weight CHRYSLER VOYAGER 1996 Owner's Guide

(5) Test resistance of spark plug cables. Refer to
Group 8D, Ignition System.
(6) Test ignition coils primary and secondary resis-
tance. Replace parts as necessary. Refer to Group 8D,
Ignition System.
(7) Check fuel pump pressure at idle and different
RPM ranges. Refer to Group 14, Fuel System for
Specifications.
(8) The air filter elements should be replaced as
specified in Group 0, Lubrication and Maintenance.
(9) Inspect crankcase ventilation system as out-
lined in Group 25, Emission Control Systems.
(10) Road test vehicle as a final test.
HONING CYLINDER BORES
(1) Used carefully, the cylinder bore resizing hone
C-823 equipped with 220 grit stones, is the best tool
for this job. In addition to deglazing, it will reduce
taper and out-of-round as well as removing light
scuffing, scoring or scratches. Usually a few strokes
will clean up a bore and maintain the required lim-
its.
(2) Deglazing of the cylinder walls may be done
using a cylinder surfacing hone, Tool C-3501,
equipped with 280 grit stones, if the cylinder bore is
straight and round. 20-60 strokes depending on the
bore condition, will be sufficient to provide a satisfac-
tory surface. Inspect cylinder walls after each 20
strokes, using a light honing oil.Do not use engine
or transmission oil, mineral spirits or kerosene.
(3) Honing should be done by moving the hone up
and down fast enough to get a cross-hatch pattern.
When hone marksintersectat 50-60 degrees, the
cross hatch angle is most satisfactory for proper seat-
ing of rings (Fig. 2).(4) A controlled hone motor speed between
200-300 RPM is necessary to obtain the proper cross-
hatch angle. The number of up and down strokes per
minute can be regulated to get the desired 50-60
degree angle. Faster up and down strokes increase
the cross-hatch angle.
(5) After honing, it is necessary that the block be
cleaned again to remove all traces of abrasive.
CAUTION: Ensure all abrasives are removed from
engine parts after honing. It is recommended that a
solution of soap and hot water be used with a
brush and the parts then thoroughly dried. The bore
can be considered clean when it can be wiped
clean with a white cloth and cloth remains clean.
Oil the bores after cleaning to prevent rusting.
MEASURING MAIN BEARING AND CONNECTING
ROD BEARING CLEARANCES
PLASTIGAGE METHOD
Engine crankshaft bearing clearances can be deter-
mined by use of Plastigage or equivalent. The follow-
ing is the recommended procedure for the use of
Plastigage:
NOTE: The total clearance of the main bearings
can only be determined by removing the weight of
the crankshaft. This can be accomplished by either
of two methods:
PREFERRED METHOD
Shimming the bearings adjacent to the bearing to
be checked in order to remove the clearance between
upper bearing shell and the crankshaft. This can be
accomplished by placing a minimum of 0.254 mm
(0.010 in.) shim (e. g. cardboard, matchbook cover,
etc.) between the bearing shell and the bearing cap
on the adjacent bearings and tightening bolts to
14-20 N´m (10-15 ft. lbs.). The number of main bear-
ing will vary from engine to engine.
Fig. 2 Cylinder Bore Cross-Hatch Pattern
Fig. 3 Plastigage Placed in Lower Shell
NSENGINE 9 - 3
GENERAL INFORMATION (Continued)

ENGINE WITH 5 MAIN BEARINGS
²When checking #1 main bearing shim #2 main
bearing.
²When checking #2 main bearing shim #1 & 3
main bearing.
²When checking #3 main bearing shim #2 & 4
main bearing.
²When checking #4 main bearing shim #3 & 5
main bearing.
²When checking #5 main bearing shim #4 main
bearing.
ENGINE WITH 4 MAIN BEARING
²When checking #1 main bearing shim # 2 main
bearing.
²When checking #2 main bearing shim #1 & #3
main bearing.
²When checking #3 main bearing shim #2 & #4
main bearing.
²When checking #4 main bearing shim #3 main
bearing.
