE
VALUE
LOCK 2 and 3 1.5K Ohm61%
UNLOCK 2 and 3 249 Ohm61%
Fig. 5 Liftgate Lock Motor
NSPOWER DOOR LOCKS 8P - 3
SERVICE PROCEDURES (Continued)

coming from the module, replace the Memory Seat/
Mirror Module.
²If P9 low current battery is present at (cavity 5)
referenced to ground Z1 (cavity 1) of the seat switch,
verify the presence of the P9 voltage at the switch
outputs. If there is no output voltage from the
switch, replace the switch.
²If P9 voltage is present at the output of the
switch, but there is no reaction from the memory
seat/mirror module, verify that the P9 voltage is
present at the appropriate 21-way connector pins
into the module. If the P9 voltage is not present at
the 21-way connector, repair or replace the seat wir-
ing harness. If the verification check of the seat wir-
ing harness is correct, replace the control module.
(2) If the control module does not respond with a
relay click to a specific seat switch when actuated,
verify the continuity of the particular circuit between
the seat switch and the Memory Seat/Mirror Module.
If the P9 voltage is present at the correct input of the
21-way connector of the module when the switch is
actuated, but there is no response by the module,
replace the Memory Seat/Mirror Module.
(3) If the Memory Seat/Mirror Module responds
with a relay click when a seat switch is actuated for
a given direction, but there is no reaction from a seat
or recliner motor relating to that switch input, dis-
connect the 10-way connector from the control mod-
ule. Jumper the battery and ground from cavities 8
and 7 of the seat harness 10-way connector to the
proper cavities for the seat or recliner motor in ques-
tion and direction of travel desired. If the motor oper-
ates, replace the control module. If the motor does
not operate, verify continuity of the wiring into the
motor 2-way connector. Repair or replace the wiring
as necessary. If the wiring has continuity, and the
motor will not operate when fed directly, replace the
track assembly, since the motor/transmission combi-
nations are not designed to be serviced on an individ-
ual basis.
SEAT AND RECLINER POSITION SENSING
Seat and recliner position sense ground reference
circuit P28 BR/RD feed is from the memory seat/mir-
ror module (cavity 10) 21-way connector to each of
the position sense connectors.
Seat and recliner position sense +5 volt feed circuit
P29 BR/WT feed is from the memory seat/mirror
module (cavity 20) 21-way connector to each of the
position sense connectors.
To test for the presence of a sense voltage, a volt
meter must be used as follows:
²Connect the negative probe to the P28 circuit
(cavity 10) of the 21-way connector.
²Connect the positive probe to the P29 circuit
(cavity 20) of the 21-way connector and verify a volt-age reading between 3.5 and 5 volts when a seat or
recliner switch is activated.An internal timer in
the Memory Seat/Mirror Module (MSM Module)
regulates the length of time this voltage stays
active i.e., 3 seconds from the time that the
switch was activated, unless the switch is held
or while the transmission is out of PARK.If the
voltage is less than 3.5, there is a fault in the system
that is drawing it down. To troubleshoot this circuit,
disconnect the 25-way connector from the MSM Mod-
ule (this removes all of the vehicle mirror circuitry).
If the voltage is still less than 3.5, disconnect each of
the position sense connectors from each of the
motors. If the voltage remains less than 3.5, replace
the MSM Module. If the voltage increases when a
motor is disconnected from the system, determine if
the fault is in the wiring or the motor assembly.
Repair or replace the wire harness assembly as
needed. If the fault is in the motor position sensing
potentiometer, replace the track assembly.
²The potentiometers built onto the motor end-bell
provide voltages to the MSM Module through the
21-way connector, which change as follows, corre-
sponding to the given seat actuations. Refer to Seat
Actuations Table.
SERVICE PROCEDURES
REMOTE KEYLESS ENTRY (RKE) DATA LINK
The memory seat/mirror module interfaces with
the RKE via a serial data link (single wire). The pro-
gramming sequence to relate an RKE transmitter to
the chosen seat, recliner and side view mirror posi-
tions consists of the following steps:
(1) Adjust the seat, recliner and side view mirrors
to the desired position.
