oil filter CHRYSLER VOYAGER 1996 Owner's Guide

3.3/3.8L ENGINE
INDEX
page page
DESCRIPTION AND OPERATION
ENGINE COMPONENTS.................. 93
ENGINE IDENTIFICATION................. 93
ENGINE LUBRICATION SYSTEM............ 93
DIAGNOSIS AND TESTING
CHECKING ENGINE OIL PRESSURE......... 96
HYDRAULIC TAPPETS.................... 94
SERVICE PROCEDURES
CRANKSHAFT END PLAY................. 99
FITTING CONNECTING ROD BEARINGS...... 97
FITTING MAIN BEARINGS................. 98
FITTING PISTONS AND RINGS............. 97
MEASURING TIMING CHAIN FOR STRETCH . . . 96
VALVE SERVICE RECONDITION........... 100
VALVE TIMING.......................... 96
REMOVAL AND INSTALLATION
CAMSHAFT BEARINGS.................. 114
CAMSHAFT........................... 113
CRANKSHAFT DAMPER................. 106
CRANKSHAFT OIL SEALÐFRONT.......... 117
CRANKSHAFT OIL SEALÐREAR........... 118
CRANKSHAFT......................... 116
CYLINDER HEAD COVER................ 107
CYLINDER HEAD....................... 108
ENGINE ASSEMBLY..................... 104
ENGINE MOUNTS...................... 102
ENGINE OIL GALLERY PLUGS............. 119OILFILTER ............................ 119
OILPAN .............................. 114
PISTON AND CONNECTING ROD.......... 115
ROCKER ARMS AND SHAFT ASSEMBLY..... 106
TAPPET REMOVAL...................... 110
TIMING CHAIN COVER................... 111
TIMING CHAIN......................... 112
VALVE STEM SEALS OR SPRINGS,
CYLINDER HEAD NOT REMOVED........ 106
VALVES AND VALVE SPRINGS............ 109
WIPER UNIT.......................... 102
DISASSEMBLY AND ASSEMBLY
HYDRAULIC TAPPETS................... 120
OIL PUMP............................ 119
CLEANING AND INSPECTION
CYLINDER HEAD....................... 120
ENGINE BLOCK AND BORE............... 121
OILPAN .............................. 121
OIL PUMP............................ 121
ADJUSTMENTS
ENGINE MOUNTS...................... 123
SPECIFICATIONS
3.3/3.8L ENGINE....................... 123
TORQUE CHART....................... 125
SPECIAL TOOLS
3.3/3.8L ENGINE....................... 127
DESCRIPTION AND OPERATION
ENGINE IDENTIFICATION
The engine identification number is located on the
rear of the cylinder block just below the cylinder
head (Fig. 1).
ENGINE LUBRICATION SYSTEM
The lubrication system is a full flow filtration pres-
sure feed type. Oil from the oil pan is pumped by a
internal gear type oil pump directly coupled to the
crankshaft. The pressure is regulated by a relief
valve located in the chain case cover. The oil is
pumped through an oil filter and feeds a main oil
galley. This oil gallery feeds oil under pressure to the
main and rod bearings, camshaft bearings. Passages
in the cylinder block feed oil to the hydraulic lifters
and rocker shaft brackets which feeds the rocker arm
pivots (Fig. 2).
ENGINE COMPONENTS
ENGINE:The 3.3L (201 Cubic Inches) and 3.8L
(231 Cubic Inches) displacement engines are 60É V
type six cylinder power plants with cast iron cylinder
blocks and aluminum cylinder heads (Fig. 3). Firing
order for these engines is 1-2-3-4-5-6. High turbu-
lence cylinder heads allow a 8.9-1 compression ratio.
CRANKSHAFT:The nodular iron crankshaft is
supported by four main bearings, with number two
being the thrust bearing. Crankshaft end sealing is
provided by front and rear rubber seals.
PISTONS:The pistons are cast aluminum alloy.
Three rings are used. Piston pins, press fitted into
place, join the pistons to forged steel connecting rods.
