1996 CHRYSLER VOYAGER Service Manual

(3) Oil the bearings and journals and install
crankshaft and O-ring in cylinder block.
CAUTION: Use only the specified anaerobic sealer
on the bedplate or damage may occur to the
engine.
(4) Apply 1.5 to 2.0 mm (0.059 to 0.078 in.) bead of
Mopar Torque Cure Gasket Maker to cylinder block
as shown in (Fig. 66).
(5) Install lower main bearings into main bearing
cap/bedplate. Make certain the bearing tabs areseated into the bedplate slots. Install the main bear-
ing/bedplate into engine block.
(6) Before installing the bolts oil threads with
clean engine oil, wipe off any excess oil.
(7) Install main bearing bedplate to engine block
bolts 11, 17 and 20 finger tight. Tighten this bolts
down together until the bedplate contacts the cylin-
der block. Torque bolts to 30 N´m (22 ft. lbs.) (Fig.
67).
Fig. 63 Bedplate BoltsFig. 64 Main Bearing Identification
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REMOVAL AND INSTALLATION (Continued)

(8) Install main bearing bedplate to engine block
bolts (1 thru 10) and torque each bolt to 81 N´m (60
ft. lbs.) in sequence shown in (Fig. 67).(9) Install main bearing bedplate to engine block
bolts (11 thru 20), with baffle studs in positions 12,
13 and 16 and torque each bolt to 30 N´m (22 ft. lbs.)
in sequence shown in (Fig. 67).
(10) After the main bearing bedplate is installed,
check the crankshaft turning torque. The turning
torque should not exceed 5.6 N´m (50 in. lbs.).
(11) Install oil pump. If crankshaft end play is to
be checked refer to service procedures in this section.
(12) Install crankshaft sprocket.
(13) Install oil filter adapter and filter.
(14) Install oil pan and collar. Refer to procedures
outlined in the section.
(15) Perform camshaft and crankshaft timing
relearn procedure as follows:
²Connect the DRB scan tool to the data link
(diagnostic) connector. This connector is located in
the passenger compartment; at the lower edge of
instrument panel; near the steering column.
²Turn the ignition switch on and access the ªmis-
cellaneousº screen.
²Select ªre-learn cam/crankº option and follow
directions on DRB screen.
OIL FILTER ADAPTER
REMOVE AND INSTALL
Ensure O-ring is in the groove on adapter. Align
roll pin into engine block and tighten assembly to 80
N´m (60 ft. lbs.) (Fig. 68).
OIL FILTER
REMOVE AND INSTALL
CAUTION: When servicing the oil filter (Fig. 69)
avoid deforming the filter, install tool band strap
against the seam at the base of the filter. The seam,
joining the can to the base is reinforced by the
base plate.
(1) Turn counterclockwise to remove.
(2) To install, lubricate new filter gasket. Check
filter mounting surface. The surface must be smooth,
flat and free of debris or old pieces of rubber. Screw
Fig. 65 Installing Main Bearing Upper Shell
Fig. 66 Main Bearing Caps/Bedplate Sealing
Fig. 67 Main Bearing Caps/Bedplate Torque
Sequence
Fig. 68 Engine Oil Filter Adapter to Engine Block
9 - 24 ENGINENS/GS
REMOVAL AND INSTALLATION (Continued)

