engine CHRYSLER VOYAGER 1996 Service Manual

(36) Operate the engine with the radiator cap off.
Inspect for leaks and continue operating the engine
until the thermostat opens. Add coolant, if required.
VALVES AND VALVE SPRINGSÐHEAD OFF
This procedure is done with the engine cylinder
head removed from the block.
REMOVAL
(1) Remove the engine cylinder head from the cyl-
inder block. Refer to cylinder head removal in this
section.
(2) Use Valve Spring Compressor Tool and com-
press each valve spring.
(3) Remove the valve locks, retainers, and springs.
(4) Use an Arkansas smooth stone or a jewelers
file to remove any burrs on the top of the valve stem,
especially around the groove for the locks.
(5) Remove the valves, and place them in a rack in
the same order as removed.
INSTALLATION
(1) Fit each valve to its respective valve guide.
NOTE: If valves and valve seats have been refaced
refer to Service Procedures in this section. Follow
The Valve Stand Down procedure.
(2) Install lower, washer and spring.
(3) Install upper spring collar, and compress valve
spring with spring compressor tool. Install split cone
retainers.
HYDRAULIC TAPPETS
REMOVAL
(1) Remove coolant pressure bottle.
(2) Remove cylinder head cover. Refer to cylinder
head cover removal in this section.
(3) Remove rocker assembly and push rods. Iden-
tify push rods to ensure installation in original loca-
tion (Fig. 34).
(4) Remove cylinder head, intake manifold, and
exhaust manifold. Refer to cylinder head removal in
this section.
(5) Remove yoke retainer and aligning yokes (Fig.
35).
(6) Slide Hydraulic Tappet Remover/Installer Tool
through opening in block and seat tool firmly in the
head of tappet.
(7) Pull tappet out of bore with a twisting motion.
If all tappets are to be removed, identify tappets to
ensure installation in original location.
(8) If the tappet or bore in cylinder block is scored,
scuffed, or shows signs of sticking, ream the bore to
next oversize. 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 dis-
assemble a tappet on a dirty work bench.
INSTALLATION
(1) Lubricate tappets.
(2) Install tappets and yoke retainers in their orig-
inal positions. Ensure that the oil feed hole in the
side of the tappet body faces up (away from the
crankshaft).
Fig. 34 Tappet and Rocker Arm Assembly
Fig. 35 Tappet and Yoke
9 - 60 ENGINENS/GS
REMOVAL AND INSTALLATION (Continued)

(3) Install cylinder head, intake manifold, and
exhaust manifold. Refer to cylinder head installation
in this section.
(4) Install push rods in original positions.
(5) Install rocker arms in original positions.
(6) Install cylinder head cover. Refer to cylinder
valve cover installation in this section.
(7) 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.
VIBRATION DAMPER
REMOVAL
(1) Disconnect the battery cable.
(2) Raise vehicle on hoist.
(3) Remove right side lower splash shield.
(4) Remove generator, power steering belt. Refer to
Group 7, Cooling.
(5) Remove water pump belt. Refer to Group 7,
Cooling.
(6) Remove engine starter. Refer to Group, 8B for
procedure
(7) Install flywheel locking tool VM.1014 to pre-
vent engine rotation.
NOTE: Crankshaft damper nut is left handed
thread.
(8) Remove vibration damper nut.
(9) Remove vibration damper. No special tool is
needed for removal.
CAUTION: If thread sealant is used it is important
to remove all the old thread sealant from the
threads on the crankshaft.
INSTALLATION
NOTE: Before installing damper be sure the O-ring
inside the center of the damper is in its grove.
(1) Install vibration damper.
CAUTION: Correct torque on the vibration damper
nut is important or engine damage can occur.
(2) Install vibration damper nut and tighten to 441
N´m (325 ft. lbs.).
(3) Remove flywheel locking tool, and install
engine starter.(4) Install both accessary drive belts. Refer to
Group 7, Cooling.
(5) Install right splash shield.
(6) Lower vehicle.
(7) Connect the battery cable.
TIMING GEAR COVER OIL SEAL
REMOVAL
(1) Disconnect the battery cable.
(2) Remove vibration damper. Refer to vibration
damper removal in this section.
(3) Pry out seal (Fig. 36).
INSTALLATION
Remove the oil seal ring. The seating diameter
must be 68.000 - 68.030 mm.
(1) Install new seal using special tool VM-1015.
(2) Install vibration damper. Refer to vibration
damper installation in this section.
(3) Connect the battery cable.
INJECTION PUMP
For removal and installation of injection pump
refer to Group 14, Fuel.
TIMING GEAR COVER
REMOVAL
(1) Disconnect the battery cable.
(2) Raise vehicle on hoist.
(3) Remove right splash shield.
(4) Remove accessary drive belts. Refer to Group 7,
Cooling.
(5) Remove vibration damper nut.
NOTE: Crankshaft damper nut is left handed
thread.
(6) Remove vibration damper.
Fig. 36 Front Cover Seal
NS/GSENGINE 9 - 61
REMOVAL AND INSTALLATION (Continued)