CAMSHAFT:The nodular iron camshaft is
mounted in four steel backed babbitt bearings. A
thrust plate located in front of the first bearing, and
bolted to the block, controls end play. Silent timing
chain drives the camshaft. This chain is enclosed by
a cast aluminum cover which also carries a front
NS3.3/3.8L ENGINE 9 - 93

(20) Remove rear transmission mount and bracket.
(21) Remove power steering pump and bracket
assembly.
(22) Remove wiring harness and connectors from
front of engine.
(23) Remove bending braces and install tool num-
ber 6912 on engine.
(24) Remove transmission inspection cover and
mark flexplate to torque converter.
(25) Remove driveplate to torque converter bolts.
(26) Lower the vehicle.
(27) Remove ground straps to body.
(28) Raise vehicle enough to allow engine dolly
Special Tool 6135 and cradle Special Tool 6710 with
post Special Tool 6848 and adaptor Special Tool 6909
to be installed under vehicle (Fig. 28).
(29) Loosen cradle engine mounts to allow move-
ment for positioning onto engine locating holes on the
engine. Lower vehicle and position cradle mounts
until the engine is resting on mounts. Tighten
mounts to cradle frame. This will keep mounts from
moving when removing or installing engine and
transmission.
(30) Lower vehicle so the weight ofONLY THE
ENGINE AND TRANSMISSIONis on the cradle.
(31) Remove right engine mount assembly and left
transmission mount through bolt. Refer to Engine
Mounts Section of this Group.
(32) Raise vehicle slowly. It may be necessary to
move the engine/transmission assembly on the cradle
to allow for removal around body flanges.INSTALLATION
(1) Position engine and transmission assembly
under vehicle and slowly lower the vehicle over the
engine and transmission. It may be necessary to
move the engine/transmission assembly with the cra-
dle for clearance around body flanges.
(2) Align engine and transmission mounts to
attaching points. Install mounting bolts at the right
engine and left transmission mounts. Refer to proce-
dures outlined in this section.
(3) Slowly raise vehicle enough to remove the
engine dolly and cradle Special Tools 6135, 6710,
6848 and 6909.
(4) Remove Special tools 6912 and install bending
braces.
(5) Lower vehicle. Install generator and wiring
harness.
(6) Connect wiring harness on the front of the
engine.
(7) Install Air Conditioning Compressor.
(8) Install power steering pump and bracket and
accessory drive belt. Refer to Accessory drive Section
Located in group 7 for installation procedure.
(9) Raise vehicle and install axle shafts. Refer to
Group 3, Differential and Driveline for procedure.
(10) Install transmission and engine mount and
bracket assemblies. Refer to Engine Mounts section
of this Group.
(11)(AWD equipped)Install propeller shaft to
power transfer unit. Refer to Group 3, Differential
and Driveline for procedure.
(12) Connect exhaust system to manifold. Refer to
Group 11, Exhaust System and Intake Manifold for
procedure and torque specifications.
(13) Install crossmember cradle plate (Fig. 27).
(14) Install left and right inner splash shields.
(15) Connect automatic transmission shifter link-
age. Refer to Group 21, Transmission for procedures.
(16) Lower vehicle and connect fuel line and
heater hoses. Remove plugs from rear heater hoses
and install, if equipped.
(17) Install ground straps. Connect engine and
throttle body connections and harnesses.
(18) Connect throttle body linkage. Refer to Group
14, Fuel System for procedure.
(19) Install radiator and fan module assembly.
Install radiator hoses. Fill cooling system. See Group
7 for filling procedure.
(20) Install battery tray, battery and cover.
(21) Install air cleaner and hoses.
(22) Install oil filter. Fill engine crankcase with
proper oil to correct level.
(23) Start engine and run until operating temper-
ature is reached.
(24) Adjust transmission linkage, if necessary.
Fig. 28 Positioning Engine Cradle Support Post
MountsÐTypical
NS3.3/3.8L ENGINE 9 - 105
REMOVAL AND INSTALLATION (Continued)

Install new gasket and tighten screws to 12 N´m (105
in. lbs.).
