1996 CHRYSLER VOYAGER coolant

cause of low compression unless some malfunc-
tion is present.
(11) Clean or replace spark plugs as necessary
and adjust gap as specified in Group 8, Electrical.
Tighten to specifications.
(12) Test resistance of spark plug cables. Refer to
Group 8, Electrical Ignition System Secondary Cir-
cuit Inspection.
(13) Test coil output voltage, primary and second-
ary resistance. Replace parts as necessary. Refer to
Group 8, Electrical Ignition System.
(14) Check fuel pump pressure at idle and differ-
ent RPM ranges. Refer to Group 14, Fuel System for
Specifications.
(15) The air filter elements should be replaced as
specified in Group 0, Lubrication and Maintenance,.
(16) Inspect crankcase ventilation system as out
lined in Group 0, Lubrication and Maintenance. For
emission controls see Group 25, Emission Controls
for service procedures.
(17) Inspect and adjust accessory belt drives refer-
ring to Group 7, Cooling System, Accessory Drive
Belts for proper adjustments.
(18) Road test vehicle as a final test.
CYLINDER COMBUSTION PRESSURE LEAKAGE
TEST
The combustion pressure leakage test provides an
accurate means for determining engine condition.
Combustion pressure leakage testing will detect:
²Exhaust and intake valve leaks (improper seat-
ing).
²Leaks between adjacent cylinders or into water
jacket.
²Any causes for combustion/compression pressure
loss.
WARNING: DO NOT REMOVE THE RADIATOR CAP
WITH THE SYSTEM HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM COOLANT CAN
OCCUR.
Check the coolant level and fill as required. DO
NOT install the radiator cap.
Start and operate the engine until it attains nor-
mal operating temperature, then turn the engine
OFF.
Clean spark plug recesses with compressed air.
Remove the spark plugs.
Remove the oil filler cap.
Remove the air cleaner.
Calibrate the tester according to the manufactur-
er's instructions. The shop air source for testing
should maintain 483 kPa (70 psi) minimum, 1 379
kPa (200 psi) maximum and 552 kPa (80 psi) recom-
mended.Perform the test procedures on each cylinder
according to the tester manufacturer's instructions.
While testing, listen for pressurized air escaping
through the throttle body, tailpipe and oil filler cap
opening. Check for bubbles in the radiator coolant.
All gauge pressure indications should be equal,
with no more than 25% leakage.
FOR EXAMPLE:At 552 kPa (80 psi) input pres-
sure, a minimum of 414 kPa (60 psi) should be main-
tained in the cylinder.
LASH ADJUSTER (TAPPET) NOISE DIAGNOSIS
A tappet-like noise may be produced from several
items. Check the following items.
(1) Engine oil level too high or too low. This may
cause aerated oil to enter the adjusters and cause
them to be spongy.
(2) Insufficient running time after rebuilding cylin-
der head. Low speed running up to 1 hour may be
required.
(3) During this time, turn engine off and let set for
a few minutes before restarting. Repeat this several
times after engine has reached normal operating
temperature.
(4) Low oil pressure.
(5) The oil restrictor pressed into the vertical oil
passage to the cylinder head is plugged with debris.
(6) Air ingested into oil due to broken or cracked
oil pump pick up.
(7) Worn valve guides.
(8) Rocker arm ears contacting valve spring
retainer.
(9) Rocker arm loose, adjuster stuck or at maxi-
mum extension and still leaves lash in the system.
(10) Faulty lash adjuster.
a. Check lash adjusters for sponginess while
installed in cylinder head. Depress part of rocker
arm over adjuster. Normal adjusters should feel very
firm. Spongy adjusters can be bottomed out easily.
b. Remove suspected lash adjusters, and disassem-
bleDo not reuse retainer caps. Do not inter-
change parts and make sure that care and
cleanliness is exercised in the handling of parts.
c. Clean out dirt and varnish with solvent.
d. Reassemble with engine oil.
e. Check for sponginess.
f. If still spongy, replace with new adjuster.
