width CHRYSLER VOYAGER 1996 User Guide

a. Oil ring expander.
b. Upper oil ring side rail.
c. Lower oil ring side rail.
d. No. 2 Intermediate piston ring.
e. No. 1 Upper piston ring.
(2) Install the side rail by placing one end
between the piston ring groove and the expander.
Hold end firmly and press down the portion to be
installed until side rail is in position.Do not use a
piston ring expander(Fig. 7).
(3) Install upper side rail first and then the lower
side rail.
(4) Install No. 2 piston ring and then No. 1 piston
ring.
(5) Position piston ring end gaps as shown in (Fig.
8).
(6) Position oil ring expander gap at least 45É
from the side rail gaps butnoton the piston pin cen-
ter or on the thrust direction. Staggering ring gap is
important for oil control.FITTING CONNECTING ROD BEARINGS
Engine connecting rod bearing clearances can be
determined by use of Plastigage or equivalent. The
following is the recommended procedure for the use
of Plastigage:
(1) Rotate the crankshaft until the connecting rod
to be checked is at the bottom of its stroke.
(2) Remove oil film from surface to be checked.
Plastigage is soluble in oil.
(3) Place a piece of Plastigage across the entire
width of the bearing shell in the bearing cap approx-
imately 6.35 mm (1/4 in.) off center and away from
the oil hole (Fig. 9). In addition, suspect areas can be
checked by placing plastigage in the suspect area.
(4) Before assembling the rod cap with Plastigage
in place, the crankshaft must be rotated until the
connecting rod being checked starts moving toward
the top of the engine. Only then should the cap be
assembled and torqued to specifications.Do not
rotate the crankshaft while assembling the cap
or the Plastigage may be smeared, giving inac-
curate results.
(5) Remove the bearing cap and compare the width
of the flattened Plastigage (Fig. 9) with the metric
Fig. 6 Piston Ring Installation
Fig. 7 Installing Side Rail
Fig. 8 Piston Ring End Gap Position
Fig. 9 Measuring Plastigage Width
9 - 18 2.4L ENGINENS
SERVICE PROCEDURES (Continued)

scale provided on the package. Locate the band clos-
est to the same width. This band shows the amount
of clearance in thousandths of a millimeter. Differ-
ences in readings between the ends indicate the
amount of taper present. Record all readings taken.
Refer to Engine Specifications.Plastigage gener-
ally is accompanied by two scales. One scale is
in inches, the other is a metric scale.
(6) Plastigage is available in a variety of clearance
ranges. The 0.025-0.076 mm (.001-.003 in.) is usually
the most appropriate for checking engine bearing
proper specifications.
FITTING MAIN BEARINGS
Refer to the Engine General Information Section
for Measuring Main Bearings. For Crankshaft speci-
fications refer to Crankshaft Specification Chart.
CRANKSHAFT MAIN BEARINGS
The crankshaft is supported in five main bearings.
All upper and lower bearing shells in the crankcase
have oil grooves. The number three lower main
thrust bearing is plain. Crankshaft end play is con-
trolled by a flanged bearing on the number three
main bearing journal (Fig. 10).
Upper and lower Number 3 bearing halves are
flanged to carry the crankshaft thrust loads and are
NOT interchangeable with any other bearing halves
in the engine (Fig. 10). All bearing cap bolts removed
during service procedures are to be cleaned and oiled
before installation. Bearing shells are available in
standard and the following undersized: 0.025 mm
(0.001 in.) and 0.250 mm (0.010 in.). Never install an
undersize bearing that will reduce clearance below
specifications.
MAIN BEARING INSTALLATION
(1) Install the main bearing shells with the lubri-
cation groove in the cylinder block (Fig. 11).
(2) Make certain oil holes in block line up with oil
holes in bearings. Bearing tabs must seat in the
block tab slots.
CAUTION: Do not get oil on the bedplate mating
surface. It will may effect the sealer ability to seal
the bedplate to cylinder block.
(3) Oil the bearings and journals and install
crankshaft.
CAUTION: Use only the specified anaerobic sealer
on the bedplate or damage may occur to the
engine. Ensure that both cylinder block and bed-
plate surfaces are clean.
