1996 CHRYSLER VOYAGER Service Manual

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Page 1177 of 1938

CHRYSLER VOYAGER 1996 Service Manual SPECIAL TOOLS
3.3/3.8L ENGINE
Adaptor 6909
Dolly 6135
Cradle 6710
Adaptor 6912
Puller 1023
Indicator, Cylinder Bore C-119
NS3.3/3.8L ENGINE 9 - 127

Page 1178 of 1938

CHRYSLER VOYAGER 1996 Service Manual Tester Valve Spring C-647
Valve Spring Compressor C-3422±B
Adaptor Valve Compressor 6412
Insert Crankshaft Pulley Remover L-4524-1
Front Crankshaft Seal Installer C-4992
Camshaft Bearing Remover and

Page 1179 of 1938

CHRYSLER VOYAGER 1996 Service Manual ENGINE
CONTENTS
page page
2.0L SOHC ENGINE...................... 12.5L VM DIESEL....................... 40
2.0L SOHC ENGINE
INDEX
page page
DESCRIPTION AND OPERATION
ENGINE COMPONENTS.................

ENGINE
CONTENTS
page page
2.0L SOHC ENGINE...................... 12.5L VM DIESEL....................... 40
2.0L SOHC ENGINE
INDEX
page page
DESCRIPTION AND OPERATION
ENGINE COMPONENTS.................. 3
ENGINE IDENTIFICATION................. 1
ENGINE LUBRICATION SYSTEM............ 2
GENERAL SPECIFICATION................ 2
DIAGNOSIS AND TESTING
CHECKING ENGINE OIL PRESSURE........ 3
SERVICE PROCEDURES
CRANKSHAFT END PLAY................. 6
CYLINDER BORE AND PISTON SIZING....... 4
FITTING CONNECTING RODS.............. 5
FITTING CRANKSHAFT BEARINGS.......... 6
FITTING PISTON RINGS.................. 4
REMOVAL AND INSTALLATION
CAMSHAFT OIL SEAL................... 12
CAMSHAFT............................ 7
CRANKSHAFT OIL SEALÐREAR........... 20
CRANKSHAFT......................... 21
CYLINDER HEAD COVER................. 6
CYLINDER HEAD....................... 10
FRONT CRANKSHAFT OIL SEAL........... 18
OILFILTER ........................... 24
OIL FILTER ADAPTER................... 24OILPAN .............................. 17
OIL PUMP............................ 25
PISTON AND CONNECTING ROD.......... 25
ROCKER ARM/HYDRAULIC LASH ADJUSTER . . 8
SPARK PLUG TUBE...................... 7
TIMING BELT COVER................... 11
TIMING BELT SYSTEM.................. 13
VALVE SEALS AND SPRINGS IN VEHICLE . . . 10
VIBRATION DAMPER.................... 28
DISASSEMBLY AND ASSEMBLY
OIL PUMP............................ 29
VALVE SERVICE WITH THE CYLINDER HEAD
REMOVED.......................... 29
CLEANING AND INSPECTION
CYLINDER BLOCK AND BORE............ 34
CYLINDER HEAD AND CAMSHAFT
JOURNALS.......................... 32
OIL PUMP............................ 32
SPECIFICATIONS
ENGINE 2.0L SOHC..................... 34
TORQUE CHART 2.0L SOHC.............. 36
SPECIAL TOOLS
ENGINE 2.0L SOHC..................... 36
DESCRIPTION AND OPERATION
ENGINE IDENTIFICATION
The engine identification number is located on the
left rear of the cylinder block behind starter (Fig. 1).
Fig. 1 Engine Identification SOHC
NS/GSENGINE 9 - 1

Page 1180 of 1938

CHRYSLER VOYAGER 1996 Service Manual GENERAL SPECIFICATION
Type .............In-Line OHV, DOHC & SOHC
Bore.....................87.5mm (3.445 Inch)
Stroke...................83.0mm (3.268 inch)
Compression Ratio....DOHC - 9.6:1 SOHC - 9.8:

