1996 CHRYSLER VOYAGER Service Manual

Install new gasket and tighten screws to 12 N´m (105
in. lbs.).
OIL FILTER
CAUTION: When servicing the oil filter (Fig. 71)
avoid deforming the filter can by installing the
remove/install tool band strap against the can-to-
base lock seam. The lock seam joining the can to
the base is reinforced by the base plate.
(1) Using Tool C-4065, turn filter counterclockwise
to remove from base. Properly discard filter.
(2) Wipe base clean, then inspect gasket contact
surface.
(3) Lubricate gasket of new filter with clean
engine oil.
(4) Install new filter until gasket contacts base.
Tighten filter 1 turn or 20 N´m (15 ft. lbs.). Use filter
wrench if necessary.
(5) Start engine and check for leaks.
ENGINE OIL GALLERY PLUGS
REMOVAL
Using a blunt tool such as a drift and a hammer,
strike the bottom edge of the cup plug. With the cup
plug rotated, grasp firmly with pliers or other suit-
able tool and remove plug (Fig. 72).CAUTION: Do not drive cup plug into the casting
as restricted cooling can result and cause serious
engine problems.
INSTALLATION
Thoroughly clean inside of cup plug hole in cylin-
der block or head. Be sure to remove old sealer.
Lightly coat inside of cup plug hole with Loctite Stud
N' Bearing Mount or equivalent. Make certain the
new plug is cleaned of all oil or grease. Using proper
drive plug, drive plug into hole so that the sharp
edge of the plug is at least 0.5 mm (0.020 in.) inside
the lead-in chamfer.
DISASSEMBLY AND ASSEMBLY
OIL PUMP
It is necessary to remove the oil pan, oil pickup
and chain case cover to service the oil pump rotors.
The oil pump pressure relief valve can be serviced by
removing the oil pan and oil pickup tube. Refer to
Timing Chain Cover Removal and Installation of this
section for procedures.
DISASSEMBLY
(1) To remove the relief valve, proceed as follows:
Fig. 70 Rear Crankshaft Oil SealÐInstallation
Fig. 71 Oil Filter
Fig. 72 Core Hole Plug Removal
NS3.3/3.8L ENGINE 9 - 119
REMOVAL AND INSTALLATION (Continued)

(2) Drill a 3.175 mm (1/8 inch) hole into the relief
valve retainer cap and insert a self-threading sheet
metal screw into cap.
(3) Clamp screw into a vise and while supporting
chain case cover, remove cap by tapping chain case
cover using a soft hammer. Discard retainer cap and
remove spring and relief valve (Fig. 73).
(4) Remove oil pump cover screws, and lift off
cover.
(5) Remove pump rotors.
(6) Wash all parts in a suitable solvent and inspect
carefully for damage or wear (Fig. 76).
OIL PUMP ASSEMBLY
(1) Assemble pump, using new parts as required.
Install the inner rotor with chamfer facing the
cast iron oil pump cover.
(2) Tighten cover screws to 12 N´m (105 in. lbs.).
(3) Prime oil pump before installation by filling
rotor cavity with engine oil.
(4) Install chain case cover. Refer to Timing Chain
Cover Installation of this section.
HYDRAULIC TAPPETS
DISASSEMBLY
(1) Pry out plunger retainer spring clip (Fig. 74).
(2) Clean varnish deposits from inside of tappet
body above plunger cap.
(3) Invert tappet body and remove plunger cap,
plunger, flat or ball check valve, check valve spring,
check valve retainer and plunger spring. Check valve
could be flat or ball.
ASSEMBLY
(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, valve
is pitted, or valve seat on end of plunger indicates
any condition that would prevent valve from seating,
install a new tappet assembly.
(4) Assemble tappets (Fig. 74).
CLEANING AND INSPECTION
CYLINDER HEAD
(1) Before cleaning, check for leaks, damage and
cracks.
(2) Clean cylinder head and oil passages.
(3) Check cylinder head for flatness (Fig. 75).
(4) Inspect all surfaces with a straightedge if there
is any reason to suspect leakage. If out of flatness
exceeds 0.019 mm (0.00075 in.) times the span length
in inches, in any direction, either replace head or
lightly machine the head surface. As an example, if a
12 inch span is 0.1 mm (.004 in.) out of flat, allow-
able is 12 x .019 mm (.00075 in.) equals .22 mm (.009
in.) This amount of out of flat is acceptable. Maxi-
mum of 0.2 mm (.008 in.) for grinding is permitted.
CAUTION: This is a combined total dimension of
stock removal from cylinder head and block top
surface.
Fig. 73 Oil Pressure Relief Valve
Fig. 74 Hydraulic Roller Tappet Assembly
Fig. 75 Check Cylinder Head
9 - 120 3.3/3.8L ENGINENS
DISASSEMBLY AND ASSEMBLY (Continued)