OIL FILTER
CAUTION: When servicing the oil filter (Fig. 71)
avoid deforming the filter can by installing the
remove/install tool band strap against the can-to-
base lock seam. The lock seam joining the can to
the base is reinforced by the base plate.
(1) Using Tool C-4065, turn filter counterclockwise
to remove from base. Properly discard filter.
(2) Wipe base clean, then inspect gasket contact
surface.
(3) Lubricate gasket of new filter with clean
engine oil.
(4) Install new filter until gasket contacts base.
Tighten filter 1 turn or 20 N´m (15 ft. lbs.). Use filter
wrench if necessary.
(5) Start engine and check for leaks.
ENGINE OIL GALLERY PLUGS
REMOVAL
Using a blunt tool such as a drift and a hammer,
strike the bottom edge of the cup plug. With the cup
plug rotated, grasp firmly with pliers or other suit-
able tool and remove plug (Fig. 72).CAUTION: Do not drive cup plug into the casting
as restricted cooling can result and cause serious
engine problems.
INSTALLATION
Thoroughly clean inside of cup plug hole in cylin-
der block or head. Be sure to remove old sealer.
Lightly coat inside of cup plug hole with Loctite Stud
N' Bearing Mount or equivalent. Make certain the
new plug is cleaned of all oil or grease. Using proper
drive plug, drive plug into hole so that the sharp
edge of the plug is at least 0.5 mm (0.020 in.) inside
the lead-in chamfer.
DISASSEMBLY AND ASSEMBLY
OIL PUMP
It is necessary to remove the oil pan, oil pickup
and chain case cover to service the oil pump rotors.
The oil pump pressure relief valve can be serviced by
removing the oil pan and oil pickup tube. Refer to
Timing Chain Cover Removal and Installation of this
section for procedures.
DISASSEMBLY
(1) To remove the relief valve, proceed as follows:
Fig. 70 Rear Crankshaft Oil SealÐInstallation
Fig. 71 Oil Filter
Fig. 72 Core Hole Plug Removal
NS3.3/3.8L ENGINE 9 - 119
REMOVAL AND INSTALLATION (Continued)

Service Tappets Available........Std., 0.025 mm
(0.001), 0.20 mm (0.008 in.),
0.762 mm (0.030 in.)
Cylinder Head
Gasket Thickness (Compressed)........1.78 mm
(0.070 in.)
Cylinder Head Valve Seat
Angle±Intake and Exhaust...........45-45.5É
Runout (Max)............0.0762 mm (0.003 in.)
Width (Finish)±Intake...........1.75 - 2.25 mm
(0.069 - 0.088 in.)
Width (Finish)±Exhaust.........1.50 - 2.00 mm
(0.057 - 0.078 in.)
Valve Guides
Type..................Powdered Metal Inserts
Guide Bore Diameter...........7.975 - 8.00 mm
(0.314 - 0.315 in.)
ValvesÐIntake
Face Angle...........................44.5É
Head Diameter..............45.5 mm (1.79 in.)
Length (Overall)..........127.005 - 128.036 mm
(5.000 - 5.041 in.)
Minimum Valve Length
After Tip Grinding...................124.892
(4.916 in.)
Lift (Zero Lash)...........10.16 mm (0.400 in.)
Stem Diameter (Standard)......7.935 - 7.953 mm
(0.312 - 0.313 in.)
Valve Tip Height (From
Cylinder Head Surface)......49.541 - 51.271 mm
(1.950 - 2.018 in.)
Stem-to-Guide Clearance.......0.025 - 0.095 mm
(0.001 - 0.003 in.)
Max. Allowable (Rocking Method). . . .0.247 mm
(0.010 in.)
Valves for Service
(Oversize Stem Diameters).......Std., 0.015 mm
(0.005 in.), 0.40 mm (0.015 in.),
0.80 mm (0.030 in.)
ValvesÐExhaust
Face Angle.............................45É
Head Diameter.............37.5 mm (1.476 in.)
Length Overall..............127.825 - 128.465
(5.032 - 5.058 in.)