GENERAL SPECIFICATION
Type .............In-Line OHV, DOHC & SOHC
Bore.....................87.5mm (3.445 Inch)
Stroke...................83.0mm (3.268 inch)
Compression Ratio....DOHC - 9.6:1 SOHC - 9.8:1
Displacement.........2.0Liters (122 Cubic Inch)
Firing Order........................1,3,4,2
Compression Pressure...........1172-1551 kPa
(170 - 225 psi)
Maximum Variation Between Cylinders......25%
Lubrication . . . Pressure Feed - Full Flow Filtration
(Crankshaft Driven Pump)
Engine Oil Capacity . . Refer to Group 0, Lubrication
and Maintenance
ENGINE LUBRICATION SYSTEM
ENGINE LUBRICATION
Refer to Group 0, Lubrication and Maintenance for
recommended oil to be used in various engine appli-
cation. System is full flow filtration, pressure feed
type. The oil pump is mounted in the front engine
cover and driven by the crankshaft. Pressurized oil is
then routed through the main oil gallery, running the
length of the cylinder block, supplying main and rodbearings with further routing. Rod bearing oil throw-
off lubricates the pistons from directed slots on the
side of the connecting rod assemblies. Camshaft and
valve mechanisms are lubricated from a full-length
cylinder head oil gallery supplied from the crankcase
main oil gallery.
PRESSURE LUBRICATION
Oil drawn up through the pickup tube is pressur-
ized by the pump and routed through the full flow fil-
ter to the main oil gallery running the length of the
cylinder block. A cylinder head restrictor, located in
the block, provides increased oil flow to the main oil
gallery (Fig. 2).
MAIN/ROD BEARINGS
A diagonal hole in each bulkhead feeds oil to each
main bearing. Drilled passages within the crankshaft
route oil from main bearing journals to connecting
rod journals.
CAMSHAFT/HYDRAULIC LASH ADJUSTERS
A vertical hole at the number five bulkhead routes
pressurized oil through a restrictor up into the cylin-
der head. The rocker shafts route oil to the rocker
arms/hydraulic lash adjuster assemblies.
Engine Lubrication Components
9 - 2 ENGINENS/GS
DESCRIPTION AND OPERATION (Continued)

Page 1181 of 1938

CHRYSLER VOYAGER 1996 Service Manual SPLASH LUBRICATION
Oil returning to the pan from pressurized compo-
nents supplies lubrication to the valve stems. Cylin-
der bores and wrist pins are splash lubricated from
directed slots on the conn

SPLASH LUBRICATION
Oil returning to the pan from pressurized compo-
nents supplies lubrication to the valve stems. Cylin-
der bores and wrist pins are splash lubricated from
directed slots on the connecting rod thrust collars.
ENGINE COMPONENTS
CYLINDER BLOCK AND BEDPLATE ASSEM-
B LY:A partial open deck is used for cooling and
weight reduction with water pump molded into the
block. Nominal wall thickness is 4 mm. The bedplate
incorporates main bearing caps. Rear seal retainer is
integral with the block.
CRANKSHAFT:A nodular cast iron crankshaft is
used. The engine has 5 main bearings, with number
3 flanged to control thrust. The 52 mm diameter
main and 48 mm diameter crank pin journals (all)
have undercut fillet radiuses that are deep rolled for
added strength. To optimize bearing loading 8 coun-
terweights are used. Hydrodynamic seals provide end
sealing, where the crankshaft exits the block.
Anaerobic gasket material is used for parting line
sealing. A sintered iron timing belt sprocket is
mounted on the crankshaft nose. This sprocket trans-
mits crankshaft movement, via timing belt to the
camshaft sprocket providing timed valve actuation.
PISTONS:The SOHC EngineDOES NOThave
provision for a free wheeling valve train. Non free
wheeling valve train means, in the event of a broken
timing belt Pistons will contact the Valves. All
engines use pressed-in piston pins to attach forged
powdered metal connecting rods. The connecting rods
are a cracked cap design and are not repairable. Hexhead cap screw are used to provide alignment and
durability in the assembly. Pistons And Connecting
rods are serviced as an assembly.
PISTON RINGS:The piston rings include a
molybdenum faced top ring for reliable compression
sealing and a taper faced intermediate ring for addi-
tional cylinder pressure control. Oil Control Ring
Package consist of 2 steel rails and a expander
spacer.
CYLINDER HEADÐSOHC:It features a Single
Over Head Camshaft, four-valves per cylinder cross
flow design. The valves are arranged in two inline
banks, with the two intake per cylinder facing
toward the radiator. The exhaust valves facing
toward the dash panel. Rocker arm shafts mount
directly to the cylinder head. It incorporates powder
metal valve guides and seats. The hollow rocker arm
shafts supplies oil to the hydraulic lash adjusters,
camshaft and valve mechanisms.
CAMSHAFTÐSOHC:The nodular iron camshaft
has five bearing journals and 3 cam lobes per cylin-
der. Provision for cam position sensor on the cam at
the rear of cylinder head which also acts as thrust
plate. A hydrodynamic oil seal is used for oil control
at the front of the camshaft.
VALVESÐSOHC:Four valves per cylinder are
actuated by roller rocker arms/hydraulic lash adjust-
ers assemblies which pivot on rocker arm shafts. All
valves have 6 mm diameter chrome plated valve
stems. The valve train has 33 mm (1.299 inch) diam-
eter intake valves and 28 mm (1.10 inch) diameter
exhaust valves. Viton rubber valve stem seals are
integral with spring seats. Valve springs, spring
retainers, and locks are conventional design.
INTAKE MANIFOLD:The intake manifold is a
molded plastic composition, attached to the cylinder
head with ten fasteners. This long branch design
enhances low and mid-range torque.
EXHAUST MANIFOLD:The exhaust manifold is
made of nodular cast iron for strength and high tem-
peratures. Exhaust gasses exit through a machined,
articulated joint connection to the exhaust pipe.
DIAGNOSIS AND TESTING
CHECKING ENGINE OIL PRESSURE
(1) Remove oil pressure switch and install gauge
assembly C-3292 with adaptor.
(2) Run engine until thermostat opens.
CAUTION: If oil pressure is 0 at idle, Do Not per-
form the 3000 RPM test in the next step.
(3) Oil Pressure:Curb Idle25 kPa (4 psi) mini-
mum3000 RPM170-550 kPa (25-80 psi).
Fig. 2 Engine Lubrication SystemÐ SOHC
NS/GSENGINE 9 - 3
DESCRIPTION AND OPERATION (Continued)