NOTE: REMOVE ALL SHIMS BEFORE REASSEM-
BLING ENGINE
ALTERNATIVE METHOD
The weight of the crankshaft can be supported by a
jack under the counterweight adjacent to the bearing
being checked.
PLASTIGAGE PROCEDURE
(1) Remove oil film from surface to be checked.
Plastigage is soluble in oil.
(2) Place a piece of Plastigage across the entire
width of the bearing shell in the cap approximately
6.35 mm (1/4 in.) off center and away from the oil
holes (Fig. 3). (In addition, suspected areas can be
checked by placing the Plastigage in the suspected
area). Torque the bearing cap bolts of the bearing
being checked to the proper specifications.
(3) Remove the bearing cap and compare the
width of the flattened Plastigage (Fig. 4) with the
metric scale provided on the package. Locate the
band closest to the same width. This band shows theamount of clearance in thousandths of a millimeter.
Differences in readings between the ends indicate the
amount of taper present. Record all readings taken.
Refer to Engine Specifications.Plastigage gener-
ally is accompanied by two scales. One scale is
in inches, the other is a metric scale.
NOTE: Plastigage is available in a variety of clear-
ance ranges. Use the most appropriate range for
the specifications you are checking.
CONNECTING ROD BEARING CLEARANCE
Engine connecting rod bearing clearances can be
determined by use of Plastigage or equivalent. The
following is the recommended procedure for the use
of Plastigage:
(1) Rotate the crankshaft until the connecting rod
to be checked is at the bottom of its stroke.
(2) Remove oil film from surface to be checked.
Plastigage is soluble in oil.
(3) Place a piece of Plastigage across the entire
width of the bearing shell in the bearing cap approx-
imately 6.35 mm (1/4 in.) off center and away from
the oil hole (Fig. 3). In addition, suspect areas can be
checked by placing plastigage in the suspect area.
(4) Assemble the rod cap with Plastigage in place.
Tighten the rod cap to the specified torque.Do not
rotate the crankshaft while assembling the cap
or the Plastigage may be smeared, giving inac-
curate results.
(5) Remove the bearing cap and compare the
width of the flattened Plastigage (Fig. 4) with the
scale provided on the package. Locate the band clos-
est to the same width. This band indicates the
amount of oil clearance. Differences in readings
between the ends indicate the amount of taper
present. Record all readings taken. Refer to Engine
Specifications.Plastigage generally is accompa-
nied by two scales. One scale is in inches, the
other is a metric scale. If the bearing clearance
exceeds 0.076 mm (0.003 in.) replace bearing.
NOTE: Plastigage is available in a variety of clear-
ance ranges. Use the most appropriate range for
the specifications you are checking.
REPAIR OF DAMAGED OR WORN THREADS
Damaged or worn threads (including aluminum
head spark plug threads) can be repaired. Essen-
tially, this repair consists of drilling out worn or
damaged threads, tapping the hole with a special
Heli-Coil Tap, (or equivalent) and installing an insert
into the tapped hole. This brings the hole back to its
original thread size.
Fig. 4 Clearance Measurement
9 - 4 ENGINENS
GENERAL INFORMATION (Continued)

BALANCE SHAFTS
Balance shaft lubrication is provided through an
oil passage from the number 1 main bearing cap
through the balance shaft carrier support leg. This
passage directly supplies oil to the front bearings and
internal machined passages in the shafts that routes
oil from front to rear shaft bearing journals
SPLASH LUBRICATION
Oil returning to the pan from pressurized compo-
nents supplies lubrication to the valve stems. Cylin-
der bores and wrist pins are splash lubricated from
directed slots on the connecting rod thrust collars.
ENGINE COMPONENTS
BALANCE SHAFTS:2.4L engines are equipped
with two balance shafts installed in a carrier
attached to the lower crankcase. The shafts intercon-
nect through gears to rotate in opposite directions.These gears are driven by a short chain from the
crankshaft, to rotate at two times crankshaft speed.
This counterbalances certain engine reciprocating
masses.
