engine oil CHRYSLER VOYAGER 1996 Service Manual

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)

(3) Add oil, verify crankcase oil level and start
engine. Inspect filter area for oil leaks.
TIMING PROCEDURE
CAUTION: If a timing gear is removed you must
loosen the rocker arm supports before rotating the
crankshaft or camshaft. This will prevent the valves
hitting the pistons.
For the engine components to be in proper timing
order, the timing gear marks (dots) must be aligned
as shown in (Fig. 7). To facilitate reassembly, align
the timing marks as shown in (Fig. 7), or mark the
timing gear positions before removal of any marked
gears or gear driven component(s).
VALVE AND SEAT REFACING
VALVE REFACING
(1) Use a valve refacing machine to reface the
intake and exhaust valves to the specified angle.
(2) After refacing, a margin of at least 4.52-4.49
mm (.178-.177 inch) must remain (Fig. 8). If the mar-
gin is less than 4.49 mm (.177 inch), the valve must
be replaced.
VALVE SEAT REFACING
(1) Install a pilot of the correct size in the valve
guide bore. Reface the valve seat to the specified
angle with a good dressing stone. Remove only
enough metal to provide a smooth finish.
(2) Use tapered stones to obtain the specified seat
width when required.
Fig. 7 Aligning Timing Marks
Fig. 8 Valve Specification
NS/GSENGINE 9 - 49
SERVICE PROCEDURES (Continued)

VALVE STAND DOWN
Valve stand down is to maintain the adequate com-
pression ratio.
(1) Invert cylinder head.
(2) Fit each valve to its respective valve guide.
(3) Using a straight edge and feeler gauge (Fig. 9),
check valve head stand down: Inlet valve head stand
down .80 to 1.2 mm (.031 to .047 in.) and exhaust
valve stand down .79 to 1.19 mm (.031 to .047 in).
(4) If valve head stand down is not in accordance
with above, discard original valves, check stand down
with new valves and recut valve seat inserts to
obtain correct stand down.
VALVE GUIDE HEIGHT
(1) Valve Guides height requirement.
(2) Measurement A (Fig. 10): 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.
FITTING PISTON RING
(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 (Fig. 11). Check gap with feeler gauge.
Top compression ring gap .25 to .50mm (.0098 to
.0196 in.). Second compression ring gap .25 to .35mm
(.0098 to .0137 in.). Oil control ring gap .25 to .58mm
(.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. 12).
Top compression ring gap .08 to .130mm (.0031 to
.0051 in.). Second compression ring gap .070 to
.102mm (.0027 to .0040 in.). Oil control ring gap .040
to .072mm (.0015 to .0028 in.).
CRANKSHAFT END PLAY
(1) Attach dial indicator to engine block (Fig. 13).
(2) Move crankshaft toward front of engine and
zero indicator.
(3) Move crankshaft toward the rear of engine and
record measurement.
(4) Subtract specified crankshaft end float from
figure obtained. Crankshaft end float 0.08 to
0.21mm.
(5) Select thrust washer which will give correct
end float.
Fig. 9 Checking Valve Stand Down
Fig. 10 Valve Guide Height
Fig. 11 Ring Gap Measurement
9 - 50 ENGINENS/GS
SERVICE PROCEDURES (Continued)

