1996 CHRYSLER VOYAGER check engine

(2) Tighten mount to transmission bolts to 55 N´m
(40 ft. lbs.) (Fig. 22).
Tighten through bolt to 75 N´m (55 ft. lbs.)
(3) Engine mount adjustment, Refer to Engine
Mount Insulator Adjustment of this section.
REAR MOUNT
(1) Raise vehicle on hoist.
(2) Support the transmission with a transmission
jack so it will not rotate.
(3) Remove the insulator through bolt from the
mount and rear suspension crossmember.
(4) Remove the four transmission mount fasteners
and remove the mount.
(5) Reverse the removal procedure for installation.
Refer to (Fig. 23).
ENGINE MOUNT RUBBER INSULATORS
Insulator location on (right side) is adjustable to
allow right/left drive train adjustment in relation to
driveshaft assembly length. See Engine Mount
Adjustments in this section.
Check and reposition right engine mount insulator.
Adjust drive train position, if required, for the follow-
ing conditions:
²Driveshaft distress: See Group 2, Suspension
and Driveshafts.
²Any front end structural damage (after repair).
²Insulator replacement.
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) Remove battery cover, battery and battery tray,
with integral vacuum reservoir, from vehicle.
(5) Block off heater hoses to rear heater assembly,
if equipped.
(6) Drain cooling system. Refer to Group 7, Cooling
System for procedure.
(7) Disconnect heater hoses.
(8) Remove fan module and radiator. Refer to
Group 7, Cooling System for procedure.
(9) Disconnect transmission shift linkage.
(10) Disconnect throttle body linkage and vacuum
hoses from throttle body.
(11) Remove accessory drive belts. Refer to Acces-
sory Drive System located in Group 7, Cooling Sys-
tem for procedure.
(12) Remove air conditioning compressor from
engine and set it aside.
(13) Disconnect generator wiring harness and
remove generator.
(14) Hoist vehicle and remove axle shafts. Refer to
Group 2, Driveshaft for procedure.
(15) Remove right and left inner splash shields.
(16) Disconnect exhaust pipe from manifold.
(17) Remove front engine mount and bracket as an
assembly.
(18) Remove rear transmission mount and bracket.
(19) Remove power steering pump and bracket
assembly.
(20) Remove wiring harness and connectors from
front of engine.
(21) Remove bending braces and install tool num-
ber 6910 on engine.
(22) Remove trans inspection cover and mark flex-
plate to torque converter.
(23) Remove driveplate to torque converter bolts.
(24) Lower the vehicle.
Fig. 22 Engine MountÐLeft
Fig. 23 Engine MountÐRear
NS3.0L ENGINE 9 - 69
REMOVAL AND INSTALLATION (Continued)

(6) When removing right cylinder head cover, dis-
connect generator wiring and remove generator.
(7) Relocate spark plug wires.
(8) Remove vacuum connections.
(9) Remove rocker cover screws and remove cover
(Fig. 25).
INSTALLATION
(1) Clean cylinder head and cover mating surfaces.
Install new gasket.
(2) See (Fig. 25) and apply sealant such as Mopar
Silicone Rubber Adhesive Sealant to cover ends.
(3) Install cover and tighten cover bolt washer and
gasket assembly to 10 N´m (88 in. lbs.).
(4) Reverse removal procedures for installation.
CAMSHAFT
REMOVAL
NOTE: SEE AUTO LASH ADJUSTER FUNCTION
CHECK BEFORE DISASSEMBLY
(1) Install auto lash adjuster retainers (Fig. 26).
(2) Remove distributor adaptor (Fig. 27).
(3) When removing camshaft bearing caps do not
remove the bolts from the bearing caps. Remove the
rocker arm, rocker shafts and bearing cap as an
assembly.
CAMSHAFT INSPECTION
(1) Inspect camshaft bearing journals for damage
and binding (Fig. 28). If journals are binding, also
check the cylinder head for damage. Also check cyl-
inder head oil holes for clogging.
(2) Front cylinder head camshaft check the tooth
surface of the distributor drive gear teeth of the cam-
shaft and replace if abnormal wear is evident (Fig.
28).
(3) Check the cam surface for abnormal wear and
damage and replace if defective. Also measure the
cam height (Fig. 28) and replace if out of limit, stan-
dard value is 41.25 mm (1.624 in.), wearlimitis
40.75 mm (1.604 in.).
CAMSHAFT INSTALL
Lubricate camshaft journals and cams with engine
oil and install camshaft on cylinder head.
Fig. 25 Rocker Cover
Fig. 26 Auto Lash Adjuster Retainers
NS3.0L ENGINE 9 - 71
REMOVAL AND INSTALLATION (Continued)

