engine CHRYSLER VOYAGER 1996 Service Manual

PISTON AND CONNECTING ROD
(1) Identify and mark pistons.The pistons are
not interchangeable from bank to bank(Fig. 45).
(2) Pistons with the letter R and arrow toward the
front of engine are to be installed in cylinders 1-3-5.
Pistons with the letter L and arrow toward the front
of engine are to be installed in cylinders 2-4-6.
(3) Mark connecting rod and cap with cylinder
number (Fig. 46).
(4) Remove piston rings (Fig. 47).
FITTING PISTONS
Measure approximately 2 mm (0.080 in.) above the
bottom of the piston skirt and across the thrust face
(Fig. 48). See Boring Cylinder in Cylinder Block.
Fig. 44 Pistons and Connecting Rods
Fig. 45 Mark Pistons
Fig. 46 Mark Matching Parts
Fig. 47 Remove Piston Rings
9 - 78 3.0L ENGINENS
REMOVAL AND INSTALLATION (Continued)

FITTING PISTON RINGS
(1) Wipe cylinder bore clean. Insert ring and push
down with piston to ensure it is square in bore. The
ring gap measurement must be made with the ring
positioning at least 16 mm (0.63 in.) from bottom of
cylinder bore. Check gap with feeler gauge (Fig. 49).
Refer to Piston Ring Specification Chart.
(2) Check piston ring to groove clearance (Fig. 50).
Refer to Piston Ring Specification Chart.PISTON RINGSÐINSTALLATION
(1) The No. 1 and No. 2 piston rings have a differ-
ent cross section. Install rings with manufacturers
mark and size mark facing up, to the top of the pis-
ton (Fig. 51).
CAUTION: Install piston rings in the following
order:
a. Oil ring expander.
b. Upper oil ring side rail.
PISTON RING SPECIFICATION CHART
Ring Position Ring Gap Ring Gap Wear
LimitGroove Clearance Maximum Groove
Clearance
Upper Ring 0.30 - 0.45 mm
(0.012 - 0.018 in.)0.8 mm (0.031 in.) 0.05 - 0.09 mm
(0.002 - 0.0035 in.)0.10 mm (0.004 in.)
Intermediate Ring 0.25 - 0.40 mm
(0.010 - 0.016 in.)0.8 mm (0.031 in.) 0.02 - 0.06 mm
(0.0007 - 0.002 in.)0.10 mm (0.004 in.)
Oil Control Ring 0.30 - 0.90 mm
(0.012 - 0.035 in.)1.0 mm (0.039 in.) Oil Ring Side Rails Must Be Free To Rotate
After Assembly
Fig. 48 Piston Clearance and Wear
Fig. 49 Check Gap on Piston Rings
Fig. 50 Piston Ring Clearance
Fig. 51 Piston RingÐInstallation
NS3.0L ENGINE 9 - 79
REMOVAL AND INSTALLATION (Continued)

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. 52).
(3) Install upper side rail first and then the lower
side rail.
(4) Install No. 2 piston ring and then No. 1 piston
ring (Fig. 53).
(5)
Position piston ring end gaps as shown in (Fig. 54).
(6) Position oil ring expander gap at least 45É from
the side rail gaps butnoton the piston pin center or
on the thrust direction.
(7) Connecting rod front mark 72 must always face
forward, toward timing belt end. (Fig. 55)
(8) Install the piston and connecting rod assembly
into there respective bore from the cylinder block top.
CAUTION: Piston assemblies are not to be inter-
changed from bank to bank.(9) Check alignment marks made during disassem-
bly and that bearing position notches new or used
are on the same side as shown in (Fig. 56).
Fig. 52 Side RailÐInstallation
Fig. 53 Installing Upper and Intermediate Rings
Fig. 54 Piston Ring End Gap Position
Fig. 55 Identify Piston and Rod Assembly for
Cylinder Installation
Fig. 56 Connecting Rod and Cap
9 - 80 3.0L ENGINENS
REMOVAL AND INSTALLATION (Continued)

CRANKSHAFT
REMOVAL
(1) Remove front mounted oil pump assembly and
gasket (Fig. 57) and (Fig. 58).
(2) Remove rear oil seal retainer and seal as
assembly (Fig. 59).(3) Release mono-block main bearing cap bolts
evenly. Remove lower bearing shells and identify for
reassembly.
(4) Lift out crankshaft and remove upper thrust
washers from each side of number three main bear-
ing in the crankcase (Fig. 57).
Fig. 57 Crankshaft and Cylinder Block
Fig. 58 Oil Pump Assembly
Fig. 59 Rear Seal Assembly
NS3.0L ENGINE 9 - 81
REMOVAL AND INSTALLATION (Continued)