ENGINE ASSEMBLY
REMOVAL
(1) Disconnect the battery.
(2) Remove the air cleaner assembly and inlet
hose.
(3) Remove both hoses at intercooler and engine.
(4) Disconnect EGR vacuum hose.
(5) Disconnect brake booster vacuum hose.
(6) Disconnect oil pressure switch connector (Fig.
19).
(7) Disconnect Wiring harness bracket at transaxle
shift tower.
(8) Disconnect transaxle wiring at speed sensor,
crank sensor, and backup light switch.
(9) Remove both transmission shift cables at trans-
mission.
(10) Remove negative battery cable at cylinder
block (Fig. 19).
(11) Remove oil separator.
(12) Remove connectors at coolant temperature
sensor and A/C compressor.
(13) Disconnect fuel injection pump wiring connec-
tors (Fig. 19).
(14) Disconnect glow plug connectors.
(15) Disconnect electrical connector at number 1
fuel injector.
(16) Raise vehicle on hoist.
(17) Remove right side splash shield (Fig. 20).
WARNING: THE COOLANT IN A RECENTLY OPER-
ATED ENGINE IS HOT AND PRESSURIZED. USE
CARE TO PREVENT SCALDING BY HOT COOLANT.CAREFULLY RELEASE THE PRESSURE BEFORE
REMOVING THE RADIATOR DRAIN COCK AND CAP.
(18) Drain the cooling system (refer to Group 7,
Cooling).
(19) Lower vehicle.
(20) Remove Coolant pressure bottle and discon-
nect low coolant level sensor.
(21) Disconnect both heater hoses.
(22) Remove the lower radiator hose.
(23) Remove the upper radiator hose.
(24) Remove fuel line at injector pump and cap.
(25) Remove power steering reservoir and reposi-
tion.
(26) Remove upper radiator crossmember.
(27) Disconnect cooling fan module connector.
Fig. 18 Shift Cables at Rear MountFig. 19 Component Locations
Fig. 20 Right Side Splash Shield
NS/GSENGINE 9 - 53
REMOVAL AND INSTALLATION (Continued)

(28) Remove radiator support bolts.It is neces-
sary to loosen the receiver/dryer to gain access
to the radiator bolts.
(29) Remove radiator and fans as an assembly.
(30) Remove accessory drive belt generator/power
steering. Refer to Group 7, for procedure.
(31) Remove both power steering lines at pump,
and cap both lines.
NOTE: It is not necessary to discharge A/C system
for engine removal.
(32) Remove A/C compressor. Secure compressor
away from engine for clearance during engine
removal.
(33) Remove Generator and adjusting bracket.
NOTE: Do not remove the mounting base from the
generator. It is aligned at the factory and cannot be
realigned in the field.
(34) Hoist vehicle.
(35) Remove exhaust pipe at turbo outlet.
(36) Remove connections at starter.
(37) Remove power steering high pressure line
bracket at rear of oil pan.
(38) Remove both driveshafts from transaxle. Refer
to Group 2, Suspension and Driveshafts.
(39) Disconnect clutch cable at transaxle.
(40) Remove reinforcement plate on lower cross-
member.
(41) Remove front and rear engine mounts. Refer
to procedure outlined in this section.
(42) Drain engine oil and remove oil filter if neces-
sary.
(43) Mount both special tool, engine support brack-
ets VM-1026 to cylinder block (Fig. 21).
(44) Using engine dolly and cradle assembly with
4 adjustable posts align posts with holes in the
engine support brackets.
(45) Lower vehicle so weight ofonly the engine
and transmissionis on the dolly and cradle assem-
bly.
(46) Remove left side splash shield to gain access
to thru bolt for left side mount.
(47) Remove right engine mount and left side
mount. Refer to procedure outlined in this section.
(48) Raise vehicle slowly. It may be necessary to
move the engine/transmission assembly on the dolly
to allow for removal around body.
(49) Reverse removal procedure for installation.
CYLINDER HEAD COVER
REMOVAL
(1) Disconnect the battery cables.
(2) Remove generator bracket.(3) Remove breather hose.
(4) Remove coolant pressure tank.
(5) Remove cylinder head cover.
INSTALLATION
(1) Install cylinder head cover, torque nuts to 23.5
N´m (208 in. lbs.).
(2) Install coolant pressure tank.
(3) Install breather hose.
(4) Install generator bracket, tighten bolts to 7
N´m (4 ft. lbs.).
(5) Connect battery cable.
ROCKER ARMS AND PUSH RODS
REMOVAL
(1) Disconnect the battery cables.
(2) Remove generator bracket.
(3) Remove breather hose.
(4) Remove coolant pressure tank.
(5) Remove cylinder head cover.
(6) Remove rocker retaining nuts (Fig. 22).
(7) Remove rocker assembly. Place them on a
bench in the same order as removed.
(8) Remove the push rods and place them on a
bench in the same order as removed.
INSTALLATION
(1) Install the push rods in the same order as
removed.
(2) Install rocker arm assemblies in the same
order as removed. Tighten the rocker arm nuts to
29.4 N´m (264 in. lbs.) torque.
Fig. 21 Engine Removal
9 - 54 ENGINENS/GS
REMOVAL AND INSTALLATION (Continued)