INSPECTION (ENGINE OIL LEAKS IN GENERAL)
Begin with a through visual inspection of the
engine, particularly at the area of the suspected leak.
If an oil leak source is not readily identifiable, the
following steps should be followed:
(1) Do not clean or degrease the engine at this
time because some solvents may cause rubber to
swell, temporarily stopping the leak.
9 - 8 ENGINENS
DIAGNOSIS AND TESTING (Continued)

ENGINE ASSEMBLY
REMOVAL
(1) Disconnect the battery.
(2) Remove the air cleaner assembly and inlet
hose.
(3) Remove both hoses at intercooler and engine.
(4) Disconnect EGR vacuum hose.
(5) Disconnect brake booster vacuum hose.
(6) Disconnect oil pressure switch connector (Fig.
19).
(7) Disconnect Wiring harness bracket at transaxle
shift tower.
(8) Disconnect transaxle wiring at speed sensor,
crank sensor, and backup light switch.
(9) Remove both transmission shift cables at trans-
mission.
(10) Remove negative battery cable at cylinder
block (Fig. 19).
(11) Remove oil separator.
(12) Remove connectors at coolant temperature
sensor and A/C compressor.
(13) Disconnect fuel injection pump wiring connec-
tors (Fig. 19).
(14) Disconnect glow plug connectors.
(15) Disconnect electrical connector at number 1
fuel injector.
(16) Raise vehicle on hoist.
(17) Remove right side splash shield (Fig. 20).
WARNING: THE COOLANT IN A RECENTLY OPER-
ATED ENGINE IS HOT AND PRESSURIZED. USE
CARE TO PREVENT SCALDING BY HOT COOLANT.CAREFULLY RELEASE THE PRESSURE BEFORE
REMOVING THE RADIATOR DRAIN COCK AND CAP.
(18) Drain the cooling system (refer to Group 7,
Cooling).
(19) Lower vehicle.
(20) Remove Coolant pressure bottle and discon-
nect low coolant level sensor.
(21) Disconnect both heater hoses.
(22) Remove the lower radiator hose.
(23) Remove the upper radiator hose.
(24) Remove fuel line at injector pump and cap.
(25) Remove power steering reservoir and reposi-
tion.
(26) Remove upper radiator crossmember.
(27) Disconnect cooling fan module connector.
Fig. 18 Shift Cables at Rear MountFig. 19 Component Locations
Fig. 20 Right Side Splash Shield
NS/GSENGINE 9 - 53
REMOVAL AND INSTALLATION (Continued)

(28) Remove radiator support bolts.It is neces-
sary to loosen the receiver/dryer to gain access
to the radiator bolts.
(29) Remove radiator and fans as an assembly.
(30) Remove accessory drive belt generator/power
steering. Refer to Group 7, for procedure.
(31) Remove both power steering lines at pump,
and cap both lines.
NOTE: It is not necessary to discharge A/C system
for engine removal.
(32) Remove A/C compressor. Secure compressor
away from engine for clearance during engine
removal.
(33) Remove Generator and adjusting bracket.
NOTE: Do not remove the mounting base from the
generator. It is aligned at the factory and cannot be
realigned in the field.
(34) Hoist vehicle.
(35) Remove exhaust pipe at turbo outlet.
(36) Remove connections at starter.
(37) Remove power steering high pressure line
bracket at rear of oil pan.
(38) Remove both driveshafts from transaxle. Refer
to Group 2, Suspension and Driveshafts.
(39) Disconnect clutch cable at transaxle.
(40) Remove reinforcement plate on lower cross-
member.
(41) Remove front and rear engine mounts. Refer
to procedure outlined in this section.
(42) Drain engine oil and remove oil filter if neces-
sary.
(43) Mount both special tool, engine support brack-
ets VM-1026 to cylinder block (Fig. 21).
(44) Using engine dolly and cradle assembly with
4 adjustable posts align posts with holes in the
engine support brackets.
(45) Lower vehicle so weight ofonly the engine
and transmissionis on the dolly and cradle assem-
bly.
(46) Remove left side splash shield to gain access
to thru bolt for left side mount.