CRANKSHAFT BEARINGSÐINSTALLATION
(1) Install upper main bearing shells making cer-
tain oil holes are in alignment, and bearing tabs seat
in block tabs. All upper bearings have oil grooves
(Fig. 60).
(2)THRUST BEARINGS.Crankshaft thrust
bearings (washers) are installed at journal #3 sepa-
rately from the radial bearings. Thrust bearings
shown in (Fig. 60) are different, one has end position-
ing tabs, while the other is plain. Onepairof each
thrust washers are installed into the block and one
pairinto the main bearing cap (Fig. 60).(3) Apply a thin film of grease to plain side of
thrust washers and position them on each side of
number three main bearing. Grooved surface towards
crankshaft.
(4) Oil the bearings and journals and install
crankshaft.
(5) Install lower main bearing shells without oil
grooves in mono-block cap.
(6) Install one pair of thrust washers in cap. Refer
to Thrust Bearings (Fig. 60).
(7) Carefully install bearing cap with arrows (Fig.
61) toward timing belt end.
(8) Oil the bearing cap bolt threads, install and
tighten bolts progressively in sequence shown in (Fig.
61) to 80 N´m (60 ft. lbs.) torque.
Fig. 60 Main BearingsÐInstallation
9 - 82 3.0L ENGINENS
REMOVAL AND INSTALLATION (Continued)

REAR CRANKSHAFT SEAL
REAR CRANKSHAFT SEAL RETAINER
(1) Install rear crankshaft oil seal in housing with
Special Tool MD-998718 (Fig. 62).
(2) Apply Mopar Silicone Rubber Adhesive Sealant
or equivalent to oil seal housing (Fig. 63) per proce-
dure detailed in form-in-place gasket section in Stan-
dard Service Procedures.(3) Apply light coating of engine oil to the entire
circumference of oil seal lip.
(4) Install seal assembly on cylinder block and
tighten bolts to 12 N´m (104 in. lbs.)
FRONT CRANKSHAFT OIL SEAL
(1) Install oil pump gasket and oil pump case (Fig.
65) and (Fig. 64).
CAUTION: Install bolts, depending on length in
locations shown in (Fig. 64).
(2) Using front crankshaft oil seal installer Special
Tool MD-998717 install oil seal in oil pump (Fig. 65).
Fig. 62 Rear Crankshaft Oil SealÐInstallation
Fig. 61 Crankshaft Main Bearing Cap
Fig. 63 Apply Sealant to Oil Seal Housing
NS3.0L ENGINE 9 - 83
REMOVAL AND INSTALLATION (Continued)

OIL PUMP
REMOVAL
1. Remove accessory drive belts. Refer to Accessory
Drive Belts Group 7, Cooling System.
2. Remove Timing Belt. Refer to procedure in this
section.
3. Remove 5 bolts that attach oil pump to block
(Fig. 66).
INSTALLATION
(1) Clean block and pump surfaces.
(2) Install new gasket (Fig. 67) make sure correct
length bolts are used (Fig. 66).
(3) Torque bolts to 13 N´m (120 in. lbs.).
OIL FILTER AND ADAPTOR
(1) Check the oil filter mounting surface. The sur-
face must be smooth, flat and free of debris or old
pieces of rubber (Fig. 68).
(2) Check adaptor for cracks and oil leaks.
CAUTION: When servicing the oil filter avoid
deforming the filter. Install the remove/install tool
band strap against the can-to-base lock seam. The
lock seam joining the can-to-base is reinforced by
the base plate.
(3) Using Tool C-4065, turn filter counterclockwise
to remove from base. Properly discard filter.
(4) Wipe base clean, then inspect gasket contact
surface.
(5) Lubricate gasket of new filter with clean
engine oil.
Fig. 64 Oil Pump
Fig. 65 Front Crankshaft Oil SealÐInstallation
Fig. 66 Oil Pump Assembly
Fig. 67 Oil Pump Components
9 - 84 3.0L ENGINENS
REMOVAL AND INSTALLATION (Continued)

