engine CHRYSLER VOYAGER 1996 Service Manual

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)

(7) Inspect push rods and replace worn or bent
rods.
(8) Install push rods, rocker arm and shaft assem-
blies with the stamped steel retainers in the four
positions, tighten to 28 N´m (250 in. lbs.) (Fig. 36).
(9) Place new cylinder head cover gaskets in posi-
tion and install cylinder head covers. Tighten to 12
N´m (105 in. lbs.).
INTAKE MANIFOLD SEALING
The intake manifold gasket is a one-piece stamped
steel gasket with a sealer applied from the manufac-
turer. This gasket has end seals incorporated with it.
WARNING: INTAKE MANIFOLD GASKET IS MADE
OF VERY THIN METAL AND MAY CAUSE PER-
SONAL INJURY, HANDLE WITH CARE.
(1) Clean all surfaces of cylinder block and cylin-
der heads.
(2) Place a drop (about 1/4 in. diameter) of Mopart
Silicone Rubber Adhesive Sealant or equivalent, onto
each of thefourmanifold to cylinder head gasket
corners (Fig. 37).
(3) Carefully install the intake manifold gasket
(Fig. 38). Torque end seal retainer screws to 12 N´m
(105 in. lbs.).(4) Install intake manifold and (8) bolts and torque
to 1 N´m (10 in. lbs.). Then tighten bolts to 22 N´m
(200 in. lbs.) in sequence shown in (Fig. 39). Then
tighten again to 22 N´m (200 in. lbs.). After intake
manifold is in place,inspect to make sure seals
are in place.Refer to Group 11, Exhaust System
and Intake Manifold to complete intake manifold
installation.
(5) Install exhaust manifolds and tighten bolts to
27 N´m (20 ft. lbs.) and nuts to 20 N´m (15 ft. lbs.).
(6) Adjust spark plugs to specification in Group 8,
Electrical Section and install the plugs.
VALVES AND VALVE SPRINGS
REMOVAL
(1) With cylinder head removed, compress valve
springs using Valve Spring Compressor Tool
C-3422-B with adapter 6412 as shown in (Fig. 40).
(2) Remove valve retaining locks, valve spring
retainers, valve stem seals and valve springs.
Fig. 36 Rocker Arm Shaft Retainers
Fig. 37 Intake Manifold Gasket Sealing
Fig. 38 Intake Manifold Gasket Retainers
Fig. 39 Intake Manifold Removal and Installation
NS3.3/3.8L ENGINE 9 - 109
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)

(6) 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.
TIMING CHAIN COVER
REMOVAL
(1) Disconnect negative cable from battery.
(2) Drain cooling system. Refer to Cooling System
Group 7 for procedure.
(3) Support engine and remove right engine
mount.
(4) Raise vehicle on hoist. Drain engine oil.
(5) Remove oil pan and oil pump pick-up. It may
necessary to remove transaxle inspection cover.
(6) Remove right wheel and inner splash shield.
(7) Remove drive belt. Refer to Cooling System
Group 7 for procedure.
(8) Remove A/C compressor and set aside.
(9) Remove A/C compressor mounting bracket.
(10) Remove crankshaft damper (Fig. 44).
(11) Remove idler pulley from engine bracket.
(12) Remove engine bracket (Fig. 45).
(13) Remove cam sensor from chain case cover
(Fig. 46).
(14) Remove chain case cover (Fig. 46).
INSTALLATION
(1) Be sure mating surfaces of chain case cover
and cylinder block are clean and free from burrs.
Crankshaft oil seal must be removed to insure cor-
rect oil pump engagement.
NOTE: DO NOT USE SEALER ON COVER GASKET
(2) Use a new cover gasket, and O-rings (Fig. 47).
Adhere new gasket to chain case cover, making surethat the lower edge of the gasket is flush to 0.5 mm
(0.020 in.) passed the lower edge of the cover. Refer
to Oil Pan sealing outlined in this section.
Fig. 43 Roller Tappets Aligning Yoke and Retainer
Fig. 44 Crankshaft DamperÐRemoval
Fig. 45 Engine Bracket
Fig. 46 Timing Chain Case Cover
NS3.3/3.8L ENGINE 9 - 111
REMOVAL AND INSTALLATION (Continued)