(7) Remove power steering/air conditioning pulley
nut. Remove pulley.
CAUTION: Remove old loctite from threads on
pump.
(8) Remove pump shaft support bracket assembly.
(9) Disconnect the water drain pipe hose at the
timing cover.
CAUTION: When separating the timing geat cover
from the block take care not to damage the mating
surface of the timing gear cover or block. Also take
care not to damage the timing gears or components
located inside the timing gear cover near the edge.
(10) Remove timing gear cover.
INSTALLATION
(1) Apply a continuous 3 mm bead of Silicone
Sealer to timing cover, install within 10 minutes,
tighten Torx bolts to 11 N´m (96 in. lbs) (Fig. 37).
(2) Install pump shaft support bracket assembly,
tighten nuts to 24.5 N´m (216 in. lbs.).
(3) Install Power steering/air conditioning pulley,
tighten to 170 N´m (125 ft. lbs.).
CAUTION: Correct torque on the power steering/air
conditioning pulley nut is important or engine dam-
age can occur.
(4) Connect water drain pipe hose at the timing
cover.NOTE: Before installing damper be sure O-ring on
inside center of damper is in place.
(5) Install vibration damper.
CAUTION: Correct torque on the vibration damper
nut is important or engine damage can occur.
(6) Tighten vibration damper nut to 441 N´m (325
ft. lbs.).
(7) Install accessary drive belts. Refer to Group 7,
cooling for procedure.
(8) Install splash shield.
(9) Lower vehicle.
(10) Connect battery cable.
CAMSHAFT
REMOVAL
(1) To service the camshaft (Fig. 38) the engine
must be removed from the vehicle.
(2) Remove valve cover. Refer to valve cover
removal in this section.
(3) Remove rocker arms and push rods. Identify
push rods to ensure installation in there original
location.
(4) Remove cylinder head. Refer to cylinder head
removal in this section.
(5) Remove hydraulic tappets. Refer to tappet
removal in this section.
(6) Remove vibration damper. Refer to vibration
damper removal in this section.
(7) Remove power steering pulley.
(8) Remove pump shaft support bracket.
(9) Remove timing gear cover. Refer to timing gear
cover removal in this section.
(10) Remove camshaft.
Fig. 37 Front Cover Sealer Location
Fig. 38 Camshaft Assembly
9 - 62 ENGINENS/GS
REMOVAL AND INSTALLATION (Continued)