CRANKSHAFT SPECIFICATION CHART
Crankshaft End-Play
New Part: 0.09 - 0.24 mm (0.0035 - 0.0094 in.)
Wear Limit: 0.37 mm (0.015 in.)
Main Bearing Clearance
New Part: 0.018 - 0.058 mm (0.0007 - 0.0023 in.)
Connecting Rod Bearing Clearance
New Part: 0.025 - 0.071 mm (0.001 - 0.003 in.)
Wear Limit: 0.075 mm (0.003 in.)
Crankshaft Journal Sizes
Main Bearing Journal Diameter
Standard 60.00060.008 mm (2.362260.0003 in.)
1 st Undersize 59.97560.008 mm (2.36160.0003 in.)
Connecting Rod Journals
Standard 49.99260.008 mm (1.96860.0003 in.)
1 st Undersize 49.96760.008 mm (1.96760.0003 in.)
Fig. 10 Main Bearing Identification
Fig. 11 Installing Main Bearing Upper Shell
NS2.4L ENGINE 9 - 19
SERVICE PROCEDURES (Continued)

(2) Inspect the remaining margin after the valves
are refaced (Fig. 18). Intake valves with less than 1.2
mm (3/64 inch.) margin and Exhaust valves with less
than 0.9 mm (1/32 inch.) margin should be discarded.
(3) When refacing valve seats, it is important that
the correct size valve guide pilot be used for reseat-
ing stones. A true and complete surface must be
obtained.
(4) Measure the concentricity of valve seat and
valve guide using a valve seat runout dial indicator.
Total runout should not exceed. 0.051 mm (0.002
inch.) (total indicator reading).
(5) Inspect the valve seat with Prussian blue to
determine where the valve contacts the seat. To do
this, coat valve seatLIGHTLYwith Prussian blue
then set valve in place. Rotate the valve with light
pressure. If the blue is transferred to the center of
valve face, contact is satisfactory. If the blue is trans-
ferred to top edge of the valve face, lower valve seat
with a 15 degrees stone. If the blue is transferred to
the bottom edge of valve face raise valve seat with a
65 degrees stone.²Intake valve seat diameter is 34.37 34.63 mm
(1.158 1.363 inch.)
²Exhaust valve seat diameter is 29.37 29.63 mm
(1.156 1.166 inch.)
(6) Valve seats which are worn or burned can be
reworked, provided that correct angle and seat width
are maintained. Otherwise the cylinder head must be
replaced.
(7) When seat is properly positioned the width of
intake and exhaust seats should be 0.9 to 1.3 mm
(0.35 to 0.051 inch.) (Fig. 19).
(8) Check valve tip height dimensions A after
grinding the valve seats or faces (Fig. 20). Grind
valve tip to 47.99 mm (1.889 in.) for exhaust valve
and 48.04 mm (1.891 in.) for intake valve when
installed in the head. The valve tip chamfer may
Fig. 17 Testing Valve Springs
Intake and Exhaust Valves
VALVE SPECIFICATION CHART
Face Angle
Intake and Exhaust: 44.5É-45É
Head Diameter
Intake: 34.67 - 34.93 mm
(1.364 - 1.375 in.)
Exhaust: 30.37 - 30.63 mm
(1.195 - 1.205 in.)
Length (Overall)
Intake: 112.76 - 113.32 mm
(4.439 - 4.461 in.)
Exhaust: 109.59 - 110.09 mm
(4.314 - 4.334 in.)
Stem Diameter
Intake: 5.934 - 5.952 mm
(0.2337 - 0.2344 in.)
Exhaust: 5.906 - 5.924 mm
(0.2326 - 0.2333 in.)
Valve Margin
Intake: 1.285 - 1.615 mm
(0.050 - 0.063 in.)
Exhaust: 0.985 - 1.315 mm
(0.038 - 0.051 in.)
Fig. 18 Refacing Intake and Exhaust Valves
9 - 22 2.4L ENGINENS
SERVICE PROCEDURES (Continued)

SPECIFICATIONS
2.4L ENGINE
Type....................In-Line OHV, DOHC
Number of Cylinder.......................4
Bore.....................87.5 mm (3.445 in.)