(3) Rotate crankshaft so that the oil pump drive
flats are vertical.
(4) Position oil pump inner rotor so the mating
flats are in the same position as the crankshaft drive
flats (Fig. 47).
(5) Install cover onto crankshaft. Make sure the oil
pump is engaged on the crankshaft correctly or
severe damage may result.
(6) Install chain case cover screws and torque to
27 N´m (20 ft. lbs.).
(7) Install crankshaft oil seal (Fig. 48).
(8) Install crankshaft pulley (Fig. 49).
(9) Install engine bracket (Fig. 45) and torque fas-
teners to 54 N´m (40 ft. lbs.).(10) Install idler pulley on engine bracket.
(11) Install cam sensor. Refer to Group 8D, Igni-
tion System for installation procedure.
(12) Install A/C compressor mounting bracket.
(13) Install A/C compressor.
(14) Install drive belt Refer to Group 7, Cooling
System for installation procedure.
(15) Install inner splash shield and wheel.
(16) Install oil pump pick-up and oil pan and tran-
saxle inspection cover if removed.
(17) Install engine mount.
(18) Fill crankcase with oil to proper level.
(19) Fill cooling system. Refer to Group 7, Cooling
System for procedure.
(20) Connect negative cable to battery.
TIMING CHAIN
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove timing chain cover. Refer to procedure
outlined in this section.
(3) Remove camshaft sprocket attaching bolt, and
timing chain with camshaft sprocket.
(4) Using a suitable puller remove the crankshaft
sprocket. Be careful not to damage the crankshaft
surface.
INSTALLATION
(1) Position a new crankshaft sprocket on the
shaft, install sprocket with suitable tool and mallet.
Be sure sprocket is seated into position.
(2) Rotate crankshaft so the timing arrow is to the
12 o'clock position.
(3) Place timing chain around camshaft sprocket
and place the timing mark to the 6 o'clock position.
(4) Align the dark colored links with the dot on the
camshaft sprocket, place timing chain around crank-
shaft sprocket with the dark colored link lined up
Fig. 47 Timing Chain Case Cover Gaskets and
O-Rings
Fig. 48 Crankshaft Oil SealÐInstallation
Fig. 49 Crankshaft DamperÐInstallation
9 - 112 3.3/3.8L ENGINENS
REMOVAL AND INSTALLATION (Continued)

with the dot on the sprocket and install camshaft
sprocket into position.
(5) Use a straight edge to check alignment of tim-
ing marks (Fig. 50).
(6) Install camshaft bolt and washer. Tighten to 54
N´m (40 ft. lbs.).
(7) Rotate crankshaft 2 revolutions. Timing marks
should line up. If timing marks do not line up
remove cam sprocket and realign.
(8) Check camshaft end play. With new thrust
plate the specification is 0.0127 to 0.304 mm (0.005
to 0.012 in.). Old thrust plate specification is 0.31
mm (0.012 in.) maximum. If not within these limits
install new thrust plate.
(9) Install timing chain cover and connect negative
cable to battery.
CAMSHAFT
REMOVALÐENGINE REMOVED FROM
VEHICLE
Remove intake manifold, cylinder head covers, cyl-
inder heads, timing chain case cover and timing
chain.
(1) Remove rocker arm and shaft assemblies.
(2) Remove push rods and tappets; identify so each
part will be replaced in its original location.
(3) Remove camshaft thrust plate (Fig. 51).
(4) Install a long bolt into front of camshaft to
facilitate removal of the camshaft; remove camshaft,
being careful not to damage cam bearings with the
cam lobes.
INSTALLATION
(1) Lubricate camshaft lobes and camshaft bearing
journals and insert the camshaft to within 2 inches
of its final position in cylinder block.(2) Install camshaft thrust plate with two screws
as shown in (Fig. 51). Tighten to 12 N´m (105 in. lbs.)
torque.
(3) Rotate crankshaft so the timing arrow is at the
12 o'clock position.
(4) Place timing chain around camshaft sprocket
and place the timing mark to the 6 o'clock position.
(5) Align the dark colored links with the dot on the
camshaft sprocket, place timing chain around crank-
shaft sprocket with the dark colored link lined up
with the dot on the sprocket and install camshaft
sprocket into position.
(6) Using straight edge to check alignment of tim-
ing marks (Fig. 52).
(7) Install the camshaft bolt. Tighten bolt to 54
N´m (40 ft. lbs.).
(8) Rotate crankshaft 2 revolutions. Timing marks
should line up. If timing marks do not line up,
remove cam sprocket and realign.
(9) Measure camshaft end play. End Play should
measure 0.0127 to 0.304 mm (0.005 to 0.012 inches.)
Fig. 50 Timing Marks Alignment
Fig. 51 Camshaft Thrust Plate
Fig. 52 Alignment of Timing Marks
NS3.3/3.8L ENGINE 9 - 113
REMOVAL AND INSTALLATION (Continued)