CYLINDER BLOCK AND BEDPLATE ASSEM-
B LY:A closed deck design is used for cooling and
weight reduction with water pump molded into the
block. Nominal wall thickness is 4.5 mm. The bed-
plate incorporates main bearing caps. Rear seal
retainer is integral with the block.
CRANKSHAFT:A nodular cast iron crankshaft is
used. The engine has 5 main bearings, with number
3 flanged to control thrust. The 60 mm diameter
main and 50 mm diameter crank pin journals (all)
have undercut fillets that are deep rolled for added
strength. To evenly distribute bearing loads and min-
imize internal stress, 8 counterweights are used.
Hydrodynamic seals provide end sealing, where the
crankshaft exits the block. Anaerobic gasket material
is used for parting line sealing in the block. A sin-
tered powder metal timing belt sprocket is mounted
on the crankshaft nose. This sprocket provides
motive power; via timing belt to the camshaft sprock-
ets (providing timed valve actuation) and to the
water pump.
PISTONS:There is provisions for free wheeling
valve train. Piston has a unique height. All engines
use pressed in piston pins to attach forged powder
metal connecting rods. Incorporate hex head cap
screw threaded into the connecting rod. Piston and
Rods are serviced as a assembly.
PISTONS RINGS:The piston rings include a
molybdenum faced top ring for reliable compression
EngineÐ2.4L
Fig. 1 Engine Identification
NS2.4L ENGINE 9 - 15
DESCRIPTION AND OPERATION (Continued)

(4) Apply 1.5 to 2.0 mm (0.059 to 0.078 in.) bead
of anaerobic sealer MopartTorque Cure Gasket
Maker to cylinder block as shown in (Fig. 12).
(5) Install lower main bearings into main bearing
cap/bedplate. Make certain the bearing tabs are
seated into the bedplate slots. Install the main bear-
ing/bedplate into engine block.
(6) Before installing bolts, lubricate the threads
with clean engine oil, wipe off any excess oil.
(7) Install main bearing bedplate to engine block
bolts 11, 17 and 20 finger tight. Tighten these bolts
down together until the bedplate contacts the cylin-
der block.
(8) To ensure correct thrust bearing alignment,
perform the following steps:
²Step 1: Rotate crankshaft until number 4 piston
is at TDC.
²Step 2: Move crankshaft rearward to limits of
travel.²Step 3: Then, move crankshaft forward to limits
of travel.
²Step 4: Wedge an appropriate tool between the
rear of the cylinder block(NOT BED PLATE)and
the rear crankshaft counterweight. This will hold the
crankshaft in it's furthest forward position.
²Step 5: Install and tighten bolts (1 ± 10) in
sequence shown in (Fig. 13) to 41 N´m (30 ft. lbs.).
²Step 6: Remove wedge tool used to hold crank-
shaft.
(9) Tighten bolts (1 ± 10) again to 41 N´m (30 ft.
lbs.) + 1/4 turn in sequence shown in (Fig. 13).
(10) Install main bearing bedplate to engine block
bolts (11 through 20), and torque each bolt to 28 N´m
(20 ft. lbs.) in sequence shown in (Fig. 13).
(11) After the main bearing bedplate is installed,
check the crankshaft turning torque. The turning
torque should not exceed 5.6 N´m (50 in. lbs.).
CRANKSHAFT END PLAY
(1) Mount a dial indicator to front of engine, locat-
ing probe on nose of crankshaft (Fig. 14).
(2) Move crankshaft all the way to the rear of its
travel.
(3) Zero the dial indicator.
(4) Move crankshaft all the way to the front and
read the dial indicator. Refer to Crankshaft Specifi-
cation Chart for end-play specification.
Fig. 12 Main Bearing Caps/Bedplate Sealing
Fig. 13 Main Bearing Caps/Bedplate Torque
SequenceFig. 14 Checking Crankshaft End PlayÐTypical
CRANKSHAFT SPECIFICATION CHART
Crankshaft End-Play
New Part: 0.09 - 0.24mm
(0.0035 - 0.0094 in.)
Wear Limit: 0.37 mm
(0.015 in.)