Stroke....................101 mm (3.976 in.)
Compression Ratio......................9.4:1
Displacement.......2.4 Liters (148 Cubic Inches)
Firing Order.......................1,3,4,2
Compression Pressure...........1172-1551 kPa
(170-225 psi)
Maximum Variation Between Cylinder......25%
Lubrication. . . .Pressure Feed-Full Flow Filtration
(Direct Crankshaft Driven Pump)
Cylinder Block
Cylinder Bore Diameter. . . .87.4924 - 87.5076 mm
(3.4446 - 3.4452 in.)
Out-of-Round (Max.)........0.051 mm (0.002 in.)
Taper (Max.)..............0.051 mm (0.002 in.)
Pistons
Clearance at 14 mm (9/16 in.)
From Bottom of Skirt.........0.024 - 0.057 mm
(0.0009 - 0.0022 in.)
Weight......................332 - 346 grams
(11.85 - 12.20 oz.)
Top Land Clearance
(Diametrical)................0.614 - 0.664 mm
(0.024 - 0.026 in.)
Piston Length.............60.30 mm (2.374 in.)
Piston Ring Groove Depth
No.1........4.640 - 4.784 mm (0.182 - 0.188 in.)
No.2........4.575 - 4.719 mm (0.180 - 0.185 in.)
No.3........4.097 - 4.236 mm (0.161 - 0.166 in.)
Piston Pins
Clearance in Piston...........0.005 - 0.018 mm
In Rod (Interference)..........0.018 - 0.043 mm
(0.0007 - 0.0017 in.)
Diameter.................21.998 - 22.003 mm
(0.8660 - 0.8662 in.)
End Play.............................None
Length.....................72.75 - 73.25 mm
(2.864 - 2.883 in.)
Piston Ring Gap
Top Compression Ring...........0.25 - 0.51 mm
(0.0098 - 0.020 in.)
2nd Compression Ring...........0.23 - 0.48 mm
(0.009 - 0.018 in.)
Oil Control (Steel Rails).........0.25 - 0.64 mm
(0.0098 - 0.025 in.)
Piston Ring Side Clearance
Top and Second
Compression Rings...........0.030 - 0.080 mm
(0.0011 - 0.0031 in.)Oil Ring (Pack)..............0.012 - 0.178 mm
(0.0004 - 0.0070 in.)
Piston Ring Width
Compression Rings.............1.47 - 1.50 mm
(0.057 - 0.059 in.)
Oil Ring (Pack)................2.72 - 2.88 mm
(0.107 - 0.1133 in.)
Connecting Rod
Bearing Clearance............0.025 - 0.071 mm
(0.0009 - 0.0027 in.)
Piston Pin Bore Diameter......20.96 - 20.98 mm
(0.8252 - 0.8260 in.)
Large End Bore Diameter. . . .53.007 - 52.993 mm
(2.0868 - 2.0863)
Side Clearance..............0.013 - 0.0150 mm
(0.0051 - 0.0150 in.)
Total Weight (Less Bearing).........565.8 grams
(19.96 oz.)
Crankshaft
Connecting Rod
Journal Diameter..........49.984 - 50.000 mm
(1.967 - 1.9685 in.)
Out-of-Round (Max.)......0.0035 mm (0.0001 in.)
Taper (Max.)............0.0038 mm (0.0001 in.)
Main Bearing Diametrical
Clearance No.1-5...........0.018 - 0.058 mm
(0.0007 - 0.0023 in.)
End Play.....................0.09 - 0.24 mm
(0.0035 - 0.0094 in.)
Main Bearing Journals
Diameter.................59.992 - 60.008 mm
(2.361 - 2.3625 in.)
Out-of-Round (Max.)......0.0035 mm (0.0001 in.)
Taper (Max.)...............0.0038 (0.0001 in.)
Hydraulic Lash Adjusters
Body Diameter.............15.901 - 15.913 mm
(0.626 - 0.6264 in.)
Plunger Travel Minimum (Dry)..........3.0 mm
(0.118 in.)