(2) Press momentarily and release memory switch
S.
(3) Press momentarily and release memory switch
1or2.
(4) Press momentarily and release a LOCK button
on an RKE transmitter.
(5) To program the second driver's position, follow
the previous sequence with a second transmitter.
(6) To recall either of the programmed positions
with an RKE transmitter, press momentarily and
release an UNLOCK button on one of the pro-
grammed RKE transmitters.An unprogrammed
RKE transmitter will have no effect on the sys-
tem.
(7) The RKE receiver uses the serial data link to
notify the module of a request from a programmed
transmitter, that an UNLOCK button has been
pressed. This UNLOCK request (from a transmitter
associated with either switch 1 or 2) will activate the
NSPOWER SEATS 8R - 9
DIAGNOSIS AND TESTING (Continued)

SEAT BELT CHIME
The seat belt chime will sound for 4 to 8 seconds,
when the ignition is turned on and the driver's seat
belt is not buckled (seat belt switch is closed to
ground). This is a reminder to the driver to buckle
the seat belt. The seat belt lamp is controlled by the
mechanical instrument cluster. The cluster will also
illuminate the seat belt warning lamp for 6 seconds.
Buckling the driver's seat belt before the time out
has expired will cause the chime to stop immediately.
Chime rate: 38 to 62 chimes per minute.
To test the seat belt warning system, the ignition
switch must be in the OFF position for 1 minute
before starting the test. Turn the ignition switch to
the on position with the driver's seat belt not buck-
led. The seat belt warning lamp should light and the
chime should sound 4 to 8 seconds.
SEAT BELT LAMP
The seat belt lamp in the instrument cluster sig-
nals the vehicle passengers to fasten their seat belts.
The seat belt lamp is illuminated directly by the
instrument cluster for 6 seconds after the instrument
cluster receives the message from the Body Control
Module. The seat belt lamp is therefore illuminated
for 6 seconds whenever the ignition switch is moved
to run/start position.
(1) While ignition is off, the seat belt lamp will not
be illuminated.
(2) The ignition power feed status will be updated
every 250 milliseconds or on change.
(3) This lamp will be checked by the instrument
cluster for 6 seconds with every run/start cycle of the
ignition switch.
TURN SIGNAL ON CHIME
The turn signal on chime will warn the driver that
the turn signals have been left on. When the Body
Control Module receives a turn signal input for 1.6
km (1.0 miles), vehicle speed is greater than 24 km/h
(15 mph), the chime will sound continuously until the
turn signal is turned OFF. If vehicle speed drops
below 24 km/h (15 mph) prior to the warning being
activated, the accumulated distance traveled will be
reset. The turn signal chime is not activated whenthe emergency flashers are turned on. This feature
can also be disabled in EEPROM. Chime rate: 38 to
62 chimes per minute.
For the turn signal warning system to operate:
²Must have input from either the right or left
turn signal lamps. Creates a voltage change between
0 and battery voltage.
²The vehicle speed sensor sends a message to the
Powertrain Control Module that vehicle has exceeded
24 km/h (15 mph) for 1.6 km (1.0 miles).
²When the above two conditions are met, the
chime will sound. The chime will stop when no fur-
ther voltage change is detected.
²If hazard warning signals are pulsing, no chime
will sound.
²If speed drops below 24 km/h (15 mph) before
the warning is issued, the warning will not be issued
and the distance counter will be reset.
²If turn signal lamps are not working properly,
the chime will not sound.
²When using the scan tool, refer to the proper
Body Diagnostic Manual for the procedure.
WARNING LAMP ANNOUNCEMENT CHIME
The warning lamp announcement chime will warn
the driver to scan the instrument cluster to observe
which warning lamp is illuminated. Whenever the
volts, low fuel, low washer fluid, coolant level (gas/
diesel), low coolant level, engine temperature high
(diesel only), door ajar or gate ajar lamps are first
illuminated, the chime will sound one tone. The door/
liftgate ajar warning lamp announcement chime
sounds only if the vehicle speed is above 2 m.p.h.