Minimum Valve Length
After Tip Grinding.......125.512 mm (4.941 in.)
Lift (Zero Lash)............10.16 mm (0.40 in.)
Valve Tip Height (From
Cylinder Head Surface)......49.541 - 51.271 mm
(1.950 - 2.018 in.)
Stem Diameter (Standar).......7.906 - 7.924 mm
(0.3112 - 0.3119 in.)
Stem to Guide Clearance.......0.051 - 0.175 mm
(0.002 - 0.006 in.)Max. Allowable (Rocking Method)......0.414 mm
(0.016 in.)
Valves for Service (Oversize
Stem Diameters)......Std., 0.015 mm (0.005 in.),
0.40 mm (0.015 in.), 0.80 mm (0.030 in.)
Valve Springs
Free Length (Approx.).......48.5 mm (1.909 in.)
Wire Diameter.............4.75 mm (0.187 in.)
Number of Coils.........................6.8
Spring Tension (Valve Closed).......95-100lbs.
@ 1.57 in.
Spring Tension (Valve Open).......207 - 229 lbs.
@ 1.169 in.
Installed Height (Spring
Seat to Bottom of Retainer)......41.2 - 42.7 mm
(1.622 - 1.681 in.)
Oil Pump
Pump Type...............Rotary Full Pressure
Clearance Over Rotors
(Inner & Outer Max.)........0.10 mm (0.004 in.)
Cover Out-of-Flat (Max.).....0.025 mm (0.001 in.)
Inner Rotor Thickness (Min.) . .7.64 mm (0.301 in.)
Outer Rotor Thickness (Min.) . .7.64 mm (0.301 in.)
Outer Rotor Diameter (Min.) .79.95 mm (3.148 in.)
Outer Rotor Clearance.......0.39 mm (0.015 in.)
Tip Clearance Between Rotors (Max.). . . .0.20 mm
(0.008 in.)
Oil Pressure
Minimum Pressure at Idle (Engine
Fully Warmed Up)*...........34.47 kPa (5 psi)
At 3000 rpm.........205 - 551 kPa (30 - 80 psi)
Oil Filter Bypass Valve Setting......62-103kPa
(9 - 15 psi)
Oil Filter Type.....................Full Flow
Oil Pressure Switch Actuating
Pressure (Min.)...........14-28kPa(2 - 4 psi)
CAUTION: * If pressure is ZERO at curb Idle, DO
NOT run engine at 3,000 rpm.
NS3.3/3.8L ENGINE 9 - 125
SPECIFICATIONS (Continued)

TORQUE CHART
DESCRIPTION TORQUE
A/C Compressor Mounting
Compressor Bracket to Water Pump Bolt . .41 N´m
(30 ft. lbs.)
Compressor to Bracket Bolt. . . .68 N´m (50 ft. lbs.)
Compressor Support Bolt.....41N´m(30ft.lbs.)
Camshaft Sprocket
Bolt......................54N´m(40ft.lbs.)
Camshaft Thrust Plate
Bolt.....................12N´m(105 in. lbs.)
Connecting Rod
Nut...............54N´m(40ft.lbs.) +
1¤4Turn
Crankshaft Damper Pulley to Crankshaft
Bolt......................54N´m(40ft.lbs.)
Cylinder Head
Bolts.......Refer to Cylinder Head Removal and
Installation Procedure in this Section
Cylinder Head Cover
Bolts....................12N´m(105 in. lbs.)
Exhaust Manifold
Bolts....................23N´m(200 in. lbs.)
Exhaust Crossover Pipe Flange
Fasteners..................33N´m(25ft.lbs.)
Generator Mounting
Adjusting Strap Bolt........23N´m(200 in. lbs.)
Adjusting Strap Mounting Bolt..........41N´m
(30 ft. lbs.)
Bracket Bolt...............41N´m(30ft.lbs.)
Pivot Nut..................41N´m(30ft.lbs.)
Intake Manifold
Bolts....................23N´m(200 in. lbs.)