(10) Disconnect EGR tube from EGR valve (Fig.
25).
(11) Remove exhaust pipe from turbocharger elbow
and.
(12) Disconnect oil feed line from turbo (Fig. 24).
(13) Disconnect oil drain line from turbo.
(14) Remove Intake manifold. Refer to Group 11,
Exhaust System and Intake Manifold.
(15) Remove lift eye and brake vacuum tube at
rear of exhaust manifold.(16) Remove the support strut from block to turbo-
charger exhaust elbow.
(17) Remove Exhaust manifold. Refer to Group 11,
Exhaust System and Intake Manifold.
(18) Remove oil line at pressure switch.
(19) Remove oil feed line for rocker arm assemblies
(Fig. 26).
(20) Remove Crankcase breather hose from valve
cover
(21) Remove the engine cylinder head cover.
Fig. 23 Intercooler Assembly
Fig. 24 Turbocharger
Fig. 25 EGR Valve and Tube
Fig. 26 Rocker Arm Oil Feed Lines
9 - 56 ENGINENS/GS
REMOVAL AND INSTALLATION (Continued)

(3) Zero the dial indicator on the cylinder block
mating surface.
(4) Setup the dial indicator on the piston crown
(above the center of the piston pin) 5mm (1/8 in.)
from the edge of the piston and note the measure-
ment (Fig. 31).
(5) Repeat the procedure with the rest of the cyl-
inders.
(6) Establish the thickness of the gasket for all
four cylinder heads on the basis of the greatest pis-
ton protrusion (Fig. 32).
INSTALLATION CYLINDER HEAD
(1) Remove the shop towels from the cylinder
bores. Coat the bores with clean engine oil.
(2) Install cylinder head alignment studs
(VM-1009).
(3) After determining the correct head gasket
thickness, clean the block and head mating surfaces,
place the engine cylinder head gasket over the dow-
els.
(4) Place the engine cylinder head over the dowels.
CAUTION: Engine cylinder head bolts can be
reused up to three times.(5) Tighten the engine cylinder head bolts in
sequence according to the following procedure (Fig.
33):
a. The threads and underside heads of the bolts
should be lubricated. Use the cylinder head align-
ment studs tool number VM-1009. Position the heads
on the block and secure with the ten large center
bolts and spacers (clamps), finger tight only.
b. Ensure that the various clamps are installed
correctly and the head gasket remain in their proper
position, completely covered. Then, lubricate and
install the eight small bolts, also finger tight.
(6) Loosen assembly oil feed line for rocker arm
assemblies
(7) Install the intake and exhaust manifolds with
new gaskets, partially tightening the nuts to a max-
imum of 5 N´m (44 in. lbs.). This will align the heads
(refer to Group 11, Exhaust System and Intake Man-
ifold for the proper procedures). Install lift eye and
brake vacuum tube at this time.
(8) Then, tighten the 12mm bolts with special tool
VM-1019 in the following manner:
(9)1st Phase:Tightening Head Bolts (Fig. 33).
Central bolts (A-L): Tighten all bolts, starting with
bolt A then B-C-D-E-F-G-H-I-L, to 30 N´m. Repeat
the operation with the same torque. Following the
same sequence rotate each bolt through an angle of
Fig. 30 Measuring Piston Protrusion
Fig. 31 Piston Protrusion Chart
Fig. 32 Head Gasket Identification
9 - 58 ENGINENS/GS
REMOVAL AND INSTALLATION (Continued)