Camshaft
Bearing Bore
Diameters No. 1±6..........26.020 - 26.041 mm
(1.024 - 1.025 in.)
Diametrical Bearing Clearance . .0.069 - 0.071 mm
(0.0027 - 0.003 in.)
End Play...................0.050 - 0.170 mm
(0.0019 - 0.0066 in.)
Bearing Journal
Diameter No. 1±6..........25.951 - 25.970 mm
(1.021 - 1.022 in.)
Lift (Zero Lash) Intake.......8.25 mm (0.324 in.)
Lift (Zero Lash) Exhaust.....6.52 mm (0.256 in.)
Valve Timing ± Intake Valve
Closes (ABDC)..........................51É
Opens (BTDC)...........................1É
NS2.4L ENGINE 9 - 55

Duration.............................232É
Valve Timing ± Exhaust Valve
Closes (ATDC)...........................8É
Opens (BBDC)..........................52É
Duration.............................240É
Valve Timing
Valve Overlap...........................9É
Cylinder Head
Material.....................Cast Aluminum
Gasket Thickness (Compressed)........1.15 mm
(0.045 in.)
Cylinder Head Valve Seat
Angle.................................45É
Runout (Max.).............0.050 mm (0.002 in.)
Width (Finish) Intake and Exhaust. . .0.9 - 1.3 mm
(0.035 - 0.051 in.)
Guide Bore Diameter (Std).......11.0-11.02 mm
(0.4330 - 0.4338 in.)
Finish Guide Bore ID..........5.975 - 6.000 mm
(0.235 - 0.236 in.)
Valves
Face Angle......................44-1/2É - 45É
Head Diameter Intake.........34.67 - 34.93 mm
(1.364 - 1.375 in.)
Head Diameter Exhaust.......30.37 - 30.63 mm
(1.195 - 1.205 in.)
Length±Intake (Overall)......112.76 - 113.32 mm
(4.439 - 4.461 in.)
Length±Exhaust (Overall). . . .109.59 - 110.09 mm
(4.314 - 4.334 in.)
Valve Margin±Intake..........1.285 - 1.615 mm
(0.050 - 0.063 in.)
Valve Margin±Exhaust........0.985 - 1.315 mm
(0.038 - 0.051 in.)
Valve Stem Tip Height±Intake........48.04 mm
(1.891 in.)Valves
Valve Stem Tip Height±Exhaust.......47.99 mm
(1.889 in.)
Stem Diameter±Intake........5.934 - 5.952 mm
(0.234 - 0.234 in.)
Stem Diameter±Exhaust.......5.906 - 5.924 mm
(0.233 - 0.233 in.)
Stem-to-Guide
Clearance±Intake............0.048 - 0.066 mm
(0.0018 - 0.0025 in.)
Stem-to-Guide
Clearance±Exhaust..........0.0736 - 0.094 mm
(0.0029 - 0.0037 in.)
Max. Allowable Stem-to-Guide
Clearance±Intake and Exhaust.......0.025 mm
(0.010 in.)
Valve Springs
Free Length (Approx.).......48.4 mm (1.905 in.)
Spring Tension
(Valve Closed).........338 N620 N @ 38.0 mm
(75.98 lbs.64.5 lbs. @ 1.496 in.)
Spring Tension
(Valve Open).........607 N630 N @ 29.75 mm
(136 lbs.67 @ 1.172 in.)
Number of Coils........................7.82
Wire Diameter.............3.86 mm (0.151 in.)
Installed Spring Height.....38.00 mm (1.496 in.)
Oil Pump
Clearance Over Rotors (Max.). .0.10 mm (0.004 in.)
Cover Out-of-Flat (Max.).....0.025 mm (0.001 in.)
Inner Rotor Thickness (Min.) . .9.40 mm (0.370 in.)
Outer Rotor (Oil Pump)
Clearance (Max.)...........0.39 mm (0.015 in.)
Diameter (Min.)...........79.95 mm (3.148 in.)
Thickness (Min.)............9.40 mm (0.370 in.)
Tip Clearance Between Rotors (Max.). . . .0.20 mm
(0.008 in.)