9 - 20 2.4L ENGINENS
SERVICE PROCEDURES (Continued)

ENGINE ASSEMBLY
REMOVAL
(1) Perform fuel pressure release procedure. Refer
to Group 14, Fuel System for procedure. Remove fuel
line to fuel rail.
(2) Disconnect battery.
(3) Remove Air cleaner and hoses.
(4) Drain cooling system. Refer to Group 7, Cooling
System for procedure.
(5) Remove upper radiator hose and remove radia-
tor fans. Refer to Group 7, Cooling System for proce-
dure.
(6) Remove lower radiator hose.
(7) Disconnect automatic transmission cooler lines
and plug, if equipped.
(8) Disconnect transmission shift linkage.
(9) Disconnect throttle body linkage.
(10) Disconnect engine wiring harness.
(11) Disconnect heater hoses.
(12) Discharge Air Conditioning System. Refer to
Group 24, Air Conditioning for procedure.
(13) Hoist vehicle and remove right inner splash
shield. Remove wheels and tires.
(14) Loosen power steering belt for pump removal.
Refer to Group 7, Cooling System for procedure.
(15) Remove axle shafts. Refer to Group 2, Suspen-
sion and Driveshafts for procedure.
(16) Disconnect exhaust pipe from manifold.
(17) Remove front and rear engine mount brackets
from the body.
(18) Remove bending braces and front engine
mount bracket. Remove transmission inspection
cover.
(19) Mark flexplate to torque converter and
remove torque converter bolts.
(20) Install front engine mount bracket.
(21) Lower vehicle.
(22) Remove power steering pump. Set pump
aside.
(23) Remove A/C lines at compressor and cap.
(24) Remove ground straps to body.
(25) Raise vehicle enough to allow engine dolly
Special Tool 6135, cradle Special Tool 6710 with
Posts Special Tool 6848 and Adaptor Special Tool
8130 to be installed under vehicle (Fig. 27).
(26) Loosen cradle posts to allow movement for
proper positioning. Locate two rear posts (right side
of engine) into the holes on the engine bedplate.
Locate the two front posts (left side of engine) on the
front engine bracket and A/C compressor bracket
(Fig. 27). 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.(27) Lower vehicle so the weight ofONLY THE
ENGINE AND TRANSMISSIONare on the cradle.
(28) Remove engine and transmission mount bolts.
(29) Raise vehicle slowly. It may be necessary to
move the engine/transmission assembly on the cradle
to allow for removal around the body.
INSTALLATION
(1) Position engine and transmission assembly
under vehicle and slowly lower the vehicle over the
engine and transmission.
(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 and 6710.
(4) Install axle shafts. Refer to Group 2, Suspen-
sion and Driveshafts for procedure.
(5) Install transmission and engine braces and
splash shields.
(6) Connect exhaust system to manifold. Refer to
Group 11, Exhaust System and Intake Manifold for
procedure and torque specifications.
(7) Install power steering pump. Refer to Cooling
System Group 7, Accessory Drive Section for belt ten-
sion adjustment.
(8) Install A/C compressor hoses. Refer to Group
24, Heater and Air Conditioning for procedure.
(9) Install accessory drive belts. Refer to Group 7,
Cooling System Accessory Drive Section for belt ten-
sion adjustment.
(10) Install front and rear engine mounts. Refer to
this section for procedure.
(11) Install inner splash shield. Install wheels and
tires.
(12) Connect automatic transmission cooler lines,
and shift linkage. Refer to Group 21, Transmission
for procedures.
(13) Connect fuel line and heater hoses.
(14) Install ground straps. Connect engine and
throttle body connections and harnesses. Refer to
Group 8, Electrical for procedure.
(15) Connect throttle body linkage. Refer to Group
14, Fuel System for procedure.
(16) Install radiator fans. Install radiator hoses.
Fill cooling system. Refer to Group 7, Cooling System
for filling procedure.
(17) Connect battery.
(18) Install air cleaner and hoses.
(19) Install oil filter. Fill engine crankcase with
proper oil to correct level.
(20) Start engine and run until operating temper-
ature is reached.
(21) Adjust transmission linkage, if necessary.