ROCKER ARMS
INSTALL ROCKER ARM SHAFT ASSEMBLY
(1) Apply Mopar Silicone Rubber Adhesive Sealant
at bearing cap ends as shown in (Fig. 29).
(2) Install the rocker arm shaft assembly making
sure that the arrow mark on the bearing cap and the
arrow mark on the cylinder head are in the same
direction (Fig. 29).
NOTE: The direction of arrow marks on the front
and rear assemblies are opposite to each other.
(3) Tighten bearing cap bolts in the following order
to 10 N´m (85 in. lbs.). First #3, then #2, #1 and #4.
(4) Repeat step 3 increasing the torque to 20 N´m
(180 in.lbs.).
(5) Install distributor drive adaptor assembly (Fig.
30).
CAMSHAFT SEAL
CAMSHAFT END SEAL (PLUG)Ð IN VEHICLE
SERVICE
(1) Remove air cleaner assembly from engine.
(2) Use a small punch and a hammer, carefully
remove cam plug from cylinder head.
Fig. 27 Cylinder Heads and Camshafts
Fig. 28 Checking Camshafts
9 - 72 3.0L ENGINENS
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)

FITTING PISTON RINGS
(1) Wipe cylinder bore clean. Insert ring and push
down with piston to ensure it is square in bore. The
ring gap measurement must be made with the ring
positioning at least 16 mm (0.63 in.) from bottom of
cylinder bore. Check gap with feeler gauge (Fig. 49).
Refer to Piston Ring Specification Chart.
(2) Check piston ring to groove clearance (Fig. 50).
Refer to Piston Ring Specification Chart.PISTON RINGSÐINSTALLATION
(1) The No. 1 and No. 2 piston rings have a differ-
ent cross section. Install rings with manufacturers
mark and size mark facing up, to the top of the pis-
ton (Fig. 51).
CAUTION: Install piston rings in the following
order:
a. Oil ring expander.
b. Upper oil ring side rail.
PISTON RING SPECIFICATION CHART
Ring Position Ring Gap Ring Gap Wear
LimitGroove Clearance Maximum Groove
Clearance
Upper Ring 0.30 - 0.45 mm
(0.012 - 0.018 in.)0.8 mm (0.031 in.) 0.05 - 0.09 mm
(0.002 - 0.0035 in.)0.10 mm (0.004 in.)
Intermediate Ring 0.25 - 0.40 mm
(0.010 - 0.016 in.)0.8 mm (0.031 in.) 0.02 - 0.06 mm
(0.0007 - 0.002 in.)0.10 mm (0.004 in.)
Oil Control Ring 0.30 - 0.90 mm
(0.012 - 0.035 in.)1.0 mm (0.039 in.) Oil Ring Side Rails Must Be Free To Rotate
After Assembly
Fig. 48 Piston Clearance and Wear
Fig. 49 Check Gap on Piston Rings
Fig. 50 Piston Ring Clearance
Fig. 51 Piston RingÐInstallation
NS3.0L ENGINE 9 - 79
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)

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)

(6) Install new filter until gasket contacts base.
Tighten filter 1 turn or 20 N´m (15 ft. lbs.). Use filter
wrench if necessary.
(7) Start engine and check for leaks.
DISASSEMBLY AND ASSEMBLY
ROCKER ARMS AND SHAFTS
(1) Check rocker arms for wear or damage (Fig.
69). Replace as necessary. Also see Auto Lash
Adjuster.
ROCKER ARM SHAFTS
The rocker arm shaft is hollow and is used as a
lubrication oil duct. The rocker arm shaft on the
inletside hasa3mm(0.188 in.) diameter oil pas-
sage hole from the cylinder head. Theexhaustside
does nothave this oil passage (Fig. 70).
(1) Check the rocker arm mounting portion of the
shafts for wear or damage. Replace if heavily dam-
aged or worn.
(2) Check oil holes for clogging with small wire,
clean as required (Fig. 70).
REASSEMBLE
(1) Align the camshaft bearing caps with arrows
(depending on cylinder bank) directed as shown in(Fig. 71) and in numerical order. Identify number one
bearing cap number one and number four caps are
similar (Fig. 72).
(2) Install rocker shafts so that bearing cap num-
ber one with end notches positioned as shown in (Fig.
72) that the machined portion of the rocker shaft is
facing down.
(3) Install attaching bolts to retain assembly.
ASSEMBLE ROCKER ASSEMBLY
Install the rocker arms, bearing caps and springs.
Springs are the same and can be used at all
locationson the rocker arm shafts (Fig. 71) and
(Fig. 73). Insert bolts in number four bearing cap to
retain assembly.
Fig. 68 Oil Filter and Adaptor
Fig. 69 Inspect Rocker Arms
Fig. 70 Rocker Arm Shaft Identification
Fig. 71 Camshaft Bearing Caps Position
NS3.0L ENGINE 9 - 85
REMOVAL AND INSTALLATION (Continued)