Oil Pressure
At Curb Idle Speed*.............25kPa(4psi)
At 3000 rpm.........170 - 550 kPa (25 - 80 psi)
CAUTION: * If pressure is ZERO at curb Idle, DO
NOT run engine at 3,000 rpm.
9 - 56 2.4L ENGINENS
SPECIFICATIONS (Continued)

FITTING CONNECTING ROD BEARINGS
CONNECTING ROD CLEARANCE
(1) Following procedures specified in the Standard
Service Procedures Section for Measuring Main Bear-
ing Clearance and Connecting Rod Bearing Clear-
ance (Fig. 4). Refer to Connecting Rod Specification
Chart.
(2) Tighten nuts to 52 N´m (38 ft. lbs.).
(3) Remove connecting rod cap and measure Plas-
tigage (Fig. 4).
CAUTION: Do not rotate crankshaft or the Plasti-
gage may be smeared.
CONNECTING ROD SIDE CLEARANCE
Using a feeler gauge, check connecting rod side
clearance (Fig. 5). Refer to Connecting Rod Specifica-
tion Chart.
FITTING MAIN BEARING
INSPECTION
Visually check the main and connecting rod bear-
ing journals for wear, scuffs or scoring and replace if
necessary.
CRANKSHAFT OIL CLEARANCEÐ
MECHANICAL MEASUREMENT
Measure the journal outside diameter and the
main bearing inside diameter (Fig. 6) & (Fig. 7). If
the clearance exceeds the specifications limit, replace
the main bearing(s) and if necessary replace the
crankshaft. Refer to Crankshaft Clearance Specifica-
tion Chart.
PLASTIGAGE MEASUREMENT
(1) Remove oil from journal and bearing shell.
(2) Install crankshaft.
(3) Cut plastigage to same length as width of the
bearing and place it in parallel with the journal axis
(Fig. 8).
Fig. 3 Auto Lash AdjusterÐFunction Check
Fig. 4 Connecting RodÐChecking Bearing
Clearance
Fig. 5 Checking Connecting Rod Side Clearance
CONNECTING ROD SPECIFICATION CHART
Connecting Rod Bearing Oil Clearance
New Part: 0.018 - 0.036 mm
(0.0007 - 0.0014 in.)
Connecting Rod Side Clearance
New Part: 0.10 - 0.25 mm
(0.004 - 0.010 in.)
Wear Limit: 0.4 mm (0.015 in.)
NS3.0L ENGINE 9 - 63
SERVICE PROCEDURES (Continued)

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)

SPECIFICATIONS
3.0L ENGINE
Type.........................60É V-6 SOHC
Number of Cylinders.......................6
Bore.....................91.1 mm (3.587 in.)
Stroke.....................76mm(2.992 in.)
Compression Ratio.....................8.85:1
Displacement..............3.0L (181 Cubic in.)
Firing Order....................1±2±3±4±5±6
Basic Ignition Timing.........Refer to Emission
Control Information Label on Vehicle
Compression Pressure...............1227 kPa
(178 psi) @ 250 RPM
Maximum Variation Between Cylinders......25%
Valve Timing
Intake Valve±Open.................19É BTDC
Intake Valve±Closed................59É ABDC
Exhaust Valve±Open................59É BBDC
Exhaust Valve±Closed...............19É ATDC
Cylinder Block
Cylinder Bore Diameter......91.1 mm (3.587 in.)
Top Surface Flatness........0.05 mm (0.002 in.)
Service Limit.............0.1 mm (0.0039 in.)
Grinding Limit of Top Surface*..........0.2 mm
(0.008 in.)
*Includes/Combined with cylinder Head Grinding
Pistons
Piston Diameter.................91.06 - 91.09
Piston to Cylinder Clearance......0.03 - 0.05 mm
(0.0012 - 0.002 in.)
Piston Ring End Gap No. 1......0.30 - 0.45 mm
(0.012 - 0.018 in.)
Service Limit..............0.8 mm (0.031 in.)
Piston Ring End Gap No. 2......0.45 - 0.60 mm
(0.018 - 0.024 in.)
Service Limit..............0.8 mm (0.031 in.)