Two seconds after ignition switch is turned ON or
until the seat belt warning chime ends, all warning
announcement chimes will be consolidated into one
warning announcement. This will occur 2 seconds
after the seat belt warning chime ends. If a warning
announcement should occur while another warning
chime in progress (turn signal, low oil pressure or
high speed warnings), no additional chimes will
sound after the chime in progress ends. All associ-
ated lamps will be illuminated, and the active chime
will be the warning announcement.
NS/GSCHIME WARNING/REMINDER SYSTEM 8U - 3
DIAGNOSIS AND TESTING (Continued)

OVERHEAD CONSOLE
CONTENTS
page page
DESCRIPTION AND OPERATION
COMPASS MINI-TRIP COMPUTER (CMTC).... 1
COMPASS/TEMPERATURE MINI TRIP
COMPUTER SELF-DIAGNOSTIC TEST....... 1
THERMOMETER AND COMPASS............ 2
UNIVERSAL TRANSMITTER................ 2
DIAGNOSIS AND TESTING
READING/DOME LAMP DIAGNOSIS......... 3
TRAVELER MESSAGES.................... 3
UNIVERSAL TRANSMITTER................ 3
SERVICE PROCEDURES
COMPASS CALIBRATION PROCEDURE (FAST
METHOD)............................. 4
COMPASS CALIBRATION PROCEDURE....... 4
DEMAGNETIZING PROCEDURE............. 4UNIVERSAL TRANSMITTER................ 5
REMOVAL AND INSTALLATION
AMBIENT TEMPERATURE SENSOR.......... 5
COMPASS MINI-TRIP COMPUTER (CMTC)
LAMP BULBS......................... 6
COMPASS MINI-TRIP COMPUTER (CMTC)
MODULE............................. 6
FRONT HEADER READING/COURTESY LAMP . . 6
OVERHEAD CONSOLE.................... 6
READING/COURTESY LAMP ASSEMBLY...... 7
READING/COURTESY LAMP............... 6
UNIVERSAL TRANSMITTER................ 7
SPECIAL TOOLS
SPECIAL TOOL.......................... 9
DESCRIPTION AND OPERATION
COMPASS/TEMPERATURE MINI TRIP COMPUTER
SELF-DIAGNOSTIC TEST
The CMTC is capable of performing a diagnostic
self check on many of its internal functions. CMTC
diagnostics may be performed using a scan tool
(DRB) and the proper Body Diagnostic Procedures
manual or by the following procedure.
(1) With the ignition switch in the OFF position,
press both the US/M and STEP button.
(2) Turn ignition switch to the ON position.
The CMTC will perform internal checks while
lighting all segments of the vacuum florescent dis-
play. Upon completion of the internal check, the
CMTC will display.
²PASS
²FAIL
²CCd
If any segment of the CMTC fails to light replace
the module.
If FAIL is displayed, replace the module.
If CCd is displayed, check the CCD and Body Con-
trol Module (BCM) for proper operation, refer to the
appropriate diagnostic test procedures manual If the
CCD and the BCM are OK, replace the CMTC mod-
ule.
For additional diagnostic information on the CMTC
and for identifying CMTC problems, refer to the
proper Body Diagnostic Procedures manual.
COMPASS MINI-TRIP COMPUTER (CMTC)
The Compass Mini-Trip Computer (CMTC) system
is located in the overhead console. CMTC consists of
a electronic control module with a vacuum fluores-
cent display (VFD) and function switches. The CMTC
consists of a electronic module that displays compass,
trip computer, and temperature features. Actuating
the STEP switch will cause the CMTC to change
mode of operation when ignition is ON. Example:
²Compass/Temperature
²Trip odometer (ODO)
²Average miles per gallon (ECO)
²Instant miles per gallon (ECO)
²Distance to empty (DTE)
²Elapsed time (ET)
²Off
The CMTC module in the overhead console has
three buttons used to select various functions. The
CMTC selector buttons will not operate until the
ignition is in the RUN position (Fig. 1).