(47) Remove right engine mount and left side
mount. Refer to procedure outlined in this section.
(48) Raise vehicle slowly. It may be necessary to
move the engine/transmission assembly on the dolly
to allow for removal around body.
(49) Reverse removal procedure for installation.
CYLINDER HEAD COVER
REMOVAL
(1) Disconnect the battery cables.
(2) Remove generator bracket.(3) Remove breather hose.
(4) Remove coolant pressure tank.
(5) Remove cylinder head cover.
INSTALLATION
(1) Install cylinder head cover, torque nuts to 23.5
N´m (208 in. lbs.).
(2) Install coolant pressure tank.
(3) Install breather hose.
(4) Install generator bracket, tighten bolts to 7
N´m (4 ft. lbs.).
(5) Connect battery cable.
ROCKER ARMS AND PUSH RODS
REMOVAL
(1) Disconnect the battery cables.
(2) Remove generator bracket.
(3) Remove breather hose.
(4) Remove coolant pressure tank.
(5) Remove cylinder head cover.
(6) Remove rocker retaining nuts (Fig. 22).
(7) Remove rocker assembly. Place them on a
bench in the same order as removed.
(8) Remove the push rods and place them on a
bench in the same order as removed.
INSTALLATION
(1) Install the push rods in the same order as
removed.
(2) Install rocker arm assemblies in the same
order as removed. Tighten the rocker arm nuts to
29.4 N´m (264 in. lbs.) torque.
Fig. 21 Engine Removal
9 - 54 ENGINENS/GS
REMOVAL AND INSTALLATION (Continued)

(3) Install cylinder head cover, torque nuts to 14.7
N´m (132 in. lbs.).
(4) Install coolant pressure tank.
(5) Install breather hose.
(6) Install generator bracket, tighten bolts to 7
N´m (4 ft. lbs.).
(7) Connect the service valves to the A/C compres-
sor ports, if equipped with air conditioning.
(8) Connect battery cable.
VALVE SPRINGSÐCYLINDER HEAD NOT
REMOVED
This procedure can be done with the engine cylin-
der head installed on the block.
REMOVAL
Each valve spring is held in place by a retainer
and a set of conical valve locks. The locks can be
removed only by compressing the valve spring.
(1) Remove the engine cylinder head cover, refer to
cylinder head cover removal in this section.
(2) Remove rocker arms assemblies for access to
each valve spring to be removed.
(3) Remove push rods. Retain the push rods, and
rocker arms assemblies in the same order and posi-
tion as removed.
(4) Inspect the springs and retainer for cracks and
possible signs of weakening.
(5) Install an air hose adaptor in the fuel injector
hole.
(6) Connect an air hose to the adapter and apply
air pressure slowly. Maintain at least 621 kPa (90psi) of air pressure in the cylinder to hold the valves
against their seats.
(7) Tap the retainer or tip with a rawhide hammer
to loosen the lock from the retainer. Use Valve Spring
Compressor Tool to compress the spring and remove
the locks.
(8) Remove valve spring and retainer.
Inspect the valve stems, especially the grooves. An
Arkansas smooth stone should be used to remove
nicks and high spots.
INSTALLATION
(1) Install valve spring and retainer.
(2) Compress the valve spring with Valve Spring
Compressor Tool and insert the valve locks. Release
the spring tension and remove the tool. Tap the
spring from side-to-side to ensure that the spring is
seated properly on the engine cylinder head.
(3) Disconnect the air hose. Remove the adaptor
from the fuel injector hole and install the fuel injec-
tor.
(4) Repeat the procedures for each remaining valve
spring to be removed.
(5) Install the push rods. Ensure the bottom end of
each rod is centered in the plunger cap seat of the
hydraulic valve tappet.
(6) Install the rocker arm assemblies, at their orig-
inal location.
(7) Tighten the rocker arm assembly nut to 106
N´m (78 ft. lbs.) torque.
(8) Install the engine cylinder head cover, refer to
cylinder head cover installation in this section.
CYLINDER HEAD
REMOVAL
(1) Disconnect the battery cable.