Page 1182 of 1938

CHRYSLER VOYAGER 1996 Service Manual (4) If oil pressure is 0 at idle. Shut off engine,
check for pressure relief valve stuck open, a clogged
oil pick-up screen or a damaged oil pick-up tube
O-ring.
SERVICE PROCEDURES
CYLINDER BORE AND P

(4) If oil pressure is 0 at idle. Shut off engine,
check for pressure relief valve stuck open, a clogged
oil pick-up screen or a damaged oil pick-up tube
O-ring.
SERVICE PROCEDURES
CYLINDER BORE AND PISTON SIZING
The cylinder walls should be checked for out-of-
round and taper with Tool C-119 (Fig. 3). The cylin-
der bore out-of-round is 0.050 mm (.002 inch)
maximum and cylinder bore taper is 0.051 mm (0.002
inch) maximum. If the cylinder walls are badly
scuffed or scored, the cylinder block should be
rebored and honed, and new pistons and rings fitted.
Whatever type of boring equipment is used, boring
and honing operation should be closely coordinated
with the fitting of pistons and rings in order that
specified clearances may be maintained.Refer to
Honing Cylinder Bores outlined in the Stan-
dard Service Procedures for specification and
procedures.
Measure the cylinder bore at three levels in direc-
tions A and B (Fig. 3). Top measurement should be
10 mm (3/8 inch) down and bottom measurement
should be 10 mm (3/8 inch.) up from bottom of bore.
Refer to Cylinder Bore and Piston Specifications
Chart.
SIZING PISTONS
Piston and cylinder wall must be clean and dry.
Piston diameter should be measured 90 degrees to
piston pin about 17.5 mm (11/16 inch) from the bot-tom of the skirt as shown in (Fig. 4). Cylinder bores
should be measured halfway down the cylinder bore
and transverse to the engine crankshaft center line
shown in (Fig. 3). Refer to Cylinder Bore and Speci-
fications Table. Correct piston to bore clearance must
be established in order to assure quiet and economi-
cal operation.
Chrysler engines use pistons designed specifically
for each engine model. Clearance and sizing locations
vary with respect to engine model.
NOTE: Pistons and cylinder bores should be mea-
sured at normal room temperature, 21ÉC (70ÉF).
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 12 mm (0.50 inch) from bottom of
cylinder bore. Check gap with feeler gauge (Fig. 5).
Refer to Piston Ring Specification Chart.
Fig. 3 Checking Cylinder Bore Size
CYLINDER BORE AND PISTON
SPECIFICATION CHART
Standard Bore Maximum
Out-of-RoundMaximum
Taper
87.5 mm
(3.445 in.)0.051 mm
(0.002 in.)0.051 mm
(0.002 in.)
Standard Piston Size
Federal
Emission:87.463 - 87.481 mm
(3.4434 - 3.4441 in.)
Low Emission
Vehicle (LEV):87.456 - 87.474 mm
(3.4432 - 3.4439 in.)
Piston to Bore Clearance
Federal
Emission:0.012 - 0.044 mm
(0.0004 - 0.0017 in.)
Low Emission
Vehicle (LEV):0.18 - 0.050 mm
(0.0008 - 0.0020 in.)
Measurements Taken at Piston Size Location
Fig. 4 Piston Measurements
9 - 4 ENGINENS/GS
DIAGNOSIS AND TESTING (Continued)

