1996 CHRYSLER VOYAGER Service Manual

CAUTION: This is a combined total dimension of
stock removal from cylinder head if any and block
top surface.
CYLINDER BORE
INSPECTION
(1) Measure the cylinder bore at three levels in
directions A and B (Fig. 77). Top measurementshould be 12 mm (0.50 in.) down and bottom mea-
surement should be 10 mm (0.38 in.) up.
(2) Standard bore dimension: 91.1 mm (3.587 in.)
(3) Maximum out-of-round or taper: 0.02 mm
(0.0008 in.).
OIL PUMP
(1) Check oil pump case for damage. Remove rear
oil pump cover.
(2) Remove pump rotors and inspect case for exces-
sive wear.
(3) Measure clearance between case and inner
rotor (Fig. 78).
(4) Insert the rotor into the oil pump case and
measure clearance between outer rotor and case with
a feeler gauge (Fig. 79). Replace if out of specifica-
tions.
Fig. 74 Timing Belt Inspection
Fig. 75 Timing Belt Covers
Fig. 76 Check Cylinder Head
Fig. 77 Checking Cylinder Bore Size
NS3.0L ENGINE 9 - 87
CLEANING AND INSPECTION (Continued)

(5)Using a feeler gauge, measure clearance between
inner rotor tip and outer rotor (Fig. 80). Clearance spec-
ification is: 0.06 - 0.18 mm (0.003 - 0.007 in.). Replace
both rotors if not within specifications
(6) Place a straightedge across face of pump hous-
ing (Fig. 81). Clearance specification is: 0.04 - 0.10
mm (0.0015 - 0.0039 in.). Replace oil pump assembly
if not within specifications.
OIL RELIEF PLUNGER
(1) Check that the oil relief plunger slides
smoothly.
(2) Check for broken relief spring.
ADJUSTMENTS
ENGINE MOUNTS
ENGINE MOUNT INSULATOR ADJUSTMENT
(1) Remove the load on the engine motor mounts
by carefully supporting the engine and transmission
assembly with a floor jack.
(2) Loosen the right engine mount insulator verti-
cal fastener and the fore and aft fasteners, and the
front engine mount bracket to front crossmember
screws.
(3) Pry the engine right or left as required to
achieve the proper drive shaft assembly length. Refer
to Group 2, Suspension and Driveshafts for drive-
shaft identification and related assembly length mea-
suring.
(4) Tighten engine mounts and fasteners in the
following order:
(a) Right engine mount insulator vertical bolts
to 102 N´m (75 ft. lbs.) and the fore and aft bolts to
150 N´m (110 ft. lbs.).
(b) Front engine mount screws to 54 N´m (40 ft.
lbs.) the clearance between the snubbers and the
engine should be 2 mm (0.078 inch.) each side.
(c) Left engine mount through bolt to 75 N´m (55
ft. lbs.).
(5) Recheck driveshaft length.
Fig. 78 Inner Rotor to Case
Fig. 79 Measuring Clearance Between Outer Rotor
and Case
Fig. 80 Measuring Clearance Between Rotors
Fig. 81 Measuring Clearance Over Rotors
9 - 88 3.0L ENGINENS
CLEANING AND INSPECTION (Continued)