filter on until gasket contacts base. Tighten to 21
N´m (15 ft. lbs.).
OIL PUMP
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove Timing Belt. Refer to Timing Belt Sys-
tem, in this section.
(3) Remove Oil Pan. Refer to Oil Pan Removal in
this section.
(4) Remove Crankshaft Sprocket using Special Tool
6793 and insert C-4685-C2 (Fig. 70).
(5) Remove oil pick-up tube.
(6) Remove oil pump (Fig. 71) and front crankshaft
seal.
INSTALLATION
(1) Make sure all surfaces are clean and free of oil
and dirt.(2) Apply MopartGasket Maker to oil pump as
shown in (Fig. 72). Install o±ring into oil pump body
discharge passage.
(3) Prime oil pump before installation.
(4) Align oil pump rotor flats with flats on crank-
shaft as you install the oil pump to the block.
NOTE: Front crankshaft seal MUST be out of pump
to align, or damage may result.
(5) Torque all oil pump attaching bolts to 28 N´m
(250 in. lbs.)
(6) Install new front crankshaft seal using Special
Tool 6780 (Fig. 73).
(7) Install crankshaft sprocket, using Special Tool
6792 (Fig. 74).
(8) Install oil pump pick-up tube and oil pan.
(9) Install Timing Belt. Refer to procedure outlined
in this section.
(10) Connect negative cable to battery.
PISTON AND CONNECTING ROD
REMOVAL
(1) Remove top ridge of cylinder bores with a reli-
able ridge reamer before removing pistons from cyl-
inder block.Be sure to keep tops of pistons
covered during this operation. Mark piston with
matching cylinder number (Fig. 75).
(2) Remove oil pan. Scribe the cylinder number on
the side of the rod and cap (Fig. 76) for identification.
(3) Pistons will have a stamping in the approxi-
mate location shown in (Fig. 75). These stamps will
be either a directional arrow or a weight identifica-
tion for the assembly. L is for light and H is for
heavy. These assemblies should all be the same
weight class. Service piston assemblies are marked
with a S and can be used with either L or H produc-
tion assemblies. The weight designation stamps
should face toward the timing belt side of the engine.
(4) Pistons and connecting rods must be removed
from top of cylinder block. Rotate crankshaft so that
each connecting rod is centered in cylinder bore.
(5) Remove connecting rod cap boltsDo not use
old bolts if reinstalling connecting rod.Push
each piston and rod assembly out of cylinder bore.
NOTE: Be careful not to nick crankshaft journals.
(6) After removal, install bearing cap on the mat-
ing rod.
(7) Piston and Rods are serviced as an assembly.
PISTON RINGÐREMOVAL
(1) ID mark on face of upper and intermediate pis-
ton rings must point toward piston crown.
Fig. 69 Engine Oil Filter
Fig. 70 Crankshaft SprocketÐRemoval
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REMOVAL AND INSTALLATION (Continued)

(2) Using a suitable ring expander, remove upper
and intermediate piston rings (Fig. 77).
(3) Remove the upper oil ring side rail, lower oil
ring side rail and then oil ring expander from piston.
(4) Clean ring grooves of any carbon deposits.
PISTON RINGSÐINSTALLATION
(1) Install rings with manufacturers I.D. mark fac-
ing up, to the top of the piston (Fig. 78).
CAUTION: Install piston rings in the following
order:
a. Oil ring expander.b. Upper oil ring side rail.
c. Lower oil ring side rail.
d. No. 2 Intermediate piston ring.
Fig. 71 Oil Pump and Tube
Fig. 72 Oil Pump Sealing
Fig. 73 Front Crankshaft SealÐInstallation
9 - 26 ENGINENS/GS
REMOVAL AND INSTALLATION (Continued)

e. No. 1 Upper piston ring.
f. 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. 79).
(2) Install upper side rail first and then the lower
side rail.
(3) Install No. 2 piston ring and then No. 1 piston
ring (Fig. 78).(4) Position piston ring end gaps as shown in (Fig.
80).
(5) Position oil ring expander gap at least 45É from
the side rail gaps butnoton the piston pin center or
Fig. 74 Crankshaft SprocketÐInstallation
Fig. 75 Piston Markings
Fig. 76 Identify Connecting Rod to Cylinder
Fig. 77 Piston RingsÐRemoving and Installing
Fig. 78 Piston Ring Installation
Fig. 79 Installing Side Rail
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REMOVAL AND INSTALLATION (Continued)