9 - 26 2.4L ENGINENS
REMOVAL AND INSTALLATION (Continued)

(7) Install main bearing bedplate to engine block
bolts 11, 17 and 20 finger tight. Tighten these bolts
down together until the bedplate contacts the cylin-
der block.
(8) To ensure correct thrust bearing alignment per-
form the following steps:
²Step 1: Rotate crankshaft until number 4 pis-
ton is at TDC.
²Step 2: Move crankshaft rearward to limits of
travel.
²Step 3: Then, move crankshaft forward to lim-
its of travel.
²Step 4: Wedge an appropraite tool between the
rear of the cylinder block(NOT BED PLATE)and
the rear crankshaft counterweight. This will hold the
crankshaft in it's furthest forward position.
²Step 5: Install and tighten bolts (1-10) in
sequence shown in (Fig. 84) to 41 Nzm (30 ft. lbs.).
²Step 6: Remove wedge tool used to hold crank-
shaft.
(9) Tighten bolts (1-10) again to 41 Nzm (30 ft. lbs)
+ 1/4 turn in sequence shown in (Fig. 84).
(10) Install main bearing bedplate to engine block
bolts (11-20), and torque each bolt to 28 Nzm (20 ft.
lbs.) in sequence shown in (Fig. 84).
(11) After the main bearing bedplate is installed,
check the crankshaft turning torque. The turning
torque should not exceed 5.6 Nzm (50 in. lbs.).
OIL FILTER
CAUTION: When servicing the oil filter avoid
deforming the filter can by installing the remove/in-
stall 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) Turn counterclockwise to remove.
(2) To install, lubricate new filter gasket. Check
filter mounting surface. The surface must be smooth,
flat and free of debris or old pieces of rubber. Screw
filter on until the gasket contacts base. Tighten to 21
N´m (15 ft. lbs.).
OIL PUMP
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove Timing Belt. Refer to procedure out-
lined in this section.
(3) Remove Oil Pan. Refer to procedure outlined in
this section.
(4) Remove Crankshaft Sprocket using Special Tool
6793 and insert C-4685-C2 (Fig. 85).
(5) Remove oil pick-up tube.
(6) Remove oil pump, (Fig. 86) and front crank-
shaft seal.
Fig. 85 Crankshaft SprocketÐRemoval
NS2.4L ENGINE 9 - 47
REMOVAL AND INSTALLATION (Continued)

SPECIFICATIONS
2.4L ENGINE
Type....................In-Line OHV, DOHC
Number of Cylinder.......................4
Bore.....................87.5 mm (3.445 in.)
Stroke....................101 mm (3.976 in.)
Compression Ratio......................9.4:1
Displacement.......2.4 Liters (148 Cubic Inches)
Firing Order.......................1,3,4,2
Compression Pressure...........1172-1551 kPa
(170-225 psi)
Maximum Variation Between Cylinder......25%
Lubrication. . . .Pressure Feed-Full Flow Filtration
(Direct Crankshaft Driven Pump)
Cylinder Block
Cylinder Bore Diameter. . . .87.4924 - 87.5076 mm
(3.4446 - 3.4452 in.)
Out-of-Round (Max.)........0.051 mm (0.002 in.)
Taper (Max.)..............0.051 mm (0.002 in.)
Pistons
Clearance at 14 mm (9/16 in.)
From Bottom of Skirt.........0.024 - 0.057 mm
(0.0009 - 0.0022 in.)
Weight......................332 - 346 grams
(11.85 - 12.20 oz.)
Top Land Clearance
(Diametrical)................0.614 - 0.664 mm
(0.024 - 0.026 in.)
Piston Length.............60.30 mm (2.374 in.)
Piston Ring Groove Depth
No.1........4.640 - 4.784 mm (0.182 - 0.188 in.)
No.2........4.575 - 4.719 mm (0.180 - 0.185 in.)
No.3........4.097 - 4.236 mm (0.161 - 0.166 in.)
Piston Pins
Clearance in Piston...........0.005 - 0.018 mm
In Rod (Interference)..........0.018 - 0.043 mm
(0.0007 - 0.0017 in.)