OIL PAN
(1) Clean oil pan in solvent and wipe dry with a
clean cloth. Clean all gasket material from mounting
surfaces of pan and block.
(2) Inspect oil drain plug and plug hole for
stripped or damaged threads and repair as necessary.
Install a new drain plug gasket. Tighten to 27 N´m
(20 ft. lbs.).
(3) Inspect oil pan mounting flange for bends or
distortion. Straighten flange if necessary.
(4) Clean oil screen and pipe in clean solvent.
Inspect condition of screen.
OIL PUMP
INSPECTION AND REPAIR
(1) Clean all parts thoroughly. Mating surface of
the chain case cover should be smooth. Replace pump
cover if scratched or grooved.
(2) Lay a straightedge across the pump cover sur-
face (Fig. 77). If a 0.025 mm (0.001 in.) feeler gauge
can be inserted between cover and straight edge,
cover should be replaced.
(3) Measure thickness and diameter of outer rotor.
If outer rotor thickness measures 7.64 mm (0.301 in.)
or less (Fig. 78), or if the diameter is 79.95 mm
(3.148 inches.) or less, replace outer rotor.
(4) If inner rotor measures 7.64 mm (0.301 in.) or
less replace inner rotor (Fig. 79).
(5) Slide outer rotor into chain case cover, press to
one side with fingers and measure clearance between
rotor and chain case cover (Fig. 80). If measurement
is 0.39 mm (0.015 in.) or more, replace CCC only if
outer rotor is in specification.
(6) Install inner rotor into chain case cover. If
clearance between inner and outer rotors (Fig. 81) is
0.203 mm (0.008 in.) or more, replace both rotors.
(7) Place a straightedge across the face of the
chain case cover, between bolt holes. If a feeler gaugeof 0.10 mm (0.004 in.) or more can be inserted
between rotors and the straightedge, replace pump
assembly (Fig. 82).ONLYif rotors are in specs.
(8) Inspect oil pressure relief valve plunger for
scoring and free operation in its bore. Small marks
may be removed with 400-grit wet or dry sandpaper.
(9) The relief valve spring has a free length of
approximately 49.5 mm (1.95 inches) it should test
between 19.5 and 20.5 pounds when compressed to
34 mm (1-11/32 inches). Replace spring that fails to
meet specifications (Fig. 73).
(10) If oil pressure is low and pump is within spec-
ifications, inspect for worn engine bearings or other
reasons for oil pressure loss.
ENGINE BLOCK AND BORE
CLEANING AND INSPECTION
(1) Clean cylinder block thoroughly and check all
core hole plugs for evidence of leaking.
Fig. 76 Oil Pump
Fig. 77 Checking Oil Pump Cover Flatness
Fig. 78 Measuring Outer Rotor Thickness
NS3.3/3.8L ENGINE 9 - 121
CLEANING AND INSPECTION (Continued)

(2) If new core plugs are installed, see Engine Core
Oil and Cam Plugs.
(3) Examine block for cracks or fractures.
CYLINDER BORE INSPECTION
The cylinder walls should be checked for out-of-
round and taper with Tool C-119 (Fig. 83). If the cyl-
inder walls are badly scuffed or scored, the cylinder
block should be replaced.
Measure the cylinder bore at three levels in direc-
tions A and B (Fig. 83). Top measurement should be
12 mm (0.50 in.) down and bottom measurement
should be 12 mm (0.50 in.) up from bottom of bore.
Refer to Cylinder Bore and Piston Specification
Chart.
Fig. 79 Measuring Inner Rotor Thickness
Fig. 80 Measuring Outer Rotor Clearance in
Housing
Fig. 81 Measuring Clearance Between Rotors
Fig. 82 Measuring Clearance Over Rotors
Fig. 83 Checking Cylinder Bore Size
9 - 122 3.3/3.8L ENGINENS
CLEANING AND INSPECTION (Continued)