Intake Manifold Gasket Retaining
Screws..................12N´m(105 in. lbs.)
Intake Manifold Plenum
Bolts....................28N´m(250 in. lbs.)
Main Bearing Cap
Bolts..............41N´m(30ft.lbs.) +
1¤4Turn
Oil Filter Attaching
Nipple....................41N´m(30ft.lbs.)DESCRIPTION TORQUE
Oil Pan
Bolts....................12N´m(105 in. lbs.)
Drain Plug.................27N´m(20ft.lbs.)
Level Sensor Plug...........41N´m(30ft.lbs.)
Oil Pressure Gauge Sending Unit
..........................7N´m(60in.lbs.)
Oil Pump
Cover Bolts...............12N´m(105 in. lbs.)
Pick-up Tube Bolt..........28N´m(250 in. lbs.)
Rocker Shaft Bracket
Bolts....................28N´m(250 in. lbs.)
Spark Plug
.........................27N´m(20ft.lbs.)
Starter Mounting
Bolt......................68N´m(50ft.lbs.)
StrutÐIntake Manifold to Cylinder Head
Bolt......................54N´m(40ft.lbs.)
Tappet Retainer Yoke
Bolt.....................12N´m(105 in. lbs.)
Temperature Gauge Sending Unit
..........................7N´m(60in.lbs.)
Timing Chain Case Cover
Bolt±M831.25.............27N´m(20ft.lbs.)
Bolt±M1031.5.............54N´m(40ft.lbs.)
Water Pump to Chain Case Cover
Bolts....................12N´m(105 in. lbs.)
9 - 126 3.3/3.8L ENGINENS
SPECIFICATIONS (Continued)

Tester Valve Spring C-647
Valve Spring Compressor C-3422±B
Adaptor Valve Compressor 6412
Insert Crankshaft Pulley Remover L-4524-1
Front Crankshaft Seal Installer C-4992
Camshaft Bearing Remover and Installer C-3132±A
Crankshaft Main Bearing Remover and Installer
C-3059
Rear Crankshaft Seal Guide and Installer 6926-1 and
6926-2
Oil Filter Wrench C-4065
9 - 128 3.3/3.8L ENGINENS
SPECIAL TOOLS (Continued)

ENGINE
CONTENTS
page page
2.0L SOHC ENGINE...................... 12.5L VM DIESEL....................... 40
2.0L SOHC ENGINE
INDEX
page page
DESCRIPTION AND OPERATION
ENGINE COMPONENTS.................. 3
ENGINE IDENTIFICATION................. 1
ENGINE LUBRICATION SYSTEM............ 2
GENERAL SPECIFICATION................ 2
DIAGNOSIS AND TESTING
CHECKING ENGINE OIL PRESSURE........ 3
SERVICE PROCEDURES
CRANKSHAFT END PLAY................. 6
CYLINDER BORE AND PISTON SIZING....... 4
FITTING CONNECTING RODS.............. 5
FITTING CRANKSHAFT BEARINGS.......... 6
FITTING PISTON RINGS.................. 4
REMOVAL AND INSTALLATION
CAMSHAFT OIL SEAL................... 12
CAMSHAFT............................ 7
CRANKSHAFT OIL SEALÐREAR........... 20
CRANKSHAFT......................... 21
CYLINDER HEAD COVER................. 6
CYLINDER HEAD....................... 10
FRONT CRANKSHAFT OIL SEAL........... 18
OILFILTER ........................... 24
OIL FILTER ADAPTER................... 24OILPAN .............................. 17
OIL PUMP............................ 25
PISTON AND CONNECTING ROD.......... 25
ROCKER ARM/HYDRAULIC LASH ADJUSTER . . 8
SPARK PLUG TUBE...................... 7
TIMING BELT COVER................... 11
TIMING BELT SYSTEM.................. 13
VALVE SEALS AND SPRINGS IN VEHICLE . . . 10
VIBRATION DAMPER.................... 28
DISASSEMBLY AND ASSEMBLY
OIL PUMP............................ 29
VALVE SERVICE WITH THE CYLINDER HEAD
REMOVED.......................... 29
CLEANING AND INSPECTION
CYLINDER BLOCK AND BORE............ 34
CYLINDER HEAD AND CAMSHAFT
JOURNALS.......................... 32
OIL PUMP............................ 32
SPECIFICATIONS
ENGINE 2.0L SOHC..................... 34
TORQUE CHART 2.0L SOHC.............. 36
SPECIAL TOOLS
ENGINE 2.0L SOHC..................... 36
DESCRIPTION AND OPERATION
ENGINE IDENTIFICATION
The engine identification number is located on the
left rear of the cylinder block behind starter (Fig. 1).