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAIN COCK WITH THE SYSTEM HOT AND PRES-
SURIZED BECAUSE SERIOUS BURNS FROM THE
COOLANT CAN OCCUR.
(2) Drain the cooling system. Refer to Group 7,
Cooling.
(3) Remove wiper module. Refer to Group 8K,
Windshield Wiper Unit Removal for procedure.
(4) Remove coolant pressure bottle.
(5) Remove intercooler hose at intake manifold
(Fig. 23).
(6) Remove intercooler hose at turbocharger inter-
cooler tube.
(7) Remove the upper radiator hose.
(8) Remove water manifold.
(9) Disconnect the heater hoses and coolant pres-
sure bottle hoses.
Fig. 22 Rocker Arm Retaining Nut
NS/GSENGINE 9 - 55
REMOVAL AND INSTALLATION (Continued)

70É using angle torque tool. Then rotate the bolts an
additional 70É following tightening sequence.
(10) Then, tighten the 14mm bolts with special
tool VM-1018 in the following manner:
(11) Side bolts (M1-M2): Tighten M1 bolts to 30
N´m, then rotate them 85É (65). Tighten M2 bolts to
30 N´m, then rotate them 85É (65).
(12)2nd Phase:After 20 minutes of engine oper-
ation at operating temperature, allow engine to cool
down completely. Then retorque the head bolts as fol-
lows:
(13) Central bolts A-L: Starting from bolt A,
slacken and retorque it immediately to 30 N´m + 65É.
Rotate the bolt an additional 65É. Then proceed in
the same way, bolt by bolt, following alphabetical
order, as indicated.
(14) Side bolts M1-M2:Without slackening,
torque bolts M1 then bolts M2 to 90 N´m (66 ft. lbs.).
(15) Tighten intake nuts to 30 N´m (22 ft. lbs.) and
exhaust manifolds nuts to 30 N´m (22 ft. lbs.) speci-
fied torque after completing Phase 2.
(16) If the engine cylinder head is to be replaced
and the original valves used, measure the valve stem
diameter. Only standard size valves can be used with
a service replacement engine cylinder head unless
the replacement head valve stem guide bores are
reamed to accommodate oversize valve stems.
Remove all carbon buildup and reface the valves.
(17) Tighten oil feed lines for rocker arm assem-
blies and oil pressure switch to 13 N´m (112 in. lbs.).
(18) Install push rods and rocker arm assemblies,
tighten nut to 29.4 N´m (264 in. lbs.).(19) Install fuel injectors use tool VM-1012 (refer
to Group 14, Fuel System).
(20) Install valve cover, tighten nuts to 14.7 N´m
(132 in. lbs.).
(21) Connect crankcase breather hose.
(22) Connect the injector sensor wire connector,
and the glow plug connectors.
(23) Install oil feed line, tighten banjo bolts to 12.7
N´m (108 in. lbs), and oil drain line to turbo.
(24) Install water manifold tighten bolts to 12 N´m
(106 in. lbs.).
(25) Install exhaust pipe to turbo elbow, tighten
bolts to 28 N´m (250 in. lbs.).
(26) Install the support strut from block to turbo-
charger exhaust elbow.
(27) Install EGR tube to EGR valve, tighten bolts
to 26 N´m (19 ft. lbs.).
(28) Install intercooler hoses at intake manifold.
(29) Install coolant pressure bottle and hoses.
(30) Install wiper module. Refer to Group 8K,
Windshield Wiper Unit Installation for procedure.
(31) Install intercooler hose at turbocharger tube.
(32) Install fuel injector lines from the pump to
injectors, tighten nuts to 17.6 N´m (156. lbs.).
(33) Connect the upper radiator hose.
(34) Connect negative cable to battery.
(35) Fill the cooling system. Check for leaks.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN DIRECT
LINE WITH THE FAN. DO NOT PUT HANDS NEAR
THE PULLEYS, BELTS OR FAN. DO NOT WEAR
LOOSE CLOTHING.