When the ignition switch is first turned to the
RUN position the CMTC display;
²Blanks momentarily
²All segments of the VFD will light for one sec-
ond
²Blanks momentarily
²Returns to the last mode setting selected before
the ignition was last switched OFF.
NSOVERHEAD CONSOLE 8V - 1

API SERVICE GRADE CERTIFIED
Use an engine oil that is API Service Grade Certi-
fied. MOPARtprovides engine oils that conforms to
this service grade.
SAE VISCOSITY
An SAE viscosity grade is used to specify the vis-
cosity of engine oil. Use only, engine oils with multi-
ple viscosities such as 5W-30 or 10W-30. These are
specified with a dual SAE viscosity grade which indi-
cates the cold-to-hot temperature viscosity range.
Select an engine oil that is best suited to your par-
ticular temperature range and variation (Fig. 5).
ENERGY CONSERVING OIL
An Energy Conserving type oil is recommended for
gasoline engines. They are designated as either
ENERGY CONSERVING or ENERGY CONSERV-
ING II.
CONTAINER IDENTIFICATION
Standard engine oil identification notations have
been adopted to aid in the proper selection of engine
oil. The identifying notations are located on the label
of engine oil plastic bottles and the top of engine oil
cans (Fig. 6).
ENGINE OIL CHANGE
Change engine oil at mileage and time intervals
described in the Maintenance Schedule.
TO CHANGE ENGINE OIL
Run engine until achieving normal operating tem-
perature.
(1) Position the vehicle on a level surface and turn
engine off.
(2) Hoist and support vehicle on safety stands.
Refer to Hoisting and Jacking Recommendations.
(3) Remove oil fill cap.
(4) Place a suitable drain pan under crankcase
drain.
(5) Remove drain plug from crankcase and allow
oil to drain into pan. Inspect drain plug threads for
stretching or other damage. Replace drain plug and
gasket if damaged.
(6) Install drain plug in crankcase.
(7) Lower vehicle and fill crankcase with specified
type and amount of engine oil described in this sec-
tion.
(8) Install oil fill cap.
(9) Start engine and inspect for leaks.
(10) Stop engine and inspect oil level.
Fig. 5 Temperature/Engine Oil Viscosity
Fig. 6 Engine Oil Container Standard Notations
9 - 6 ENGINENS
GENERAL INFORMATION (Continued)

ENGINE DIAGNOSIS
INDEX
page page
DIAGNOSIS AND TESTING
CYLINDER COMBUSTION
PRESSURE LEAKAGE TEST.............. 8
CYLINDER COMPRESSION PRESSURE TEST . . 7
ENGINE DIAGNOSISÐMECHANICAL......... 12
ENGINE DIAGNOSISÐPERFORMANCE...... 10GENERAL INFORMATION.................. 7
INSPECTION
(ENGINE OIL LEAKS IN GENERAL)......... 8
INTAKE MANIFOLD LEAKAGE DIAGNOSIS..... 7
LASH ADJUSTER (TAPPET)
NOISE DIAGNOSIS...................... 8
DIAGNOSIS AND TESTING
GENERAL INFORMATION
Engine diagnosis is helpful in determining the
causes of malfunctions.
These malfunctions may be classified as either
mechanical (e.g., a strange noise), or performance
(e.g., engine idles rough and stalls).
Refer to the Service DiagnosisÐMechanical Chart
and the Service DiagnosisÐPerformance Chart, for
possible causes and corrections of malfunctions. Refer
to Group 14, Fuel System, for the fuel system diag-
nosis.
Additional tests and diagnostic procedures may be
necessary for specific engine malfunctions that can-
not be isolated with the Service Diagnosis charts.
