wipers CHRYSLER VOYAGER 1996 Owner's Manual

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)

(4) Remove upper intake manifold. Refer to Group
11, Exhaust System and Intake Manifolds for proce-
dure.
(5) Remove cylinder head covers and spark plugs.
(6) Remove electrical connector from ignition coils.
(7) Using suitable socket and flex handle at crank-
shaft pulley retaining screw, turn engine so the num-
ber 1 piston is at Top Dead Center on the
compression stroke.
(8) Remove rocker arms with rocker shaft and
install a dummy shaft. The rocker arms should not
be disturbed and left on shaft.
(9) With air hose attached to spark plug adapter
installed in number 1 spark plug hole, apply 90 to
100 psi air pressure (620.5 to 689 kPa). This is to
hold valves in place while servicing components.
(10) Using Tool C-4682 or equivalent, compress
valve spring and remove retainer valve locks and
valve spring.
(11) The intake valve stem seals should be pushed
firmly and squarely over the valve guide using the
valve stem as guide.Do Not Forceseal against top
of guide. When installing the valve retainer locks,
compress the springonly enoughto install the
locks.
CAUTION: Do not pinch seal between retainer and
top of valve guide.
(12) Follow the same procedure on the remaining 5
cylinders using the firing sequence 1-2-3-4-5-6.Make
sure piston in cylinder is at TDC on the valve
spring that is being covered.
(13) Remove spark plug adapter tool.
(14) Remove dummy shaft and install rocker shaft
assembly and tighten screws to 28 N´m (250 in. lbs.).
(15) Install cylinder head covers tighten screws to
14 N´m (120 in. lbs.) and electrical connector to igni-
tion coils.
(16) Install Intake Manifold. Refer to Group 11,
Exhaust System and Intake Manifold for procedure.
(17) Connect negative cable to battery.
CYLINDER HEAD COVER
REMOVAL
NOTE: The cylinder head cover can be either an
isolated type (Fig. 32) or a non-isolated type.
FRONT CYLINDER HEAD COVER
(1) Disconnect ignition cables from spark plugs.
(2) Disconnect crankcase vent hose from cylinder
head cover.
(3) Remove front cylinder head cover bolts.
(4) Remove cylinder head cover and gasket.REAR CYLINDER HEAD COVER
(1) Disconnect negative cable from battery.
(2) Remove Wiper Unit. Refer to Group 8K, Wind-
shield Wipers and Washers for procedure.
(3) Remove intake manifold upper plenum. Refer
to Group 11, Exhaust System and Intake Manifold
for procedure.
(4) Disconnect PCV hose from cylinder head cover.
(5) Remove rear cylinder head cover bolts
(6) Remove cylinder head cover and gasket.
INSTALLATION
FRONT CYLINDER HEAD COVER
(1) Clean cylinder head and cover mating surfaces.
Inspect cylinder head cover surface for flatness.
Replace gasket as necessary.
(2) Install cylinder head cover and bolts.
(3) Tighten cylinder head cover bolts to the follow-
ing specifications:
²Non±isolatedcylinder head cover to 12 N´m
(105 in. lbs.).
²Isolatedcylinder head cover to 10 N´m (90 in.
lbs.) (Fig. 32).
(4) Connect crankcase vent hose.
(5) Connect ignition cables to spark plugs.
REAR CYLINDER HEAD COVER
(1) Clean cylinder head and cover mating surfaces.
Inspect cylinder head cover surface for flatness.
Replace gasket as necessary.
(2) Install cylinder head cover and bolts.
(3) Tighten cylinder head cover bolts to the follow-
ing specifications:
Fig. 32 Cylinder Head CoverÐIsolated Type
NS3.3/3.8L ENGINE 9 - 107
REMOVAL AND INSTALLATION (Continued)