Fig. 1 Engine Identification SOHC
NS/GSENGINE 9 - 1

²Turn the ignition switch on and access the ªmis-
cellaneousº screen.
²Select ªre-learn cam/crankº option and follow
directions on DRB screen.
OIL PAN
REMOVAL
(1) Drain engine oil.
(2) Remove transmission inspection cover.
(3) If equipped with air conditioning remove oil fil-
ter and adaptor. Refer to Oil Filter Adapter Removal
and Installation in this section.
(4) Remove oil pan.(5) Clean oil pan and all gasket surfaces.
Fig. 40 Timing Belt System
Fig. 41 Camshaft Timing Marks
Fig. 42 Right Inner Splash Shield
NS/GSENGINE 9 - 17
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Apply Mopar Silicone Rubber Adhesive Sealant
or equivalent at the oil pump to engine block parting
line (Fig. 52).
(2) Install a new oil pan gasket to pan.
(3) Install pan and tighten screws to 12 N´m (105
in. lbs.).
(4) Install oil filter and adaptor.
(5) Install proper amount of oil. With oil filter 4.25
Liters (4.5 Qts.). Without oil filter 3.8 Liters (4.0
Qts.)
FRONT CRANKSHAFT OIL SEAL
REMOVAL
(1) Using Special Tool 1026 and Insert 6827±A,
remove crankshaft damper (Fig. 53).
(2) Remove outer timing belt cover and timing
belt. Refer to Timing Belt System outlined in this
section.(3) Remove crankshaft sprocket using Special Tool
6793 and insert C-4685-C2 (Fig. 54).
CAUTION: Do not nick shaft seal surface or seal
bore.
Fig. 43 Crankshaft DamperÐRemoval
Fig. 44 Right Engine Mount Bracket
Fig. 45 Timing Belt Cover
Fig. 46 Timing Belt Removal
9 - 18 ENGINENS/GS
REMOVAL AND INSTALLATION (Continued)

NOTE: When installing seal, no lube on seal is
needed.
(1) Place Special Tool 6926-1 on crankshaft. This is
a pilot tool with a magnetic base (Fig. 60).
(2) Position seal over pilot tool. Make sure you can
read the wordsTHIS SIDE OUTon seal (Fig. 60).
Pilot tool should remain on crankshaft during instal-
lation of seal. Ensure that the lip of the seal is facing
towards the crankcase during installation.
CAUTION: If the seal is driven into the block past
flush, this may cause an oil leak.
(3) Drive the seal into the block using Special Tool
6926-2 and handle C-4171 (Fig. 61) until the tool bot-
toms out against the block (Fig. 62).
CRANKSHAFT
REMOVAL
(1) Remove oil filter and adapter from bedplate.(2) Remove collar from oil pan to transmission
housing.
(3) Remove oil pan.
(4) Remove crankshaft sprocket and oil pump both
procedures outlined in this section.
(5) Remove all main bearing cap and bedplate
bolts from the engine block (Fig. 63).
(6) Using a mallet tap the bedplate loose from the
engine block dowel pins.
Fig. 57 Crankshaft SprocketÐInstallation
Fig. 58 Crankshaft DamperÐInstallation
Fig. 59 Rear Crankshaft Oil SealÐRemoval
Fig. 60 Rear Crankshaft Seal and Special Tool
6926-1
NS/GSENGINE 9 - 21
REMOVAL AND INSTALLATION (Continued)