Information concerning additional tests and diagno-
sis is provided within the following:
²Cylinder Compression Pressure Test
²Cylinder Combustion Pressure Leakage Test
²Engine Cylinder Head Gasket Failure Diagnosis
²Intake Manifold Leakage Diagnosis
INTAKE MANIFOLD LEAKAGE DIAGNOSIS
An intake manifold air leak is characterized by
lower than normal manifold vacuum. Also, one or
more cylinders may not be functioning.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
(1) Start the engine.
(2) Spray a small stream of water (Spray Bottle) at
the suspected leak area.
(3) If a change in RPM'S, the area of the suspected
leak has been found.
(4) Repair as required.
CYLINDER COMPRESSION PRESSURE TEST
The results of a cylinder compression pressure test
can be utilized to diagnose several engine malfunc-
tions.
Ensure the battery is completely charged and the
engine starter motor is in good operating condition.
Otherwise the indicated compression pressures may
not be valid for diagnosis purposes.
(1) Check engine oil level and add oil if necessary.
(2) Drive the vehicle until engine reaches normal
operating temperature. Select a route free from traf-
fic and other forms of congestion, observe all traffic
laws, and accelerate through the gears several times
briskly.
(3) Remove all spark plugs from engine. As spark
plugs are being removed, check electrodes for abnor-
mal firing indicators fouled, hot, oily, etc. Record cyl-
inder number of spark plug for future reference.
(4) Disconnect coil wire from distributor and
secure to good ground to prevent a spark from start-
ing a fire (Conventional Ignition System). For Direct
Ignition System DIS disconnect the coil connector.
(5) Be sure throttle blade is fully open during the
compression check.
(6) Insert compression gage adaptor into the #1
spark plug hole in cylinder head. Crank engine until
maximum pressure is reached on gage. Record this
pressure as #1 cylinder pressure.
(7) Repeat the previous step for all remaining cyl-
inders.
(8) Compression should not be less than (689kPa)
100 psi and not vary more than 25 percent from cyl-
inder to cylinder.
(9) If one or more cylinders have abnormally low
compression pressures, repeat the compression test.
(10) If the same cylinder or cylinders repeat an
abnormally low reading on the second compression
test, it could indicate the existence of a problem in
the cylinder in question.The recommended com-
pression pressures are to be used only as a
guide to diagnosing engine problems. An engine
should not be disassembled to determine the
NSENGINE 9 - 7

cause of low compression unless some malfunc-
tion is present.
(11) Clean or replace spark plugs as necessary
and adjust gap as specified in Group 8, Electrical.
Tighten to specifications.
(12) Test resistance of spark plug cables. Refer to
Group 8, Electrical Ignition System Secondary Cir-
cuit Inspection.
(13) Test coil output voltage, primary and second-
ary resistance. Replace parts as necessary. Refer to
Group 8, Electrical Ignition System.
(14) Check fuel pump pressure at idle and differ-
ent RPM ranges. Refer to Group 14, Fuel System for
Specifications.
(15) The air filter elements should be replaced as
specified in Group 0, Lubrication and Maintenance,.
(16) Inspect crankcase ventilation system as out
lined in Group 0, Lubrication and Maintenance. For
emission controls see Group 25, Emission Controls
for service procedures.
(17) Inspect and adjust accessory belt drives refer-
ring to Group 7, Cooling System, Accessory Drive
Belts for proper adjustments.
(18) Road test vehicle as a final test.
CYLINDER COMBUSTION PRESSURE LEAKAGE
TEST
The combustion pressure leakage test provides an
accurate means for determining engine condition.
Combustion pressure leakage testing will detect:
²Exhaust and intake valve leaks (improper seat-
ing).
²Leaks between adjacent cylinders or into water
jacket.
²Any causes for combustion/compression pressure
loss.
WARNING: DO NOT REMOVE THE RADIATOR CAP
WITH THE SYSTEM HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM COOLANT CAN
OCCUR.
Check the coolant level and fill as required. DO
NOT install the radiator cap.
Start and operate the engine until it attains nor-
mal operating temperature, then turn the engine
OFF.
Clean spark plug recesses with compressed air.