²Non±isolatedcylinder head cover to 12 N´m
(105 in. lbs.).
²Isolatedcylinder head cover to 10 N´m (90 in.
lbs.) (Fig. 32).
(4) Connect PCV hose from cylinder head cover.
(5) Install intake manifold upper plenum. Refer to
Group 11, Exhaust System and Intake Manifold for
procedure.
(6) Install Wiper Unit. Refer to Group 8K, Wind-
shield Wipers and Washers for procedure.
(7) Connect negative cable to battery.
CYLINDER HEAD
REMOVAL
(1) Drain cooling system. Refer to Group 7, Cooling
System for procedure and disconnect negative cable
from battery.
(2) Remove upper and lower intake manifolds.
Refer to Group 11, Exhaust System and Intake Man-
ifold.
WARNING: INTAKE MANIFOLD GASKET IS MADE
OF VERY THIN METAL AND MAY CAUSE PER-
SONAL INJURY, HANDLE WITH CARE.
(3) Disconnect coil wires, sending unit wire, heater
hoses and bypass hose.
(4) Remove PCV system hoses, evaporation control
system hose and cylinder head covers.
(5) Remove exhaust manifolds.
(6) Remove rocker arm and shaft assemblies.
Remove push rods andmark positions to ensure
installation in original locations.
(7) Remove the 9 head bolts from each cylinder
head and remove cylinder heads (Fig. 33).
INSTALLATION
(1) Clean all sealing surfaces of cylinder block and
cylinder heads.
(2) Install new gaskets on cylinder block (Fig. 34).
(3)The cylinder head bolts are torqued using
the torque yield method, they should be exam-
ined BEFORE reuse. If the threads are necked
down, the bolts should be replaced(Fig. 35).
(4) Necking can be checked by holding a scale or
straight edge against the threads. If all the threads
do not contact the scale the bolt should be replaced.
(5) Tighten the cylinder head bolts1-8inthe
sequence shown in (Fig. 33). Using the 4 step torque
turn method, tighten according to the following val-
ues:
²Step 1: Bolts1±8to61N´m(45ft.lbs.)
²Step 2: Bolts1±8to88N´m(65ft.lbs.)
²Step 3: Bolts1±8(again) to 88 N´m (65 ft. lbs.)
²Step 4: Bolts1±8turn an additional 1/4 Turn.
(Do not use a torque wrench for this step.)
NOTE: Bolt torque after 1/4 turn should be over 122
N´m (90 ft. lbs.). If not, replace the bolt.
(6) Tighten head bolt number 9 (Fig. 33) to 33 N´m
(25 ft. lbs.) after head bolts1±8have been tighten
to specifications.
Fig. 33 Cylinder Head Bolts Location and
Tightening Sequence
Fig. 34 Head Gasket Installation
Fig. 35 Checking Bolts for Stretching (Necking)
9 - 108 3.3/3.8L ENGINENS
REMOVAL AND INSTALLATION (Continued)

(16) Clean access urethane from exterior with
MopartSuper Kleen or equivalent.
(17) Apply 150 mm (6 in.) lengths of 50 mm (2 in.)
masking tape spaced 250 mm (10 in.) apart to hold
molding in place until urethane cures.
(18) Engage wire connectors to windshield
defroster grid.
(19) Install A-pillar trim panels.
(20) Install cowl cover and wipers.
(21) Install inside rear view mirror.
(22) After urethane has cured, remove tape strips
and water test windshield to verify repair.
BODY SIDE/SLIDING DOOR STATIONARY GLASS
The temperature of the vehicle should be at least
21É C (70É F) before removing the stationary quarter/
sliding door glass. Butyl sealer becomes more pliable
at high temperatures.
REMOVAL
(1) Remove interior trim as necessary to gain
access attaching locations on back of glass.
(2) Remove nuts holding stationary glass to fence.
(3) Using razor knife, cut butyl sealer holding
glass to fence from between the mounting studs (Fig.
6).
(4) Push glass from opening.
INSTALLATION
The stationary glass fence should be cleaned of all
old butyl sealer.
(1) Applya6mm(0.25 in.) butyl tape around
perimeter of glass assembly encapsulation track.
Ensure that the butyl tape is wrapped around the
mounting studs.
(2) Place the glass into the opening and insert
mounting studs through holes in fence.
(3) Install nuts to hold stationary glass to fence.
Fig. 3 Center Windshield and Mark at Support
Spacers
Fig. 4 Work Surface Set up and Molding Installation
Fig. 5 Lower Windshield Into Position
Fig. 6 Sliding Door Stationary Glass
23 - 6 BODYNS
REMOVAL AND INSTALLATION (Continued)