Diameter.................21.998 - 22.003 mm
(0.8660 - 0.8662 in.)
End Play.............................None
Length.....................72.75 - 73.25 mm
(2.864 - 2.883 in.)
Piston Ring Gap
Top Compression Ring...........0.25 - 0.51 mm
(0.0098 - 0.020 in.)
2nd Compression Ring...........0.23 - 0.48 mm
(0.009 - 0.018 in.)
Oil Control (Steel Rails).........0.25 - 0.64 mm
(0.0098 - 0.025 in.)
Piston Ring Side Clearance
Top and Second
Compression Rings...........0.030 - 0.080 mm
(0.0011 - 0.0031 in.)Oil Ring (Pack)..............0.012 - 0.178 mm
(0.0004 - 0.0070 in.)
Piston Ring Width
Compression Rings.............1.47 - 1.50 mm
(0.057 - 0.059 in.)
Oil Ring (Pack)................2.72 - 2.88 mm
(0.107 - 0.1133 in.)
Connecting Rod
Bearing Clearance............0.025 - 0.071 mm
(0.0009 - 0.0027 in.)
Piston Pin Bore Diameter......20.96 - 20.98 mm
(0.8252 - 0.8260 in.)
Large End Bore Diameter. . . .53.007 - 52.993 mm
(2.0868 - 2.0863)
Side Clearance..............0.013 - 0.0150 mm
(0.0051 - 0.0150 in.)
Total Weight (Less Bearing).........565.8 grams
(19.96 oz.)
Crankshaft
Connecting Rod
Journal Diameter..........49.984 - 50.000 mm
(1.967 - 1.9685 in.)
Out-of-Round (Max.)......0.0035 mm (0.0001 in.)
Taper (Max.)............0.0038 mm (0.0001 in.)
Main Bearing Diametrical
Clearance No.1-5...........0.018 - 0.058 mm
(0.0007 - 0.0023 in.)
End Play.....................0.09 - 0.24 mm
(0.0035 - 0.0094 in.)
Main Bearing Journals
Diameter.................59.992 - 60.008 mm
(2.361 - 2.3625 in.)
Out-of-Round (Max.)......0.0035 mm (0.0001 in.)
Taper (Max.)...............0.0038 (0.0001 in.)
Hydraulic Lash Adjusters
Body Diameter.............15.901 - 15.913 mm
(0.626 - 0.6264 in.)
Plunger Travel Minimum (Dry)..........3.0 mm
(0.118 in.)
Camshaft
Bearing Bore
Diameters No. 1±6..........26.020 - 26.041 mm
(1.024 - 1.025 in.)
Diametrical Bearing Clearance . .0.069 - 0.071 mm
(0.0027 - 0.003 in.)
End Play...................0.050 - 0.170 mm
(0.0019 - 0.0066 in.)
Bearing Journal
Diameter No. 1±6..........25.951 - 25.970 mm
(1.021 - 1.022 in.)
Lift (Zero Lash) Intake.......8.25 mm (0.324 in.)
Lift (Zero Lash) Exhaust.....6.52 mm (0.256 in.)
