1996 CHRYSLER VOYAGER belt

CYLINDER HEAD
REMOVAL
(1) Remove timing belt and camshaft sprockets.
See Timing Belt in this section for procedures.
(2) Remove cylinder head covers and rocker arms
and shafts. Refer to procedure outlined in this sec-
tion.
(3) Remove intake manifolds. Refer to Intake and
Exhaust Manifolds, Group 11.
(4) Remove distributor.
(5) Remove exhaust manifolds and cross over Refer
to Intake and Exhaust Manifolds, Group 11.
(6) Remove cylinder head bolts in sequence shown
in (Fig. 33) and remove cylinder head.
INSTALLATION
(1) Clean surfaces of head and block, install head
gasket over locating dowels.
(2) Install head on locating dowels.
(3) Install 10 mm Allen hex head bolts with wash-
ers.CAUTION: Attach the cylinder head bolt washer in
the direction shown in (Fig. 34).
(4) Tighten bolts in the order shown in (Fig. 35).
When tightening the cylinder head bolts, tighten
gradually, working in two or three steps and finally
tighten to specified torque of 108 N´m (80 ft. lbs.).
(5) Install rocker arms and cylinder head covers.
(6) Install camshaft sprockets and timing belt.
(7) Install exhaust manifolds and cross over pipe.
(8) Install distributor.
(9) Install intake manifolds.
Fig. 33 Cylinder Head Bolt Removal Sequence
Fig. 34 Cylinder Head Bolt Washer
Fig. 35 Cylinder Head Bolt Tightening Sequence
9 - 74 3.0L ENGINENS
REMOVAL AND INSTALLATION (Continued)

TIMING BELT
REMOVAL
(1) Mark belt running direction for installation
(Fig. 38).
(2) Loosen timing belt tensioner bolt (Fig. 40) and
remove timing belt.
(3) Remove crankshaft sprocket flange shield (Fig.
36).
Fig. 36 Timing Belt System
Fig. 37 Timing Belt Covers
NS3.0L ENGINE 9 - 75
REMOVAL AND INSTALLATION (Continued)

CAMSHAFT SPROCKETS
To remove camshaft sprockets
1. Hold camshaft sprocket with Spanner Tool
MB-990775 loosen and remove bolt and washer (Fig.
39).
2. Remove camshaft sprocket from camshaft.
To install camshaft sprockets
3. Place camshaft sprocket on camshaft.
4. Install bolt and washer to camshaft. Using
Spanner Tool MB-990775 hold camshaft sprocket and
torque bolt to 95 N´m (70 ft. lbs.) (Fig. 39).
TIMING BELT TENSIONER
(1) Install timing belt tensioner and tensioner
spring.
(2) Hook spring upper end to water pump pin and
lower end to tensioner bracket with hook out (Fig.
40).
(3) Turn timing belt tensioner counterclockwise
full travel in adjustment slot and tighten bolt to tem-
porarily hold this position (Fig. 41).
INSTALLATIONÐTIMING BELT
(1) Install timing belt on crankshaft sprocket and
keep belt tight on tension side (Fig. 38). Install belt
on the front (radiator side) camshaft sprocket. Installbelt on the water pump pulley, rear camshaft
sprocket and finally on the timing belt tensioner.
(2) Rotate the front camshaft sprocket in opposite
direction to take up belt slack. Check that all timing
marks are aligned (Fig. 38).
(3) Install crankshaft sprocket flange (Fig. 36).
(4) Loosen tensioner bolt and allow spring to ten-
sion timing belt.
Fig. 38 Timing Belt Engine Sprocket Timing
Fig. 39 Camshaft Sprockets
9 - 76 3.0L ENGINENS
REMOVAL AND INSTALLATION (Continued)

(5) Turn crankshaft two full turns in clockwise
direction.Turn smoothly and in clockwise direc-
tion ONLY.
(6) Align the timing marks on the sprockets and
tighten the timing belt tensioner locking bolt to 25
N´m (250 in. lbs.) torque.
(7) Reassembly belt covers, engine bracket, insula-
tor, crankshaft pulleys, accessories and accessory
drive belts in reverse order.
OIL PAN
Oil pan to crankcase sealing is provided with
MopartSilicone Rubber Adhesive Sealant or equiva-
lent gasket material. See Form-In-Place Gaskets in
Standard Service Procedures.
(1) Apply sealant as shown in (Fig. 42).
(2) Install pan and tighten screws to 6 N´m (50 in.
lbs.) in sequence shown in (Fig. 43).
Fig. 41 Positioning Belt Tensioner
Fig. 42 Oil Pan Sealing
Fig. 43 Oil Pan Screw Tightening Sequence
Fig. 40 Timing Belt Tensioner
NS3.0L ENGINE 9 - 77
REMOVAL AND INSTALLATION (Continued)

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

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

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

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