Page 1183 of 1938

CHRYSLER VOYAGER 1996 Service Manual (2) Check piston ring to groove side clearance (Fig.
6). Refer to Piston Ring Specification Chart.
FITTING CONNECTING RODS
(1) Follow the procedure specified in the Standard
Service Procedures Section

Page 1184 of 1938

CHRYSLER VOYAGER 1996 Service Manual FITTING CRANKSHAFT BEARINGS
Refer to Measuring Main Bearing Clearance in
Standard Service Procedures. Refer to Crankshaft
Specification Chart for specifications.
CRANKSHAFT END PLAY
DIAL INDICATOR MET

FITTING CRANKSHAFT BEARINGS
Refer to Measuring Main Bearing Clearance in
Standard Service Procedures. Refer to Crankshaft
Specification Chart for specifications.
CRANKSHAFT END PLAY
DIAL INDICATOR METHOD
(1) Mount a dial indicator to front of engine, locat-
ing probe on nose of crankshaft (Fig. 9).
(2) Move crankshaft all the way to the rear of its
travel.(3) Zero the dial indicator.
(4) Move crankshaft all the way to the front and
read the dial indicator. Refer to Crankshaft Specifi-
cation Chart for specifications.
FEELER GAGE METHOD
(1) Move crankshaft all the way to the rear of its
travel using a lever inserted between a main bearing
cap and a crankshaft cheek, using care not to dam-
age any bearing surface. Donotloosen main bearing
cap.
(2) Use a feeler gauge between number three
thrust bearing and machined crankshaft surface to
determine end play.
REMOVAL AND INSTALLATION
CYLINDER HEAD COVER
REMOVAL
(1) Remove ignition coil pack (Fig. 10).
(2) Remove the cylinder head cover bolts.
(3) Remove cylinder head cover from cylinder
head.
INSTALLATION
Before installation, clean cylinder head and cover
mating surfaces. Make certain the cylinder head
cover mating surface is flat.
(1) Install new valve cover gasket.
CAUTION: Do not allow oil or solvents to contact
the timing belt as they can deteriorate the rubber
and cause tooth skipping.
(2) Install cover assembly to head and tighten fas-
teners to 12 N´m (105 in. lbs.).
(3) Install ignition coil pack. Tighten fasteners to
23 N´m (200 in. lbs.).
CONNECTING ROD SPECIFICATION CHART
Connecting Rod Bearing Oil Clearance
New Part: 0.026 - 0.059 mm (0.001 - 0.0023 in.)
Wear Limit: 0.075 mm (0.003 in.)
Connecting Rod Side Clearance
New Part: 0.13 - 0.38 mm (0.005 - 0.015 in.)
Wear Limit: 0.40 mm (0.016 in.)
CRANKSHAFT SPECIFICATION CHART
Crankshaft End-PlayNew Part: 0.09 - 0.24 mm (0.0035 - 0.0094 in.)
Wear Limit: 0.37 mm (0.015 in.)
Main Bearing ClearanceNew Part: 0.022 - 0.062 mm (0.0008 - 0.0024 in.)
Connecting Rod Bearing ClearanceNew Part: 0.026 - 0.059 mm (0.001 - 0.0023 in.)
Wear Limit: 0.075 mm (0.003 in.)
Main Bearing Journal DiameterStandard: 52.00060.008 mm (2.047260.0003 in.)
1st Undersize: 51.98360.008 mm
(2.046660.0003 in.)
Connecting Rod Journal DiameterStandard: 48.00060.008 mm (1.889760.0003 in.)
1st Undersize: 47.98360.008 mm
(1.889160.0003 in.)
Fig. 9 Checking Crankshaft End PlayÐ Dial
Indicator
9 - 6 ENGINENS/GS
SERVICE PROCEDURES (Continued)

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