Valve Timing ± Intake Valve
Closes (ABDC)..........................51É
Opens (BTDC)...........................1É
NS2.4L ENGINE 9 - 55

3.0L ENGINE
INDEX
page page
DESCRIPTION AND OPERATION
ENGINE COMPONENTS.................. 61
ENGINE IDENTIFICATION NUMBER......... 61
ENGINE LUBRICATION................... 61
DIAGNOSIS AND TESTING
CHECKING ENGINE OIL PRESSURE......... 62
SERVICE PROCEDURES
AUTO LASH ADJUSTER................... 62
CHECKING CRANKSHAFT END PLAY........ 65
FITTING CONNECTING ROD BEARINGS...... 63
FITTING MAIN BEARING.................. 63
VALVE SERVICE RECONDITION............ 66
REMOVAL AND INSTALLATION
CAMSHAFT SEAL....................... 72
CAMSHAFT............................ 71
CRANKSHAFT.......................... 81
CYLINDER HEAD COVER................. 70
CYLINDER HEAD........................ 73
ENGINE ASSEMBLY...................... 69
ENGINE MOUNTS....................... 68
FRONT CRANKSHAFT OIL SEAL............ 83OIL FILTER AND ADAPTOR................ 84
OILPAN ............................... 77
OIL PUMP............................. 84
PISTON AND CONNECTING ROD........... 78
REAR CRANKSHAFT SEAL................ 83
ROCKER ARMS......................... 72
TIMING BELT........................... 75
DISASSEMBLY AND ASSEMBLY
ROCKER ARMS AND SHAFTS.............. 85
CLEANING AND INSPECTION
CYLINDER BORE........................ 87
CYLINDER HEAD........................ 86
OIL PUMP............................. 87
TIMING BELT........................... 86
ADJUSTMENTS
ENGINE MOUNTS....................... 88
SPECIFICATIONS
3.0L ENGINE........................... 89
TORQUE CHART 3.0L.................... 90
SPECIAL TOOLS
3.0L ENGINE........................... 91
DESCRIPTION AND OPERATION
ENGINE IDENTIFICATION NUMBER
The engine identification number is located on the
rear of the cylinder block just below the cylinder
head (Fig. 1).
ENGINE LUBRICATION
System is a full flow filtration, pressure feed type.
The oil pump is mounted behind the timing belt
cover. The pump inner rotor is driven by the crank-
shaft. The engine oil pan contains a baffle plate to
control oil level fluctuation during engine operation.
ENGINE COMPONENTS
BLOCK:The cylinder block is a light weight
design created by reducing thickness in many parts
and a short 10 mm (3/8 in.) block skirt. High rigidity
is provided with ribs cast in the outer wall, a full
length water jacket, and a mono-block or beam type,
main bearing cap. This single unit four bearing cap
is designed to control vibration of the cylinder block
partition walls.
CRANKSHAFT:A six throw, five weight crank-
shaft is supported by four main bearings with num-
ber three being the thrust bearing. The six separate
connecting rod throws pins reduce torque fluctua-tions while a torsional vibration damper is used to
control torsion caused vibration of the crankshaft.
Rubber lipped seals are used at front and rear. The
Fig. 1 Engine Identification
NS3.0L ENGINE 9 - 61

front seal is retained in the oil pump case and the
rear is retained in a block-mounted housing.
PISTONS:Are aluminum alloy with a steel strut,
short height, and thin wall so as to be autothermic
and light weight. The piston head with valve
recesses, in combination with the cylinder head,
forms a compact spherical head with clearance for
total valve lift with pistons at top dead center. The
piston skirt, top and second ring lands are finished to
a tapered roughness for oil retention and high resis-
tance to scuffing. Piston pins, pressed into place, join
the pistons to the connecting rods.
CYLINDER HEAD:The alloy cylinder heads fea-
ture cross-flow type intake and exhaust ports. Valve
guides and inserts are hardened cast iron. Valves of
heat resistance steel are arranged in a V with each
camshaft on center. To improve combustion speed the
chambers are a compact spherical design with a
squish area of approximately 30 percent of the piston
top area. The cylinder heads are common to either
cylinder bank by reversing the direction of installa-
tion.
CAMSHAFTS:Two overhead camshafts provide
valve actuation, one front (radiator side of cylinder
bank) and one rear. The front camshaft is provided
with a distributor drive and is longer. Both cam-
shafts are supported by four bearing journals, thrust
for the front camshaft is taken at journal two and
the rear at journal three. Front and rear camshaft
driving sprockets are interchangeable. The sprockets
and the engine water pump are driven by a single
notched timing belt.
ROCKER ARM SHAFTS:The shafts are retained
by the camshaft bearing journal caps. Four shafts are
used, one for each intake and exhaust rocker arm
assembly on each cylinder head. The hollow shafts
provide a duct for lubricating oil flow from the cylin-
der head to the valve mechanisms.
ROCKER ARMS:Are of light weight die-cast with
roller type follower operating against the cam shaft.