70É using angle torque tool. Then rotate the bolts an
additional 70É following tightening sequence.
(10) Then, tighten the 14mm bolts with special
tool VM-1018 in the following manner:
(11) Side bolts (M1-M2): Tighten M1 bolts to 30
N´m, then rotate them 85É (65). Tighten M2 bolts to
30 N´m, then rotate them 85É (65).
(12)2nd Phase:After 20 minutes of engine oper-
ation at operating temperature, allow engine to cool
down completely. Then retorque the head bolts as fol-
lows:
(13) Central bolts A-L: Starting from bolt A,
slacken and retorque it immediately to 30 N´m + 65É.
Rotate the bolt an additional 65É. Then proceed in
the same way, bolt by bolt, following alphabetical
order, as indicated.
(14) Side bolts M1-M2:Without slackening,
torque bolts M1 then bolts M2 to 90 N´m (66 ft. lbs.).
(15) Tighten intake nuts to 30 N´m (22 ft. lbs.) and
exhaust manifolds nuts to 30 N´m (22 ft. lbs.) speci-
fied torque after completing Phase 2.
(16) If the engine cylinder head is to be replaced
and the original valves used, measure the valve stem
diameter. Only standard size valves can be used with
a service replacement engine cylinder head unless
the replacement head valve stem guide bores are
reamed to accommodate oversize valve stems.
Remove all carbon buildup and reface the valves.
(17) Tighten oil feed lines for rocker arm assem-
blies and oil pressure switch to 13 N´m (112 in. lbs.).
(18) Install push rods and rocker arm assemblies,
tighten nut to 29.4 N´m (264 in. lbs.).(19) Install fuel injectors use tool VM-1012 (refer
to Group 14, Fuel System).
(20) Install valve cover, tighten nuts to 14.7 N´m
(132 in. lbs.).
(21) Connect crankcase breather hose.
(22) Connect the injector sensor wire connector,
and the glow plug connectors.
(23) Install oil feed line, tighten banjo bolts to 12.7
N´m (108 in. lbs), and oil drain line to turbo.
(24) Install water manifold tighten bolts to 12 N´m
(106 in. lbs.).
(25) Install exhaust pipe to turbo elbow, tighten
bolts to 28 N´m (250 in. lbs.).
(26) Install the support strut from block to turbo-
charger exhaust elbow.
(27) Install EGR tube to EGR valve, tighten bolts
to 26 N´m (19 ft. lbs.).
(28) Install intercooler hoses at intake manifold.
(29) Install coolant pressure bottle and hoses.
(30) Install wiper module. Refer to Group 8K,
Windshield Wiper Unit Installation for procedure.
(31) Install intercooler hose at turbocharger tube.
(32) Install fuel injector lines from the pump to
injectors, tighten nuts to 17.6 N´m (156. lbs.).
(33) Connect the upper radiator hose.
(34) Connect negative cable to battery.
(35) Fill the cooling system. Check for leaks.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN DIRECT
LINE WITH THE FAN. DO NOT PUT HANDS NEAR
THE PULLEYS, BELTS OR FAN. DO NOT WEAR
LOOSE CLOTHING.
Fig. 33 Engine Cylinder Head Bolt Tightening Sequence
NS/GSENGINE 9 - 59
REMOVAL AND INSTALLATION (Continued)