THRUST PLATE INSPECTION
Check the thickness (Fig. 40) of the plate at points
a-b-c-d. If the measurement is not between 3.950 -
4.050 it must be changed.
INSTALLATION
(1) Coat the camshaft journals with clean engine
oil and carefully install the camshaft complete with
thrust plate and gear. Tighten the retaining bolts to
24 N´m. Be sure to align the timing marks as shown.(2) Install hydraulic tappets and retaining yokes.
(3) Install cylinder heads.
(4) Push rods, and rocker arm assemblies. In there
original location.
(5) Install valve cover.
(6) Install Timing case cover.
(7) Install Vibration damper.
(8) Reinstall Engine.
CAMSHAFT BEARINGS
This procedure requires that the engine is removed
from the vehicle.
REMOVAL
(1) With engine completely disassembled, drive out
rear cam bearing core hole plug.
(2) Install proper size adapters and horseshoe
washers (part of Camshaft Bearing Remover/Installer
Tool) at back of each bearing shell. Drive out bearing
shells.
INSTALLATION
(1) Install new camshaft bearings with Camshaft
Bearing Remover/Installer Tool 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. If the camshaft bearing shell oil holes
are not in exact alignment, remove and install them
correctly. Install a new core hole plug at the rear of
camshaft.Be sure this plug does not leak.
CRANKSHAFT MAIN BEARINGS
REMOVAL
(1) Disconnect battery cable.
(2) Remove engine from vehicle, refer to engine
removal in this section.
(3) Install engine to engine stand.
(4) Remove accessary drive system.
(5) Remove cylinder head cover, refer to cylinder
head cover removal in this section.
(6) Remove rocker arm and push rods, refer to
rocker arm and push rod section in this section.
(7) Remove intake, exhaust manifold and turbo-
charger, refer to Group 11, Exhaust System and
Intake Manifold.
(8) Remove water manifold.
(9) Remove oil feed lines to rocker arms.
(10) Remove cylinder heads.
(11) Remove oil pan and oil pick-up.
(12) Remove piston and connecting rods from
crankshaft journals.
Fig. 39 Camshaft Removal
Fig. 40 Camshaft Thrust Plate
NS/GSENGINE 9 - 63
REMOVAL AND INSTALLATION (Continued)

(13) Remove pistons and connecting rods from
block.
(14) Remove vibration damper. Refer to procedure
in this section.
(15) Remove front cover. Refer to procedure in this
section.
(16) Remove oil pump drive gear.
(17) Install special tool VM-1004 onto crankshaft
over gear (Fig. 41).
(18) Remove main bearing oil feed and carrier
locators from block.
(19) Remove flywheel and adaptor plate from
engine block.
(20) Remove thrust bearings from rear main bear-
ing carrier (Fig. 42).
(21) Slide crankshaft and bearing carriers rear-
ward to rear of block. If you encounter difficulty in
removing the complete assembly as previously
described, slide the assembly rearward sufficiently to
gain access to the main bearing carrier bolts. Mark
the carriers for assembly and remove the bolts, two
for each carrier (Fig. 43).
(22) Separate the two halves of each carrier,
remove from the crankshaft and temporarily re-as-
semble the carriers (Fig. 44). Withdraw the crank-
shaft through the rear of the crankcase.
INSTALLATION
NOTE: Assemble engine according to sequence
described, thus saving time and preventing dam-
ages to engine components. Clean parts with a suit-
able solvent and dry them with compressed airbefore assembly. Use new gaskets where applicable
and torque wrenches for correct tightening of com-
ponents.
(1) Thoroughly clean crankcase and oil passages,
and blow dry with compressed air.
(2) Install new main bearing shells in each of the
carrier halves. Assemble the carriers to the crank-
shaft journals, ensuring that the carriers are
installed in their original locations. Secure each car-
rier with the two bolts tightening evenly to 42 N´m
(31 ft. lbs.) (Fig. 44).
(3) Slide special tool (VM-1002) over the crank-
shaft gear and, insert the crankshaft and carrier
assembly into the crankcase in the same manner
used for removal.
(4) Align the holes in the lower carriers, with the
center of the crankcase webs (Fig. 45).
(5) Secure each carrier assembly to the crankcase
with the main bearing oil feed and carrier locators
and tighten them to 54 N´m (40 ft. lbs).
(6) Install rear main bearing carrier onto crank-
shaft ensuring arrow on bearing carrier aligns with
vertical web in center of crankcase.
(7) Install rear oil seal.
(8) Install new O-rings in adaptor plate.
(9) Install adaptor plate and tighten bolts to 47
N´m (35 ft. lbs.).
(10) Install bolts to main bearing carrier and
tighten to 26.5 N´m (20 ft. lbs.).
(11) Position flywheel and O-ring on crankshaft
and align bolt holes.
NOTE: For purposes of checking crankshaft end
play used flywheel bolts may be used. Final assem-
bly requires new flywheel bolts.
(12) Install 2 flywheel bolts, 180É apart, and
tighten bolts to 20 N´m plus 60É (15 ft. lbs.) plus 60É.
(13) Attach dial indicator to engine block.
(14) Move crankshaft toward front of engine and
zero indicator.
(15) Move crankshaft toward the rear of engine
and record measurement.
(16) Subtract specified crankshaft end play from
figure obtained. Crankshaft end play 0.08 to 0.21 mm
(0.0032 to 0.0083 in.).
(17) Select thrust washers which will give correct
end play.
(18) Remove tools and flywheel.
(19) Lubricate thrust washer halves and fit them
into the rear main bearing carrier.
(20) To verify correct end play, install 2 flywheel
bolts 180É apart, and tighten bolts to 20 N´m plus 60É
(15 ft. lbs. plus 60É).
(21) Measure crankshaft end play with a dial
gauge. Crankshaft end play should not exceed 0.08-
Fig. 41 Crankshaft Special Tool VM.1004
9 - 64 ENGINENS/GS
REMOVAL AND INSTALLATION (Continued)