SPECIFICATIONS
3.0L ENGINE
Type.........................60É V-6 SOHC
Number of Cylinders.......................6
Bore.....................91.1 mm (3.587 in.)
Stroke.....................76mm(2.992 in.)
Compression Ratio.....................8.85:1
Displacement..............3.0L (181 Cubic in.)
Firing Order....................1±2±3±4±5±6
Basic Ignition Timing.........Refer to Emission
Control Information Label on Vehicle
Compression Pressure...............1227 kPa
(178 psi) @ 250 RPM
Maximum Variation Between Cylinders......25%
Valve Timing
Intake Valve±Open.................19É BTDC
Intake Valve±Closed................59É ABDC
Exhaust Valve±Open................59É BBDC
Exhaust Valve±Closed...............19É ATDC
Cylinder Block
Cylinder Bore Diameter......91.1 mm (3.587 in.)
Top Surface Flatness........0.05 mm (0.002 in.)
Service Limit.............0.1 mm (0.0039 in.)
Grinding Limit of Top Surface*..........0.2 mm
(0.008 in.)
*Includes/Combined with cylinder Head Grinding
Pistons
Piston Diameter.................91.06 - 91.09
Piston to Cylinder Clearance......0.03 - 0.05 mm
(0.0012 - 0.002 in.)
Piston Ring End Gap No. 1......0.30 - 0.45 mm
(0.012 - 0.018 in.)
Service Limit..............0.8 mm (0.031 in.)
Piston Ring End Gap No. 2......0.45 - 0.60 mm
(0.018 - 0.024 in.)
Service Limit..............0.8 mm (0.031 in.)
Piston Ring End Gap Oil Control . .0.20 - 0.60 mm
(0.008 - 0.024 in.)
Service Limit..............1.0 mm (0.039 in.)
Ring Side Clearance No. 1......0.030 - 0.090 mm
(0.002 - 0.0035 in.)
Service Limit..............1.0 mm (0.039 in.)
Ring Side Clearance No. 2......0.040 - 0.085 mm
(0.0016 - 0.0033 in.)
Service Limit..............1.0 mm (0.039 in.)
Oversize Service Pistons.........0.25 - 0.50 mm
(0.010 - 0.020 in.),
0.75 - 1.00 mm (0.030 - 0.039 in.)
Connecting Rods
Bearing Clearance............0.018 - 0.036 mm
(0.0007 - 0.0014 in.)
Side Clearance................0.10 - 0.25 mm
(0.004 - 0.010 in.)Wear Limit.................0.4 mm (0.015 in.)
Length±Center to Center.......140.9 - 141.0 mm
(5.547 - 5.551 in.)
Parallelism±Twist..........0.05 mm (0.0019 in.)
Torsion...................0.1 mm (0.0039 in.)
Crankshaft
Main Journal Diameter.......59.980 - 60.0 mm
(2.361 - 2.362 in.)
Connecting Rod
Journal Diameter..........49.980 - 50.000 mm
(1.968 - 1.969 in.)
Out-of-Round (Max.).........0.03 mm (0.001 in.)
Taper (Max.).............0.005 mm (0.0002 in.)
Main and Rod
Bearing Clearance...........0.018 - 0.036 mm
(0.0007 - 0.0014 in.)
Undersize Service
Bearings................0.25 - 0.50 - 0.75 mm
(0.010 - 0.020 - 0.030 in.)
End Play.......0.05 - 0.25 mm (0.002 - 0.010 in.)
Service Limit..............0.3 mm (0.012 in.)
Cylinder Head
Flatness of Gasket Surface. . . .0.05 mm (0.002 in.)
Grinding Limit of
Gasket Surface.............0.2 mm (0.008 in.)
Cylinder Head Valve Seat
Angle±Intake and Exhaust..........44É - 44É.3'
Contact Width...................0.9 - 1.3 mm
(0.035 - 0.051 in.)
Sinkage±Service Limit........0.2 mm (0.078 in.)
Guide Bore Diameter (Std).......7.95 - 7.98 mm
(0.313 - 0.314 in.)
Valves
Face Angle......................45É - 45É 30'
Head Diameter Intake.........48.64 - 48.90 mm
(1.915 - 1.925 in.)
Head Diameter Exhaust.......40.01 - 40.26 mm
(1.575 - 1.585 in.)
Length Intake (Overall).....103.0 mm (4.055 in.)
Length Exhaust (Overall). . . .102.7 mm (4.043 in.)
Valve Margin±Intake.........1.2 mm (0.047 in.)
Service Limit..............0.7 mm (0.027 in.)
Valve Margin±Exhaust........2.0 mm (0.079 in.)
Service Limit..............1.5 mm (0.059 in.)
Valve Stem Tip Height......49.02 mm (1.929 in.)
Stem Diameter±Intake........7.960 - 7.975 mm
(0.313 - 0.314 in.)
Stem Diameter±Exhaust.......7.930 - 7.950 mm
(0.312 - 0.3125 in.)
Stem-to-Guide Clearance±Intake . . .0.03 - 0.06 mm
(0.001 - 0.002 in.)
Service Limit.............0.10 mm (0.004 in.)
Stem-to-Guide Clearance±
Exhaust.....................0.05 - 0.09 mm
(0.0019 - 0.003 in.)
NS3.0L ENGINE 9 - 89