may be necessary to use a soldering gun to melt
the newly applied material. Do not over heat the
affected area, damage to the exterior of the trim
panel may occur.
(4) Allow the repaired area to cool and verify the
repair.
(5) Install trim panel.
REMOVAL AND INSTALLATION
A-PILLAR LOWER EXTENSION TRIM
REMOVAL
(1) Remove instrument panel side cover.
(2) Remove screw holding A-pillar extension to
door hinge pillar.
(3) Remove A-pillar extension trim from vehicle
(Fig. 1).
INSTALLATION
(1) Place A-pillar extension trim in position on
vehicle.
(2) Install screw to hold A-pillar extension to door
hinge pillar.
(3) Install instrument panel side cover.
A-PILLAR TRIM PANEL
REMOVAL
(1) Disengage hidden clips holding A-pillar trim
panel to A-pillar (Fig. 2).
(2) Remove A-pillar trim from vehicle.
INSTALLATION
(1) Position foot on A-pillar trim panel into instru-
ment panel top cover channel.
(2) Position A-pillar trim in vehicle.
(3) Align locator pins.
(4) Engage hidden clips.
COWL COVER
WARNING: No fingers or tools should be put under
the cowl cover while the wiper motor is operating.
REMOVAL
(1) Remove wiper arms. Refer to Group 8K, Wind-
shield Wipers and Washers for proper procedures.
(2) Remove screws holding lower area of cowl cover
to wiper module (Fig. 3).
(3) Disengage quarter turn fasteners holding outer
ends of cowl cover to wiper module.
(4) Release hood latch and open hood.
(5) Remove wing nuts holding front of cowl cover
to wiper module.
(6) Close hood. Do not latch. Remove outboard
screws. (Fig. 4).
(7) Lift cowl cover upward enough to gain access to
right washer hose.
(8) D
isconnect washer hose from right washer nozzle.
(9) Close hood. Do not latch.
(10) Remove cowl cover from vehicle.
INSTALLATION
For installation, reverse the above procedures.
COWL TRIM
REMOVAL
(1) Remove door sill plate.
(2) Disengage hidden clips holding cowl trim to
cowl panel (Fig. 5).
(3) Remove cowl trim from vehicle.
Fig. 1 A-pillar Lower Extension Trim
Fig. 2 A-pillar Trim
NSBODY 23 - 25
SERVICE PROCEDURES (Continued)

to support the hood, install bottom bolts to hold hood
to hinge finger tight.
(2) Install top bolts to hold hood to hinge finger
tight.
(3) Position bolts at marks and tighten bolts. The
hood should be aligned to 4 mm (0.160 in.) gap to the
front fenders and flush across the top surfaces along
fenders.
(4) Verify hood operation and alignment.
HOOD HINGE
REMOVAL
(1) Remove hood.
(2) Remove wiper unit. Refer to Group 8K, Wind-
shield Wipers and Washers, for procedure.
(3) Mark all bolt and hinge attachment locations
with a grease pencil or other suitable device to pro-
vide reference marks for installation.
(4) Remove bolts attaching body half of hood hinge
to front fender flange and remove hinge from vehicle
(Fig. 45).
INSTALLATION
(1) If necessary, paint new hinge before installa-
tion.
(2) Place body half of hood hinge in position on
vehicle.
(3) Install bolts to hold hood hinge to front fender
flange.
(4) Install wiper unit. Refer to Group 8K, Wind-
shield Wipers and Washers, for proper procedures.
(5) Install hood.
(6) Align all marks and secure bolts. The hood
should be aligned to 4 mm (0.160 in.) gap to the front
fenders and flush across the top surfaces along fend-
ers. Shims can be added or removed under hood
hinge to achieve proper hood height.
HOOD LATCH
REMOVAL
(1) Release hood latch and open hood.
(2) Remove bolts holding hood latch to radiator clo-
sure panel crossmember (Fig. 46).
(3) Remove hood latch from crossmember.
(4) Disconnect hood release cable from hood latch
(Fig. 47).
(5) Remove hood latch from vehicle.
INSTALLATION
(1) Position hood latch on vehicle.
(2) Connect hood release cable from hood latch.
(3) Position hood latch on crossmember.
(4) Align hood latch by placing latch over net-
pierced tabs. If alignment is required, flatten tabs.
(5) Install bolts attaching hood latch to radiator
closure panel crossmember.
(6) Verify hood operation and alignment. Adjust as
necessary.
Fig. 44 HoodFig. 45 Hood Hinge
Fig. 46 Hood Latch
NSBODY 23 - 41
REMOVAL AND INSTALLATION (Continued)