0.21 mm (0.0032 to 0.0083 in.) (Fig. 46). If end clear-
ance exceeds these values install oversize thrust
washer.
CAUTION: Use NEW flywheel bolt for the following
procedure.
(22) Install new O-ring on flywheel. Install fly-
wheel. The 6 flywheel bolts must be tightened as fol-
lows:
a. Torque the 6 flywheel bolts to 60 N´m (44 ft.
lbs.).
b. Loosen 2 of the 6 bolts, 180É apart. Torque the 2
bolts to 20 N´m (180 in. lbs.). Then using a torque
angle gauge rotate the 2 bolts 65É additional.
c. Loosen the next 2 bolts, 180É apart and follow
the same procedure.d. Loosen the last 2 bolts, 180É apart and follow
the same procedure.
(23) Install Transmission. Refer to procedure in
Group 21, Transmission.
(24) Install pistons and connecting rod assemblies,
refer to piston and connecting rods in this section.
(25) Install oil pick up tube and tighten bolts to 25
N´m (18 ft. lbs.).
(26) Install oil pan, refer to oil pan installation in
this section.
(27) Install vacuum pump. Tighten retaining
screws to 20 N´m (15 ft. lbs.).
Fig. 42 Crankshaft and Bearings
Fig. 43 Carrier Bolts
Fig. 44 Crankshaft and Carrier Bearing Assembly
NS/GSENGINE 9 - 65
REMOVAL AND INSTALLATION (Continued)

CAUTION: The vacuum pump must be centered in
the block and tighten with two bolts. Ensure that
the pump spins freely. If vacuum pump drags ordoes not spin freely loosen bolts and perform pro-
cedures again.
(28) Before installing oil pump check pump bore
depth in block (A) and pump body height (B) (Fig.
47). Difference between A and B should be
0.020-0.082 mm (.0007 to 0032 in.).
(29) Install oil pump and tighten retaining screws
to 27 N´m (20 ft. lbs.). Check for normal backlash
between pump and crankshaft gears.
(30) Install oil pump drive Gear.
(31) Install front cover. Refer to procedure in this
section.
(32) Install vibration damper. Refer to procedure
in this section.
(33) Install cylinder heads. Refer to procedure in
this section.
(34) Install rocker arms and push rods. Refer to
procedure in this section.
(35) Install cylinder head cover. Refer to procedure
in this section.
(36) Install accessary drive system.
(37) Install engine in vehicle. Refer to procedure in
this section.
(38) Fill engine with the correct amount of fluids
specified.
(39) Connect battery cable.OIL PAN
REMOVAL
(1) Disconnect battery cable.
(2) Raise vehicle on hoist.
Fig. 45 Main Bearing Carrier Alignment
Fig. 46 Measuring Crankshaft End Play
Fig. 47 Oil Pump Bore Depth
9 - 66 ENGINENS/GS
REMOVAL AND INSTALLATION (Continued)