Piston Ring End Gap Oil Control . .0.20 - 0.60 mm
(0.008 - 0.024 in.)
Service Limit..............1.0 mm (0.039 in.)
Ring Side Clearance No. 1......0.030 - 0.090 mm
(0.002 - 0.0035 in.)
Service Limit..............1.0 mm (0.039 in.)
Ring Side Clearance No. 2......0.040 - 0.085 mm
(0.0016 - 0.0033 in.)
Service Limit..............1.0 mm (0.039 in.)
Oversize Service Pistons.........0.25 - 0.50 mm
(0.010 - 0.020 in.),
0.75 - 1.00 mm (0.030 - 0.039 in.)
Connecting Rods
Bearing Clearance............0.018 - 0.036 mm
(0.0007 - 0.0014 in.)
Side Clearance................0.10 - 0.25 mm
(0.004 - 0.010 in.)Wear Limit.................0.4 mm (0.015 in.)
Length±Center to Center.......140.9 - 141.0 mm
(5.547 - 5.551 in.)
Parallelism±Twist..........0.05 mm (0.0019 in.)
Torsion...................0.1 mm (0.0039 in.)
Crankshaft
Main Journal Diameter.......59.980 - 60.0 mm
(2.361 - 2.362 in.)
Connecting Rod
Journal Diameter..........49.980 - 50.000 mm
(1.968 - 1.969 in.)
Out-of-Round (Max.).........0.03 mm (0.001 in.)
Taper (Max.).............0.005 mm (0.0002 in.)
Main and Rod
Bearing Clearance...........0.018 - 0.036 mm
(0.0007 - 0.0014 in.)
Undersize Service
Bearings................0.25 - 0.50 - 0.75 mm
(0.010 - 0.020 - 0.030 in.)
End Play.......0.05 - 0.25 mm (0.002 - 0.010 in.)
Service Limit..............0.3 mm (0.012 in.)
Cylinder Head
Flatness of Gasket Surface. . . .0.05 mm (0.002 in.)
Grinding Limit of
Gasket Surface.............0.2 mm (0.008 in.)
Cylinder Head Valve Seat
Angle±Intake and Exhaust..........44É - 44É.3'
Contact Width...................0.9 - 1.3 mm
(0.035 - 0.051 in.)
Sinkage±Service Limit........0.2 mm (0.078 in.)
Guide Bore Diameter (Std).......7.95 - 7.98 mm
(0.313 - 0.314 in.)
Valves
Face Angle......................45É - 45É 30'
Head Diameter Intake.........48.64 - 48.90 mm
(1.915 - 1.925 in.)
Head Diameter Exhaust.......40.01 - 40.26 mm
(1.575 - 1.585 in.)
Length Intake (Overall).....103.0 mm (4.055 in.)
Length Exhaust (Overall). . . .102.7 mm (4.043 in.)
Valve Margin±Intake.........1.2 mm (0.047 in.)
Service Limit..............0.7 mm (0.027 in.)
Valve Margin±Exhaust........2.0 mm (0.079 in.)
Service Limit..............1.5 mm (0.059 in.)
Valve Stem Tip Height......49.02 mm (1.929 in.)
Stem Diameter±Intake........7.960 - 7.975 mm
(0.313 - 0.314 in.)
Stem Diameter±Exhaust.......7.930 - 7.950 mm
(0.312 - 0.3125 in.)
Stem-to-Guide Clearance±Intake . . .0.03 - 0.06 mm
(0.001 - 0.002 in.)
Service Limit.............0.10 mm (0.004 in.)
Stem-to-Guide Clearance±
Exhaust.....................0.05 - 0.09 mm
(0.0019 - 0.003 in.)
NS3.0L ENGINE 9 - 89

PLASTIGAGE (OIL CLEARANCE)
MEASUREMENT
(1) Remove oil from journal and bearing shell.
(2) Install crankshaft.
(3) Cut plastigage to same length as width of the
bearing and place it in parallel with the journal axis
(Fig. 15).
(4) Install the main bearing cap carefully and
tighten the bolts to specified torque.
CAUTION: Do not rotate crankshaft or the plasti-
gage will be smeared.(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. 15). Refer to
Crankshaft Specification Chart for proper clearances.