(2) Remove liquid line at filter-drier (Fig. 42).
(3) Remove the (2) bolts holding filter-drier bracket
to radiator fan module bracket.
(4) Remove the lower liquid line at condenser.
(5) Remove the upper radiator crossmember.
(6) Pull up on radiator and slide filter-drier from
the mounting location.
INSTALLATION
(1) Before installation, replace both refrigerant
line O-rings. Then reverse the above procedures.
Torque filter/drier mounting bolts to 45 in. lbs.610.
(2) Evacuate and recharge system.
HEATER A/C UNIT HOUSING
REMOVAL
WARNING: IF EQUIPPED WITH AIR CONDITIONING,
THE REFRIGERATION SYSTEM MUST BE COM-
PLETELY EMPTY BEFORE PROCEEDING.
(1) Set parking brake.
(2) Disconnect battery negative cable.
(3) Using a refrigerant recovery machine, remove
refrigerant from the A/C system (Fig. 43).
(4) Remove wiper module. Refer to Group 8K,
Windshield Wipers and Washers.
(5) Pinch off rear heater lines if equipped.
(6) Drain engine coolant. Remove heater hoses at
the heater core (Fig. 44). Plug coolant lines.
(7) Remove suction and liquid lines at the expan-
sion valve (Fig. 45).(8) Remove the Instrument Panel Assembly. Refer
to Group 8E, Instrument Panel and Gauges.
(9) Remove heater ducts.
Fig. 42 Filter-Drier Assembly
Fig. 43 A/C Service Ports
Fig. 44 Heater Hoses
Fig. 45 Expansion Valve Plate
NSHEATING AND AIR CONDITIONING 24 - 29
REMOVAL AND INSTALLATION (Continued)

(2) Hand-start the stud into the expansion valve
and torque to7-11N´m(64-96in.lbs.).
(3) Carefully install the expansion valve to the
sealing plate. Install the two screws and tighten 8 to
14 N´m (70 to 130 in. lbs.) torque.
(4) Carefully install the refrigerant lines and seal-
ing plate to the expansion valve. Install the nut and
tighten 20 to 26 N´m (170 to 230 in. lbs.) torque.
(5) Install the ground wire at dash panel.
(6) Pull generator back into the proper position for
bracket mounting.
(7) Install generator field wire connector.
(8) Install the upper generator bracket.
(9) Install accessory drive belt.
(10) Evacuate and recharge system.
(11) After expansion valve is installed, the system
is charged, and leaks have checked repeat the A/C
performance check.
FILTER-DRIER ASSEMBLY
REMOVAL
WARNING: THE REFRIGERATION SYSTEM MUST
BE COMPLETELY EMPTY BEFORE PROCEEDING
WITH THIS OPERATION.
(1) Recover A/C system refrigerant.
(2) Remove liquid line at filter-drier (Fig. 21).
(3) Remove the (2) bolts holding filter-drier bracket
to radiator fan module bracket.
(4) Remove the lower liquid line at condenser.
(5) Remove the upper radiator crossmember.
(6) Pull up on radiator and slide filter-drier from
the mounting location.
INSTALLATION
(1) Before installation, replace both refrigerant
line O-rings. Then reverse the above procedures.
(2) Evacuate and recharge system.
HEATER A/C UNIT HOUSING
REMOVAL
WARNING: IF EQUIPPED WITH AIR CONDITIONING,
THE REFRIGERATION SYSTEM MUST BE COM-
PLETELY EMPTY BEFORE PROCEEDING.
(1) Set parking brake.
(2) Disconnect battery negative cable.
(3) Using a refrigerant recovery machine, remove
refrigerant from the A/C system.
(4) Remove wiper module. Refer to Group 8K,
Windshield Wipers and Washers.
(5) Drain engine coolant. Remove heater hoses at
the heater core, refer to Heater Hoses Removal and
Installation procedures. Plug coolant lines.(6) Remove suction and liquid lines at the expan-
sion valve (Fig. 27).
(7) Remove the Instrument Panel Assembly. Refer
to Group 8E, Instrument Panel and Systems.
(8) Remove heater ducts.
(9) Disconnect the two upper mounts from the
upper reinforcement and the lower mount from the
tunnel.
(10) Remove the (3) nuts (in the engine compart-
ment) securing the unit to the dash panel (Fig. 30).
(11) Disconnect the HVAC housing wiring harness.
(12) Pull the entire unit rearward until the studs
on the unit clear the dash panel. Drop the unit down.
Pull it rearward to remove it from vehicle.
INSTALLATION
(1) For installation of the assembly, reverse the
above procedures. Install new O-rings on plumbing
inlets
(2) Evacuate and recharge the A/C system.
(3) Perform HVAC control Calibration Diagnostic
and Cooldown test.
HEATER CORE
REMOVAL
(1) Drain coolant system.
(2) Remove left side lower column cover.
(3) Remove steering column assembly. Refer to
Group 19, Steering for service procedure.
(4) Remove ABS module, bracket and wiring (Fig.
31).
(5) Remove I/P to body harness interconnect and
bracket (Fig. 32).
(6) Remove lower silencer boot at base of steering
shaft (Fig. 33)
(7) Pinch off heater lines under the hood.
Fig. 30 HVAC Bolt-Up
24 - 26 HEATING AND AIR CONDITIONINGNS/GS
REMOVAL AND INSTALLATION (Continued)