(36) Operate the engine with the radiator cap off.
Inspect for leaks and continue operating the engine
until the thermostat opens. Add coolant, if required.
VALVES AND VALVE SPRINGSÐHEAD OFF
This procedure is done with the engine cylinder
head removed from the block.
REMOVAL
(1) Remove the engine cylinder head from the cyl-
inder block. Refer to cylinder head removal in this
section.
(2) Use Valve Spring Compressor Tool and com-
press each valve spring.
(3) Remove the valve locks, retainers, and springs.
(4) Use an Arkansas smooth stone or a jewelers
file to remove any burrs on the top of the valve stem,
especially around the groove for the locks.
(5) Remove the valves, and place them in a rack in
the same order as removed.
INSTALLATION
(1) Fit each valve to its respective valve guide.
NOTE: If valves and valve seats have been refaced
refer to Service Procedures in this section. Follow
The Valve Stand Down procedure.
(2) Install lower, washer and spring.
(3) Install upper spring collar, and compress valve
spring with spring compressor tool. Install split cone
retainers.
HYDRAULIC TAPPETS
REMOVAL
(1) Remove coolant pressure bottle.
(2) Remove cylinder head cover. Refer to cylinder
head cover removal in this section.
(3) Remove rocker assembly and push rods. Iden-
tify push rods to ensure installation in original loca-
tion (Fig. 34).
(4) Remove cylinder head, intake manifold, and
exhaust manifold. Refer to cylinder head removal in
this section.
(5) Remove yoke retainer and aligning yokes (Fig.
35).
(6) Slide Hydraulic Tappet Remover/Installer Tool
through opening in block and seat tool firmly in the
head of tappet.
(7) Pull tappet out of bore with a twisting motion.
If all tappets are to be removed, identify tappets to
ensure installation in original location.
(8) If the tappet or bore in cylinder block is scored,
scuffed, or shows signs of sticking, ream the bore to
next oversize. 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 dis-
assemble a tappet on a dirty work bench.
INSTALLATION
(1) Lubricate tappets.
(2) Install tappets and yoke retainers in their orig-
inal positions. Ensure that the oil feed hole in the
side of the tappet body faces up (away from the
crankshaft).
Fig. 34 Tappet and Rocker Arm Assembly
Fig. 35 Tappet and Yoke
9 - 60 ENGINENS/GS
REMOVAL AND INSTALLATION (Continued)

(3) Install cylinder head, intake manifold, and
exhaust manifold. Refer to cylinder head installation
in this section.
(4) Install push rods in original positions.
(5) Install rocker arms in original positions.
(6) Install cylinder head cover. Refer to cylinder
valve cover installation in this section.
(7) Start and operate engine. Warm up to normal
operating temperature.
CAUTION: To prevent damage to valve mechanism,
engine must not be run above fast idle until all
hydraulic tappets have filled with oil and have
become quiet.
VIBRATION DAMPER
REMOVAL
(1) Disconnect the battery cable.
(2) Raise vehicle on hoist.
(3) Remove right side lower splash shield.
(4) Remove generator, power steering belt. Refer to
Group 7, Cooling.
(5) Remove water pump belt. Refer to Group 7,
Cooling.
(6) Remove engine starter. Refer to Group, 8B for
procedure
(7) Install flywheel locking tool VM.1014 to pre-
vent engine rotation.
NOTE: Crankshaft damper nut is left handed
thread.
(8) Remove vibration damper nut.
(9) Remove vibration damper. No special tool is
needed for removal.
CAUTION: If thread sealant is used it is important
to remove all the old thread sealant from the
threads on the crankshaft.
INSTALLATION
NOTE: Before installing damper be sure the O-ring
inside the center of the damper is in its grove.
(1) Install vibration damper.
CAUTION: Correct torque on the vibration damper
nut is important or engine damage can occur.
(2) Install vibration damper nut and tighten to 441
N´m (325 ft. lbs.).
(3) Remove flywheel locking tool, and install
engine starter.(4) Install both accessary drive belts. Refer to
Group 7, Cooling.
(5) Install right splash shield.
(6) Lower vehicle.
(7) Connect the battery cable.
TIMING GEAR COVER OIL SEAL
REMOVAL
(1) Disconnect the battery cable.
(2) Remove vibration damper. Refer to vibration
damper removal in this section.
(3) Pry out seal (Fig. 36).
INSTALLATION
Remove the oil seal ring. The seating diameter
must be 68.000 - 68.030 mm.
(1) Install new seal using special tool VM-1015.
(2) Install vibration damper. Refer to vibration
damper installation in this section.
(3) Connect the battery cable.
INJECTION PUMP
For removal and installation of injection pump
refer to Group 14, Fuel.
TIMING GEAR COVER
REMOVAL
(1) Disconnect the battery cable.
(2) Raise vehicle on hoist.
(3) Remove right splash shield.
(4) Remove accessary drive belts. Refer to Group 7,
Cooling.
(5) Remove vibration damper nut.
NOTE: Crankshaft damper nut is left handed
thread.
(6) Remove vibration damper.
Fig. 36 Front Cover Seal
NS/GSENGINE 9 - 61
REMOVAL AND INSTALLATION (Continued)