1996 CHRYSLER VOYAGER Service Manual

(6) 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.
TIMING CHAIN COVER
REMOVAL
(1) Disconnect negative cable from battery.
(2) Drain cooling system. Refer to Cooling System
Group 7 for procedure.
(3) Support engine and remove right engine
mount.
(4) Raise vehicle on hoist. Drain engine oil.
(5) Remove oil pan and oil pump pick-up. It may
necessary to remove transaxle inspection cover.
(6) Remove right wheel and inner splash shield.
(7) Remove drive belt. Refer to Cooling System
Group 7 for procedure.
(8) Remove A/C compressor and set aside.
(9) Remove A/C compressor mounting bracket.
(10) Remove crankshaft damper (Fig. 44).
(11) Remove idler pulley from engine bracket.
(12) Remove engine bracket (Fig. 45).
(13) Remove cam sensor from chain case cover
(Fig. 46).
(14) Remove chain case cover (Fig. 46).
INSTALLATION
(1) Be sure mating surfaces of chain case cover
and cylinder block are clean and free from burrs.
Crankshaft oil seal must be removed to insure cor-
rect oil pump engagement.
NOTE: DO NOT USE SEALER ON COVER GASKET
(2) Use a new cover gasket, and O-rings (Fig. 47).
Adhere new gasket to chain case cover, making surethat the lower edge of the gasket is flush to 0.5 mm
(0.020 in.) passed the lower edge of the cover. Refer
to Oil Pan sealing outlined in this section.
Fig. 43 Roller Tappets Aligning Yoke and Retainer
Fig. 44 Crankshaft DamperÐRemoval
Fig. 45 Engine Bracket
Fig. 46 Timing Chain Case Cover
NS3.3/3.8L ENGINE 9 - 111
REMOVAL AND INSTALLATION (Continued)

(3) Rotate crankshaft so that the oil pump drive
flats are vertical.
(4) Position oil pump inner rotor so the mating
flats are in the same position as the crankshaft drive
flats (Fig. 47).
(5) Install cover onto crankshaft. Make sure the oil
pump is engaged on the crankshaft correctly or
severe damage may result.
(6) Install chain case cover screws and torque to
27 N´m (20 ft. lbs.).
(7) Install crankshaft oil seal (Fig. 48).
(8) Install crankshaft pulley (Fig. 49).
(9) Install engine bracket (Fig. 45) and torque fas-
teners to 54 N´m (40 ft. lbs.).(10) Install idler pulley on engine bracket.
(11) Install cam sensor. Refer to Group 8D, Igni-
tion System for installation procedure.
(12) Install A/C compressor mounting bracket.
(13) Install A/C compressor.
(14) Install drive belt Refer to Group 7, Cooling
System for installation procedure.
(15) Install inner splash shield and wheel.
(16) Install oil pump pick-up and oil pan and tran-
saxle inspection cover if removed.
(17) Install engine mount.
(18) Fill crankcase with oil to proper level.
(19) Fill cooling system. Refer to Group 7, Cooling
System for procedure.
(20) Connect negative cable to battery.
TIMING CHAIN
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove timing chain cover. Refer to procedure
outlined in this section.
(3) Remove camshaft sprocket attaching bolt, and
timing chain with camshaft sprocket.
(4) Using a suitable puller remove the crankshaft
sprocket. Be careful not to damage the crankshaft
surface.
INSTALLATION
(1) Position a new crankshaft sprocket on the
shaft, install sprocket with suitable tool and mallet.
Be sure sprocket is seated into position.
(2) Rotate crankshaft so the timing arrow is to the
12 o'clock position.
(3) Place timing chain around camshaft sprocket
and place the timing mark to the 6 o'clock position.
(4) Align the dark colored links with the dot on the
camshaft sprocket, place timing chain around crank-
shaft sprocket with the dark colored link lined up
Fig. 47 Timing Chain Case Cover Gaskets and
O-Rings
Fig. 48 Crankshaft Oil SealÐInstallation
Fig. 49 Crankshaft DamperÐInstallation
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REMOVAL AND INSTALLATION (Continued)