0.310 mm (0.012 in. Max.). If not within limits install
a new thrust plate.
(10) Each tappet reused must be installed in the
same position from which it was removed.When
camshaft is replaced, all of the tappets must be
replaced.
CAMSHAFT BEARINGS
REMOVAL
(1) With engine removed from vehicle and com-
pletely disassembled, drive out rear cam bearing core
hole plug.
(2) Install proper size adapters and horseshoe
washers (part of Tool C-3132-A) at back of each bear-
ing shell to be removed and drive out bearing shells
(Fig. 53).
INSTALLATION
(1) Install new camshaft bearings with Tool
C-3132-A by sliding the new camshaft bearing shell
over proper adapter.
(2) Position rear bearing in the tool. Install horse-
shoe lock and by reversing removal procedure, care-
fully drive bearing shell into place.
(3) Install remaining bearings in the same man-
ner. Bearings must be carefully aligned to bring oil
holes into full register with oil passages from the
main bearing. Number two bearing must index with
the oil passage to the left cylinder head and Number
three bearing must index with the oil passage to the
right cylinder head. If the camshaft bearing shell oil
holes are not in exact alignment, remove and rein-
stall them correctly. Install a new core hole plug at
the rear of camshaft.Be sure this plug does not
leak.
OIL PAN
REMOVAL
(1) Disconnect negative cable from battery and
remove engine oil dipstick.
(2) Raise vehicle on hoist and drain engine oil.(3) Remove bending brace to transaxle attaching
bolt.
(4) Remove bolts attaching dust cover to transaxle
housing. Lower dust cover to gain access to oil pan
bolts.
(5) Remove oil pan screws and remove oil pan.
INSTALLATION
(1) Clean surfaces and apply a 1/8 inch bead of
MopartSilicone Rubber Adhesive Sealant or equiva-
lent, at the parting line of the chain case cover and
the rear seal retainer (Fig. 54).
(2) Use a new pan gasket (Fig. 55).
(3) Install pan and tighten screws to 12 N´m (105
in. lb.).
(4) Install dust shield and bending brace to tran-
saxle housing.
(5) Lower vehicle and install oil dipstick.
(6) Connect negative cable to battery.
(7) Fill crankcase with oil to proper level.
Fig. 53 Removed Installation of Camshaft Bearings
with Tool C-3132±AÐTypical
Fig. 54 Oil Pan Sealing
Fig. 55 Oil Pan Gasket Installation
9 - 114 3.3/3.8L ENGINENS
REMOVAL AND INSTALLATION (Continued)

PISTON AND CONNECTING ROD
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove cylinder heads and oil pan. Refer to
procedure outlined in this section.
(3) Remove top ridge of cylinder bores with a reli-
able ridge reamer before removing pistons from cyl-
inder block.Be sure to keep tops of pistons
covered during this operation. Pistons and con-
necting rods must be removed from top of cyl-
inder block. When removing piston and
connecting rod assemblies from the engine,
rotate crankshaft so that each connecting rod
is centered in cylinder bore.
(4) Inspect connecting rods and connecting rod
caps for cylinder identification. Identify them if nec-
essary (Fig. 56).
(5) Remove connecting rod cap. Install connecting
rod bolt protectors on connecting rod bolts (Fig. 57).
Push each piston and rod assembly out of cylinder
bore.
NOTE: Be careful not to nick crankshaft journals.
(6) After removal, install bearing cap on the mat-
ing rod.
INSTALLING PISTON AND CONNECTING ROD
ASSEMBLY
(1) Before installing pistons and connecting rod
assemblies into the bore, be sure that compression
ring gaps are staggered so that neither is in line with
oil ring rail gap (Fig. 58).
(2) Before installing the ring compressor, make
sure the oil ring expander ends are butted and the
rail gaps located as shown in (Fig. 58).
(3) Lubricate the piston and rings with clean
engine oil. Position a ring compressor over the piston
and rings, and tighten the compressor.Be sure posi-
tion of rings does not change during this oper-
ation.
(4) Install connecting rod bolt protectors on rod
bolts (Fig. 57).(5) Rotate crankshaft so that the connecting rod
journal is on the center of the cylinder bore. Insert
rod and piston into cylinder bore and guide rod over
the crankshaft journal.
Fig. 56 Identify Connecting Rod to Cylinder
Fig. 57 Connecting Rod Protectors
Fig. 58 Piston Ring End Gap Position
Fig. 59 PistonÐInstallation
NS3.3/3.8L ENGINE 9 - 115
REMOVAL AND INSTALLATION (Continued)