Remove the spark plugs.
Remove the oil filler cap.
Remove the air cleaner.
Calibrate the tester according to the manufactur-
er's instructions. The shop air source for testing
should maintain 483 kPa (70 psi) minimum, 1 379
kPa (200 psi) maximum and 552 kPa (80 psi) recom-
mended.Perform the test procedures on each cylinder
according to the tester manufacturer's instructions.
While testing, listen for pressurized air escaping
through the throttle body, tailpipe and oil filler cap
opening. Check for bubbles in the radiator coolant.
All gauge pressure indications should be equal,
with no more than 25% leakage.
FOR EXAMPLE:At 552 kPa (80 psi) input pres-
sure, a minimum of 414 kPa (60 psi) should be main-
tained in the cylinder.
LASH ADJUSTER (TAPPET) NOISE DIAGNOSIS
A tappet-like noise may be produced from several
items. Check the following items.
(1) Engine oil level too high or too low. This may
cause aerated oil to enter the adjusters and cause
them to be spongy.
(2) Insufficient running time after rebuilding cylin-
der head. Low speed running up to 1 hour may be
required.
(3) During this time, turn engine off and let set for
a few minutes before restarting. Repeat this several
times after engine has reached normal operating
temperature.
(4) Low oil pressure.
(5) The oil restrictor pressed into the vertical oil
passage to the cylinder head is plugged with debris.
(6) Air ingested into oil due to broken or cracked
oil pump pick up.
(7) Worn valve guides.
(8) Rocker arm ears contacting valve spring
retainer.
(9) Rocker arm loose, adjuster stuck or at maxi-
mum extension and still leaves lash in the system.
(10) Faulty lash adjuster.
a. Check lash adjusters for sponginess while
installed in cylinder head. Depress part of rocker
arm over adjuster. Normal adjusters should feel very
firm. Spongy adjusters can be bottomed out easily.
b. Remove suspected lash adjusters, and disassem-
bleDo not reuse retainer caps. Do not inter-
change parts and make sure that care and
cleanliness is exercised in the handling of parts.
c. Clean out dirt and varnish with solvent.
d. Reassemble with engine oil.
e. Check for sponginess.
f. If still spongy, replace with new adjuster.
INSPECTION (ENGINE OIL LEAKS IN GENERAL)
Begin with a through visual inspection of the
engine, particularly at the area of the suspected leak.
If an oil leak source is not readily identifiable, the
following steps should be followed:
(1) Do not clean or degrease the engine at this
time because some solvents may cause rubber to
swell, temporarily stopping the leak.
9 - 8 ENGINENS
DIAGNOSIS AND TESTING (Continued)

CYLINDER HEAD COVER
REMOVAL
(1) Remove upper intake manifold. Refer to Group
11, Exhaust System and Intake Manifold.
(2) Remove nuts attaching front and rear intake
manifold supports from cylinder head cover attaching
studs.
(3) Remove ignition coil pack and plug wires (Fig.
28). Remove ground strap.
(4) Remove the cylinder head cover fasteners.
(5) Remove cylinder head cover from cylinder
head.
INSTALLATION
NOTE: Replace spark plug well seals when install-
ing a new cylinder head cover gasket.
(1) Clean all sealing surfaces.
(2) Install new cylinder head cover gaskets and
spark plug seals (Fig. 29).CAUTION: Do not allow oil or solvents to contact
the timing belt as they can deteriorate the rubber
and cause tooth skipping.
(3) Apply MopartSilicone Rubber Adhesive Seal-
ant at the camshaft cap corners and at the top edge
of the 1/2 round seal.
(4) Install cylinder head cover assembly to head
and tighten fasteners in sequence shown in (Fig. 30).
Using the 3 step torque method:
(a) Tighten all fasteners to 4.5 N´m (40 in. lbs.)
(b) Tighten all fasteners to 9.0 N´m (80 in. lbs.)
(c) Tighten all fasteners to 12 N´m (105 in. lbs.)
(5) Install ignition coil pack and plug wires.