The valve actuating end of the rocker arms are
machined to retain hydraulic lash adjusters, elimi-
nating valve lash adjustment.
VALVES:Are made of heat resistant steel, valve
springs are especially designed to be short. The valve
spring wire cross-section is oval shaped and provides
the same spring tension as longer springs. Valve
spring retainers, locks and seals are conventional.
INTAKE MANIFOLD:The aluminum alloy mani-
fold is a cross type with long runners to improve
inertia. The runners, attaching below at the cylinder
head, also attach above and support an air plenum.
The air plenum chamber absorbs air pulsations cre-
ated during the suction phase of each cylinder.
EXHAUST MANIFOLDS:Both manifolds are a
log style made of ductile cast iron. Exhaust gasses,collected from the front cylinder bank, leave the front
manifold through an end outlet and are fed through
an upper crossover tube to the rear manifold. The
collected exhaust from both manifolds are combined,
and exit to the exhaust pipe through an articulated
joint.
DIAGNOSIS AND TESTING
CHECKING ENGINE OIL PRESSURE
Check oil pressure using gauge at oil pressure
switch location. Oil pressure should be 41 kPa ( 6
psi.) at idle or 241 to 517 kPa (35 to 75 psi.) at 3000
RPM.
(1) Remove pressure sending unit and install oil
pressure gauge. (Fig. 2).
CAUTION: If oil pressure is 0 at idle, Do Not Run
engine at 3000 RPM.
(2) Warm engine at high idle until thermostat
opens.
SERVICE PROCEDURES
AUTO LASH ADJUSTER
The automatic lash adjusters are precision units
installed in machined openings in the valve actuating
ends of the rocker arms. Do not disassemble the auto
lash adjuster.
FUNCTION CHECK
Check auto adjusters for free play by inserting a
small wire through the air bleed hole in the rocker
arm andvery lightlypushing the auto adjuster ball
check down (Fig. 3). While lightly holding the check
ball down move the rocker up and down to check for
free play. If there is no play replace the adjuster.
Fig. 2 Checking Engine Oil Pressure
9 - 62 3.0L ENGINENS
DESCRIPTION AND OPERATION (Continued)

CAUTION: Do not rotate crankshaft or the plasti-
gage will be smeared.
(4) Install the main bearing cap carefully and
tighten the bolts to specified torque.(5) Carefully remove the bearing cap and measure
the width of the plastigage at the widest part using
the scale on the plastigage package (Fig. 9). Refer to
Crankshaft Clearance Specification Chart for proper
clearances. Also see Measuring Main and Connecting
Rod Bearing Clearance in Standard Service Proce-
dures.
CRANKSHAFT BEARING INSTALLATION
When the bearings need replacing, select and
install the proper bearing by the following procedure.
(1) Measure the crankshaft journal diameter and
confirm its classification from the following. In the
case of a bearing supplied as a service part, its iden-
tification color is painted at the position show in (Fig.
10).
NOTE: Service replacement parts have identifica-
tion marks, but factory-assembled parts have no
identification marks. Service crankshaft identifica-
tion may have marks or paint at counterweights.
Refer to Crankshaft Size Classification Chart.
Fig. 6 Measure Crankshaft Journal O.D.
Fig. 7 Measure Main Bearing I.D.
CRANKSHAFT SPECIFICATION CHART
Crankshaft End-Play
New Part: 0.05 - 0.25 mm
(0.002 - 0.001 in.)
Wear Limit: 0.30 mm (0.012 in.)
Main Bearing Oil Clearance
New Part: 0.018 - 0.036 mm
(0.0007 - 0.0014 in.)
Wear Part: 0.10 mm (0.0039 in.)
Crankshaft Main Bearing Journal
Standard Diameter: 59.980 mm (2.361 in.)
Crankshaft Connecting Rod Journal
Standard Diameter: 50.00 mm (1.968 in.)
Fig. 8 Measure Oil Clearance with Plastigage
Fig. 9 Measuring Clearance
9 - 64 3.0L ENGINENS
SERVICE PROCEDURES (Continued)