If the clearance exceeds the specified limits, replace
the main bearing(s) and if necessary, have the crank-
shaft machined to next undersize.
CAUTION: Do not rotate crankshaft or the Plasti-
gage may be smeared.
CRANKSHAFT END PLAY
DIAL INDICATOR METHOD
(1) Mount a dial indicator to front of engine, locat-
ing probe on nose of crankshaft (Fig. 16).
Fig. 12 Checking Connecting Rod Side Clearance
CONNECTING ROD SPECIFICATION CHART
Connecting Rod Bearing Clearance
New Part: 0.019 - 0.073 mm
(0.0008 - 0.0029 in.)
Wear Limit: 0.074 mm
(0.003 in.)
Connecting Rod Side Clearance
New Part: 0.13 - 0.32 mm
(0.005 - 0.013 in.)
Wear Limit: 0.38 mm
(0.015 in.)
Fig. 13 Check for Stretched (Necked) Bolts
CRANKSHAFT SPECIFICATION CHART
Crankshaft End-Play
New Part: 0.09 - 0.24 mm
(0.0036 - 0.0095 in.)
Wear Limit: 0.38 mm
(0.015 in.)
Main Bearing Clearance
New Part: 0.011 - 0.059 mm
(0.0005 - 0.0024 in.)
Wear Limit: 0.076 mm
(0.003 in.)
Crankshaft Main Bearing Journal
Standard Size: 63.992 - 64.013 mm
(2.5194 - 2.5202 in.)
Crankshaft Connecting Rod Journal
Standard Size: 57.989 - 58.005 mm
(2.2831 - 2.2837 in.)
Fig. 14 Measure Crankshaft Journal O.D.
NS3.3/3.8L ENGINE 9 - 99
SERVICE PROCEDURES (Continued)

NOTE: Valve seats which are worn or burned can
be reworked, provided that correct angle and seat
width are maintained. Otherwise cylinder head must
be replaced.
(4) When seat is properly positioned the width of
intake seats should be 1.75 to 2.25 mm (0.69 to 0.088
in.) The width of the exhaust seats should be 1.50 to
2.00 mm (0.059 to 0.078 in.) (Fig. 19).
(5) Check the valve spring installed height after
refacing the valve and seat (Fig. 22).
TESTING VALVE SPRINGS
Whenever valves have been removed for inspection,
reconditioning or replacement, valve springs should
be tested (Fig. 21).As an example;the compression
length of the spring to be tested is 33.34 mm (1-5/16
inches). Turn table of Tool C-647 until surface is in
line with the 33.34 mm (1-5/16 inch) mark on the
threaded stud and the zero mark on the front. Place
spring over stud on the table and lift compressing
lever to set tone device. Pull on torque wrench until
ping is heard. Take reading on torque wrench at this
instant. Multiply this reading by two. This will give
the spring load at test length. Fractional measure-
ments are indicated on the table for finer adjust-
ments. Refer to specifications to obtain specified
height and allowable tensions. Discard the springs
that do not meet specifications.
REMOVAL AND INSTALLATION
WIPER UNIT
When performing work on the upper engine.
Refer to Section 8K, Windshield Wipers and
Washers for removal of the Wiper Unit.
ENGINE MOUNTS
RIGHT SIDE MOUNT
REMOVAL
NOTE: Right mount should only be serviced as an
assembly to prevent noise, vibration and harshness
concerns.
(1) Remove the purge duty solenoid and wiring
harness from engine mount.
(2) Remove the two right engine mount insulator
vertical fasteners and loosen the horizontal fastener,
Do Notremove the large nut on the end of the core
from frame rail (Fig. 23).
(3) Remove the load on the engine motor mounts
by carefully supporting the engine and transmission
assembly with a floor jack.
Fig. 20 Refacing Valve SeatsFig. 21 Testing Valve Springs
Fig. 22 Checking Valve Installed Height
ITEM DESCRIPTION
A Valve Stem Height
B Valve Installed Height
9 - 102 3.3/3.8L ENGINENS
SERVICE PROCEDURES (Continued)