Tighten fasteners to 12 N´m (105 in. lbs.).
(6) Install ground strap.
(7) Install front and rear intake manifold support
brackets and attaching nuts, but do not tighten at
this time.
(8) Install upper intake manifold. Refer to Group
11, Exhaust System and Intake Manifold for proce-
dure.
(9) Final torque intake manifold support nuts to
28 N´m (250 in. lbs.).
CAMSHAFT
REMOVAL
(1) Remove cylinder head cover using procedure
outlined in this section.
(2) Remove timing belt, sprockets and covers.
Refer to Timing Belt Service outlined in this section.
(3) Bearing caps are identified for location.
Remove the outside bearing caps first (Fig. 31).
(4) Loosen the camshaft bearing cap attaching
fasteners in sequence shown (Fig. 32) one camshaft
at a time.
CAUTION: Camshafts are not interchangeable. The
intake cam number 6 thrust bearing face spacing is
wider.
Fig. 28 Ignition Coil Pack and Ground Strap
Fig. 29 Cylinder Head Cover Gasket and Spark Plug
Seals
Fig. 30 Cylinder Head Cover Tightening Sequence
9 - 28 2.4L ENGINENS
REMOVAL AND INSTALLATION (Continued)

(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)

(3) Before removing valves,remove any burrs
from valve stem lock grooves to prevent dam-
age to the valve guides.Identify valves to insure
installation in original location.
VALVE INSTALLATION
(1) Coat valve stems with clean engine oil and
insert them in cylinder head.
(2) Check valve tip to spring seat dimensions A
after grinding the valve seats or faces. Grind valve
tip to give 49.541 to 51.271 mm (1.950 to 2.018 in.)
over spring seat when installed in the head (Fig. 41).
Check valve tip for scoring, if necessary, the tip
chamfer should be reground to prevent seal damage
when the valve is installed.
(3) Install valve spring seat spacer on head (Fig.
42).
(4) Install new cup seals on all valve stems and
over valve guides (Fig. 41). Install valve springs and
valve retainers (Fig. 42).
(5) Compress valve springs with Valve Spring
Compressor Tool C-3422-B, with adapter 6412 install
locks and release tool.If valves and/or seats are
reground, measure the installed height of
springs dimension B, make sure measurementsare taken from top of spring seat to the bottom
surface of spring retainer. If height is greater
than 1-19/32 inches, (40.6 mm), install a 1/32
inch (.794 mm) spacer in head counterbore to
bring spring height back to normal 1-17/32 to
1-19/32 inch (39.1 to 40.6 mm).TAPPET REMOVAL
(1) Refer to Cylinder Head Removal in this section.
Cylinder Head must be removed to gain access to
tappets for service.
(2) Remove yoke retainer and aligning yokes.
(3) Use Tool C-4129 to remove tappets from their
bores. If all tappets are to be removed, identify tap-
pets to insure installation in original location.
NOTE: If the tappet or bore in cylinder block is
scored, scuffed, or shows signs of sticking, ream
the bore to next oversize and replace with oversize
tappet.
CAUTION: The plunger and tappet bodies are not
interchangeable. The plunger and valve must
always be fitted to the original body. It is advisable
to work on one tappet at a time to avoid mixing of
parts. Mixed parts are not compatible. Do not disas-
semble a tappet on a dirty work bench.
INSTALLATION
(1) Lubricate tappets.
(2) Install tappets in their original positions.
(3) With roller tappets, install aligning yokes (Fig.
43).
(4) Install yoke retainer and torque screws to 12
N´m (105 in. lbs.) (Fig. 43).
(5) Install cylinder heads. Refer to cylinder head
installation of this section for procedure.
Fig. 40 Compress Valve Springs with Special Tool
C-3422-B with Adapter 6412
Fig. 41 Checking Valve Installed Height
Fig. 42 Valve Seal and SpringÐInstallation
9 - 110 3.3/3.8L ENGINENS
REMOVAL AND INSTALLATION (Continued)