(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.
(7) The notch or groove on top of piston must be
pointing toward front of engine (Fig. 60).
(8) Install rod caps. Install nuts on cleaned and
oiled rod bolts and tighten nuts to 54 N´m (40 ft. lb.)
Plus 1/4 turn.
(9) Repeat procedure for each piston and rod
installation.
(10) Install cylinder heads and oil pan.
(11) Fill engine crankcase with proper oil to cor-
rect level.
(12) Connect negative cable to battery.
CRANKSHAFT
MAIN BEARINGS
Bearing caps are not interchangeable and should
be marked at removal to insure correct assembly
(Fig. 62). Upper and lower bearing halves are NOT
interchangeable. Lower main bearing halves of 1, 3
and 4 are interchangeable. Upper main bearing
halves of 1, 3 and 4 are interchangeable.
CRANKSHAFT MAIN JOURNALS
The crankshaft journals should be checked for
excessive wear, taper and scoring. (Fig. 61) Limits of
taper or out-of-round on any crankshaft journals
should be held to 0.025 mm (0.001 in.). Journal
grinding should not exceed 0.305 mm (0.012 in.)
under the standard journal diameter. Do NOT grind
thrust faces of Number 2 main bearing. Do NOT nick
crank pin or bearing fillets. After grinding, remove
rough edges from crankshaft oil holes and clean out
all passages.
CAUTION: With the nodular cast iron crankshafts
used it is important that the final paper or cloth pol-ish after any journal regrind be in the same direc-
tion as normal rotation in the engine.
Upper and lower Number 2 bearing halves are
flanged to carry the crankshaft thrust loads and are
NOT interchangeable with any other bearing halves
in the engine (Fig. 63). 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 undersizes: 0.025 mm
(0.001 in.) and 0.254 mm (0.010 in). Never install an
undersize bearing that will reduce clearance below
specifications.
REMOVAL
(1) Remove oil pan and identify bearing caps
before removal.
(2) Remove bearing caps one at a time. Remove
upper half of bearing by inserting Special Main Bear-
ing Tool C-3059. (Fig. 64) into the oil hole of crank-
shaft.
Fig. 60 Piston I.D. NotchesFig. 61 Measure Crankshaft Journal O.D.
Fig. 62 Main Bearing Cap Identification
9 - 116 3.3/3.8L ENGINENS
REMOVAL AND INSTALLATION (Continued)

(3) Slowly rotate crankshaft clockwise, forcing out
upper half of bearing shell.
INSTALLATION
NOTE: Only one main bearing should be selec-
tively fitted while all other main bearing caps are
properly tightened.
When installing a new upper bearing shell, slightly
chamfer the sharp edges from the plain side.
(1) Start bearing in place, and insert Main Bearing
Tool C-3059 into oil hole of crankshaft (Fig. 64).
(2) Slowly rotate crankshaft counterclockwise slid-
ing the bearing into position. Remove Special Main
Bearing Tool C-3059.
(3) Install each main cap and tighten bolts finger
tight.
(4) Tighten number 1, 3 and 4 main cap bolts to 41
N´m + 1/4 Turn (30 ft. lbs.+ 1/4 Turn).(5) Rotate the crankshaft until number 6 piston is
at TDC.
(6) To ensure correct thrust bearing alignment the
following procedure must be done:
a. Move crankshaft all the way to the rear of its
travel.
b. Then, move crankshaft all the way to the front
of its travel.
c. Wedge a appropriate tool between the rear of
the cylinder block and rear crankshaft counter-
weight. This will hold the crankshaft in it's most for-
ward position.
d. Tighten the #2 Thrust Bearing cap bolts to 41
N´m + 1/4 Turn (30 ft. lbs.+ 1/4 Turn). Remove the
holding tool.
(7) Install oil pan.
(8) Fill engine crankcase with proper oil to correct
level.
CRANKSHAFT OIL SEALÐFRONT
REMOVAL
(1) Disconnect negative cable from battery.
(2) Raise vehicle on hoist. Remove right wheel and
inner splash shield.
(3) Remove drive belt. Refer to Group 7, Cooling
System for procedure.
(4) Remove crankshaft damper (Fig. 65).
(5) Using Tool 6341A to remove oil seal (Fig. 66).
Be careful not to damage that crankshaft seal sur-
face of cover.
INSTALLATION
(1) Install new seal by using Tool C-4992 (Fig. 67).
(2) Place seal into opening with seal spring
towards the inside of engine. Install seal until flush
with cover.
(3) Install crankshaft pulley using plate L-4524.
Thrust Bearing/washer and 5.9 inch screw (Fig. 68).
Fig. 63 Main Bearing Identification
Fig. 64 Removing and Installing Upper Main Bearing
With Special Tool C-3059
Fig. 65 Crankshaft DamperÐRemoval
NS3.3/3.8L ENGINE 9 - 117
REMOVAL AND INSTALLATION (Continued)