Fig. 33 Engine Cylinder Head Bolt Tightening Sequence
NS/GSENGINE 9 - 59
REMOVAL AND INSTALLATION (Continued)

(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)

CYLINDER HEAD
CLEANING
Thoroughly clean the engine cylinder head and cyl-
inder block mating surfaces. Clean the intake and
exhaust manifold and engine cylinder head mating
surfaces. Remove all gasket material and carbon.
Check to ensure that no coolant or foreign material
has fallen into the tappet bore area.
Remove the carbon deposits from the combustion
chambers and top of the pistons.
INSPECTION
Use a straightedge and feeler gauge to check the
flatness of the engine cylinder head and block mating
surfaces (Fig. 70).
Minimum cylinder head thickness 89.95mm (3.541
in.)
CAUTION: If only one cylinder head is found to be
distorted and requires machining, it will also be
necessary to machine the remaining cylinders
heads and end plates by a corresponding amount
to maintain correct cylinder alignment.
VALVE GUIDE HEIGHT
(1) Valve Guides height requirement.
(2) Measurement A (Fig. 71): 13.50 - 14.00 mm.
VALVE STEM-TO-GUIDE CLEARANCE
MEASUREMENT
(1) Measure and record internal diameter of valve
guides. Valve guide internal diameter is 8.0 to 8.015
mm (.3149 to .3155 in.).
(2) Measure valve stems and record diameters.
Intake valve stem diameter 7.94 to 7.96 mm (.3125 to
.3133 in). Exhaust valve stem diameter 7.92 to 7.94
mm (.3118 to .31215 in).
(3) Subtract diameter of valve stem from internal
diameter of its respective valve guide to obtain valve
stem clearance in valve guide. Clearance of inlet
valve stem in valve guide is .040 to .075 mm (.0015
to .0029 in). Clearance of exhaust valve stem in valve
guide is .060 to .095 mm (.0023 to .0037 in).
(4) If valve stem clearance in valve guide exceeds
tolerances, new valve guides must be installed.
TIMING GEAR COVER
Be sure mating surfaces of timing gear cover and
cylinder block are clean and free from burrs.
Fig. 69 Rocker Arm Components
Fig. 70 Checking Cylinder Head Flatness
Fig. 71 Valve Guide Height
NS/GSENGINE 9 - 75
CLEANING AND INSPECTION (Continued)

VALVES AND VALVE SPRINGS
VALVE CLEANING
Clean all carbon deposits from the combustion
chambers, valve ports, valve stems, valve stem
guides and heads.
Clean all grime and gasket material from the
engine cylinder head machined gasket surfaces.
INSPECTION
Inspect for cracks in the combustion chambers and
valve ports.
Inspect for cracks on the exhaust seat.
Inspect for cracks in the gasket surface at each
coolant passage.
Inspect valves for burned, cracked or warped
heads.
Inspect for scuffed or bent valve stems.
Replace valves displaying any damage.
Check valve spring height. (Fig. 72).
HYDRAULIC TAPPETS
(1) Clean all tappet parts in a solvent that will
remove all varnish and carbon.
(2) Replace tappets that are unfit for further ser-
vice with new assemblies.
(3) If plunger shows signs of scoring or wear,
install a new tappet assembly. If valve is pitted, or
valve seat on end of plunger is prevented from seat-
ing, install a new tappet assembly.
OIL PUMP
CLEANING
Wash all parts in a suitable solvent and inspect
carefully for damage or wear (Fig. 74).
INSPECTION
(1) Before installing oil pump check pump bore
depth in block (A) and pump body height (B) (Fig.
73). Difference between A and B should be
0.020-0.082 mm.
(2) Check clearance between rotors (Fig. 75).
PISTON AND CONNECTING ROD
PISTONS
(1) Piston Diameter: Size Group A: 91.93-91.94mm
(3.6191-3.6196 in.) Size Group B: 91.94-91.95mm
Fig. 72 Valve Spring Chart
Fig. 73 Oil Pump Bore Depth
Fig. 74 Oil Pump Inner and Outer Rotors
9 - 76 ENGINENS/GS
CLEANING AND INSPECTION (Continued)