with the dot on the sprocket and install camshaft
sprocket into position.
(5) Use a straight edge to check alignment of tim-
ing marks (Fig. 50).
(6) Install camshaft bolt and washer. Tighten to 54
N´m (40 ft. lbs.).
(7) Rotate crankshaft 2 revolutions. Timing marks
should line up. If timing marks do not line up
remove cam sprocket and realign.
(8) Check camshaft end play. With new thrust
plate the specification is 0.0127 to 0.304 mm (0.005
to 0.012 in.). Old thrust plate specification is 0.31
mm (0.012 in.) maximum. If not within these limits
install new thrust plate.
(9) Install timing chain cover and connect negative
cable to battery.
CAMSHAFT
REMOVALÐENGINE REMOVED FROM
VEHICLE
Remove intake manifold, cylinder head covers, cyl-
inder heads, timing chain case cover and timing
chain.
(1) Remove rocker arm and shaft assemblies.
(2) Remove push rods and tappets; identify so each
part will be replaced in its original location.
(3) Remove camshaft thrust plate (Fig. 51).
(4) Install a long bolt into front of camshaft to
facilitate removal of the camshaft; remove camshaft,
being careful not to damage cam bearings with the
cam lobes.
INSTALLATION
(1) Lubricate camshaft lobes and camshaft bearing
journals and insert the camshaft to within 2 inches
of its final position in cylinder block.(2) Install camshaft thrust plate with two screws
as shown in (Fig. 51). Tighten to 12 N´m (105 in. lbs.)
torque.
(3) Rotate crankshaft so the timing arrow is at the
12 o'clock position.
(4) Place timing chain around camshaft sprocket
and place the timing mark to the 6 o'clock position.
(5) Align the dark colored links with the dot on the
camshaft sprocket, place timing chain around crank-
shaft sprocket with the dark colored link lined up
with the dot on the sprocket and install camshaft
sprocket into position.
(6) Using straight edge to check alignment of tim-
ing marks (Fig. 52).
(7) Install the camshaft bolt. Tighten bolt to 54
N´m (40 ft. lbs.).
(8) Rotate crankshaft 2 revolutions. Timing marks
should line up. If timing marks do not line up,
remove cam sprocket and realign.
(9) Measure camshaft end play. End Play should
measure 0.0127 to 0.304 mm (0.005 to 0.012 inches.)
Fig. 50 Timing Marks Alignment
Fig. 51 Camshaft Thrust Plate
Fig. 52 Alignment of Timing Marks
NS3.3/3.8L ENGINE 9 - 113
REMOVAL AND INSTALLATION (Continued)

0.310 mm (0.012 in. Max.). If not within limits install
a new thrust plate.
(10) Each tappet reused must be installed in the
same position from which it was removed.When
camshaft is replaced, all of the tappets must be
replaced.
CAMSHAFT BEARINGS
REMOVAL
(1) With engine removed from vehicle and com-
pletely disassembled, drive out rear cam bearing core
hole plug.
(2) Install proper size adapters and horseshoe
washers (part of Tool C-3132-A) at back of each bear-
ing shell to be removed and drive out bearing shells
(Fig. 53).
INSTALLATION
(1) Install new camshaft bearings with Tool
C-3132-A 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. Number two bearing must index with
the oil passage to the left cylinder head and Number
three bearing must index with the oil passage to the
right cylinder head. If the camshaft bearing shell oil
holes are not in exact alignment, remove and rein-
stall them correctly. Install a new core hole plug at
the rear of camshaft.Be sure this plug does not
leak.
OIL PAN
REMOVAL
(1) Disconnect negative cable from battery and
remove engine oil dipstick.
(2) Raise vehicle on hoist and drain engine oil.(3) Remove bending brace to transaxle attaching
bolt.
(4) Remove bolts attaching dust cover to transaxle
housing. Lower dust cover to gain access to oil pan
bolts.
(5) Remove oil pan screws and remove oil pan.
INSTALLATION
(1) Clean surfaces and apply a 1/8 inch bead of
MopartSilicone Rubber Adhesive Sealant or equiva-
lent, at the parting line of the chain case cover and
the rear seal retainer (Fig. 54).
(2) Use a new pan gasket (Fig. 55).
(3) Install pan and tighten screws to 12 N´m (105
in. lb.).
(4) Install dust shield and bending brace to tran-
saxle housing.
(5) Lower vehicle and install oil dipstick.
(6) Connect negative cable to battery.
(7) Fill crankcase with oil to proper level.
Fig. 53 Removed Installation of Camshaft Bearings
with Tool C-3132±AÐTypical
Fig. 54 Oil Pan Sealing
Fig. 55 Oil Pan Gasket Installation
9 - 114 3.3/3.8L ENGINENS
REMOVAL AND INSTALLATION (Continued)