(3) Drain oil.
(4) Remove oil pan bolts (Fig. 48).
(5) Remove oil pan.
INSTALLATION
(1) Install oil pan. Apply a continuous 3 mm bead
of Silicone Sealer to oil pan, install within 10 min-
utes.
(2) Install oil pan bolts and torque bolts to 11 N´m
(8 ft. lbs.).
(3) Install oil drain plug tighten to 79 N´m (58 ft.
lbs).
(4) Lower vehicle.
(5) Fill engine with proper amount of oil.
(6) Connect battery cable.
OIL PUMP
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove right splash shield.
(3) Remove both accessory drive belts. Refer to
Group 7, Cooling.
(4) Remove pump shaft support bracket assembly.
(5) Remove vibration damper. Refer to Vibration
Damper Removal in this section.
NOTE: Crankshaft damper nut is left handed
thread.
(6) Remove front cover. Refer to Timing Gear
Cover Removal in this section.
(7) Remove oil pump.
INSTALLATION
(1) Install new O-ring and lubricate with clean
engine oil.
(2) Install oil pump and tighten retaining screws
to 27.5 N´m (240 in. lbs.).(3) Install front cover. Refer to Timing Gear Cover
Installation in this section.
(4) Install pump shaft support bracket assembly.
CAUTION: Correct torque on the vibration damper
nut is important or engine damage can occur.
(5) Install vibration damper. Torque nut to 441
N´m (325 ft. lbs.)
(6) Install both accessory drive belts. Refer to
Group 7, Cooling.
(7) Install right splash shield.
OIL PUMP PRESSURE RELIEF VALVE
REMOVAL
(1) Remove oil pan.
(2) Remove clip retaining relief valve.
(3) Remove relief valve cap, spring, and plunger
(Fig. 50).
(4) Check relief valve spring length. Relief valve
spring free length is 57.5mm (2.263 in.). If spring
length is less or spring is distorted it must be
replaced.
(5) Check plunger for scoring, replace if necessary.
INSTALLATION
(1) Thoroughly clean all components and relief
valve pocket in cylinder block.
(2) Fit plunger, spring and cap into block.
(3) Compress spring and install retaining clip.
Ensure clip is completely seated in groove.
Fig. 48 Oil Pan
Fig. 49 Oil Pump Drive Gear
NS/GSENGINE 9 - 67
REMOVAL AND INSTALLATION (Continued)

OIL FILTER ADAPTER AND OIL COOLER
REMOVAL
(1) Remove oil filter.
(2) Remove oil cooler adapter bolt.
(3) Remove oil cooler (Fig. 51).
INSTALLATION
(1) Install oil cooler with new gasket, tighten oil
cooler adapter bolt to 60 N´m (44 ft. lbs.).(2) Install oil filter adapter to oil cooler and
tighten to 49 N´m (36. lbs.).
(3) Install oil filter and tighten to 9.8 N´m (85 in.
lbs.) and add oil.
VACUUM PUMP
REMOVAL
(1) Remove the front cover refer to front cover
removal in this section.
(2) Remove 4 bolts.
(3) Remove vacuum pump.
INSTALLATION
(1) To install the vacuum pump, align the outer
part of the gear with the inner part using a screw-
driver or similar tool, align with timing marks on
gear set and install.
(2) Install bolts and tighten to 20 N´m (15 ft. lbs.).
(3) Install front cover.
PISTONS AND CONNECTING ROD
REMOVAL
(1) Disconnect the battery cable.
(2) Remove cylinder heads, refer to cylinder head
removal in this section.
(3) Raise vehicle on host.
(4) Remove oil pan, refer to oil pan removal in this
section.
(5) Remove top carbon ridge of cylinder bores with
a reliable ridge reamer before removing pistons from
cylinder block.Be sure to keep tops of pistons
Fig. 50 Oil Pressure Relief Valve
Fig. 51 Oil Cooler
Fig. 52 Vacuum Pump
9 - 68 ENGINENS/GS
REMOVAL AND INSTALLATION (Continued)

covered during this operation. Mark piston with
matching cylinder number.
(6) Pistons and connecting rods must be removed
from top of cylinder block. Rotate crankshaft so that
each connecting rod is centered in cylinder bore.
(7) Remove connecting rod cap. Push each piston
and rod assembly out of cylinder bore.
CAUTION: During piston and rod removal. DO NOT
rotate piston and connecting rod or damage to theoil jets extending out into the cylinder bore will
occur (Fig. 56).
NOTE: Be careful not to nick crankshaft journals.
(8) After removal, install bearing cap on the mat-
ing rod.
PISTON PINÐREMOVAL
(1) Secure connecting rod in a soft jawed vice.
(2) Remove 2 clips securing piston pin (Fig. 57).
(3) Push piston pin out of piston and connecting
rod.
Fig. 53 Vacuum Pump Parts
Fig. 54 Vacuum Pump Mounting Hole
Fig. 55 Timing Marks
Fig. 56 Oil Jets
NS/GSENGINE 9 - 69
REMOVAL AND INSTALLATION (Continued)