(6) Install new filter until gasket contacts base.
Tighten filter 1 turn or 20 N´m (15 ft. lbs.). Use filter
wrench if necessary.
(7) Start engine and check for leaks.
DISASSEMBLY AND ASSEMBLY
ROCKER ARMS AND SHAFTS
(1) Check rocker arms for wear or damage (Fig.
69). Replace as necessary. Also see Auto Lash
Adjuster.
ROCKER ARM SHAFTS
The rocker arm shaft is hollow and is used as a
lubrication oil duct. The rocker arm shaft on the
inletside hasa3mm(0.188 in.) diameter oil pas-
sage hole from the cylinder head. Theexhaustside
does nothave this oil passage (Fig. 70).
(1) Check the rocker arm mounting portion of the
shafts for wear or damage. Replace if heavily dam-
aged or worn.
(2) Check oil holes for clogging with small wire,
clean as required (Fig. 70).
REASSEMBLE
(1) Align the camshaft bearing caps with arrows
(depending on cylinder bank) directed as shown in(Fig. 71) and in numerical order. Identify number one
bearing cap number one and number four caps are
similar (Fig. 72).
(2) Install rocker shafts so that bearing cap num-
ber one with end notches positioned as shown in (Fig.
72) that the machined portion of the rocker shaft is
facing down.
(3) Install attaching bolts to retain assembly.
ASSEMBLE ROCKER ASSEMBLY
Install the rocker arms, bearing caps and springs.
Springs are the same and can be used at all
locationson the rocker arm shafts (Fig. 71) and
(Fig. 73). Insert bolts in number four bearing cap to
retain assembly.
Fig. 68 Oil Filter and Adaptor
Fig. 69 Inspect Rocker Arms
Fig. 70 Rocker Arm Shaft Identification
Fig. 71 Camshaft Bearing Caps Position
NS3.0L ENGINE 9 - 85
REMOVAL AND INSTALLATION (Continued)

CLEANING AND INSPECTION
TIMING BELT
INSPECTION
(1) Remove the upper front outer timing belt cover
by loosening the three attaching bolts (Fig. 75).
(2) Inspect both sides of the timing belt drive &
back. Replace belt if any of the following conditions
exist:²Rubber back side is glossy, hardened back with-
out resilience and leaves no indent when pressed
with fingernail.
²Cracks on rubber back.
²Cracks or peeling of canvas.
²Cracks on rib root.
²Missing teeth.
²The sides are normal if they are sharp as if cut
by a knife (Fig. 74).
NOTE: If none of the above conditions are seen on
the belt, the belt cover can be installed.
CYLINDER HEAD
CLEANING AND INSPECTION
(1) Before cleaning, check for leaks, damage and
cracks.
(2) Clean cylinder head and oil passages.
(3) Check cylinder head for flatness (Fig. 76).
(4) Cylinder head must be flat within:
²Standard dimension = less than 0.05 mm (.002
in.)
²Service Limit = 0.2 mm (.008 in.)
²Grinding Limit = Maximum of 0.2 mm (.008 in.)
is permitted.
Fig. 73 Rocker Arm and Shafts
Fig. 72 Number One Camshaft Bearing Cap
9 - 86 3.0L ENGINENS
DISASSEMBLY AND ASSEMBLY (Continued)

CAUTION: This is a combined total dimension of
stock removal from cylinder head if any and block
top surface.
CYLINDER BORE
INSPECTION
(1) Measure the cylinder bore at three levels in
directions A and B (Fig. 77). Top measurementshould be 12 mm (0.50 in.) down and bottom mea-
surement should be 10 mm (0.38 in.) up.
(2) Standard bore dimension: 91.1 mm (3.587 in.)
(3) Maximum out-of-round or taper: 0.02 mm
(0.0008 in.).
OIL PUMP
(1) Check oil pump case for damage. Remove rear
oil pump cover.
(2) Remove pump rotors and inspect case for exces-
sive wear.
(3) Measure clearance between case and inner
rotor (Fig. 78).
(4) Insert the rotor into the oil pump case and
measure clearance between outer rotor and case with
a feeler gauge (Fig. 79). Replace if out of specifica-
tions.
Fig. 74 Timing Belt Inspection
Fig. 75 Timing Belt Covers
Fig. 76 Check Cylinder Head
Fig. 77 Checking Cylinder Bore Size
NS3.0L ENGINE 9 - 87
CLEANING AND INSPECTION (Continued)