1996 CHRYSLER VOYAGER Service Manual

(3) Install cylinder head cover, torque nuts to 14.7
N´m (132 in. lbs.).
(4) Install coolant pressure tank.
(5) Install breather hose.
(6) Install generator bracket, tighten bolts to 7
N´m (4 ft. lbs.).
(7) Connect the service valves to the A/C compres-
sor ports, if equipped with air conditioning.
(8) Connect battery cable.
VALVE SPRINGSÐCYLINDER HEAD NOT
REMOVED
This procedure can be done with the engine cylin-
der head installed on the block.
REMOVAL
Each valve spring is held in place by a retainer
and a set of conical valve locks. The locks can be
removed only by compressing the valve spring.
(1) Remove the engine cylinder head cover, refer to
cylinder head cover removal in this section.
(2) Remove rocker arms assemblies for access to
each valve spring to be removed.
(3) Remove push rods. Retain the push rods, and
rocker arms assemblies in the same order and posi-
tion as removed.
(4) Inspect the springs and retainer for cracks and
possible signs of weakening.
(5) Install an air hose adaptor in the fuel injector
hole.
(6) Connect an air hose to the adapter and apply
air pressure slowly. Maintain at least 621 kPa (90psi) of air pressure in the cylinder to hold the valves
against their seats.
(7) Tap the retainer or tip with a rawhide hammer
to loosen the lock from the retainer. Use Valve Spring
Compressor Tool to compress the spring and remove
the locks.
(8) Remove valve spring and retainer.
Inspect the valve stems, especially the grooves. An
Arkansas smooth stone should be used to remove
nicks and high spots.
INSTALLATION
(1) Install valve spring and retainer.
(2) Compress the valve spring with Valve Spring
Compressor Tool and insert the valve locks. Release
the spring tension and remove the tool. Tap the
spring from side-to-side to ensure that the spring is
seated properly on the engine cylinder head.
(3) Disconnect the air hose. Remove the adaptor
from the fuel injector hole and install the fuel injec-
tor.
(4) Repeat the procedures for each remaining valve
spring to be removed.
(5) Install the push rods. Ensure the bottom end of
each rod is centered in the plunger cap seat of the
hydraulic valve tappet.
(6) Install the rocker arm assemblies, at their orig-
inal location.
(7) Tighten the rocker arm assembly nut to 106
N´m (78 ft. lbs.) torque.
(8) Install the engine cylinder head cover, refer to
cylinder head cover installation in this section.
CYLINDER HEAD
REMOVAL
(1) Disconnect the battery cable.
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAIN COCK WITH THE SYSTEM HOT AND PRES-
SURIZED BECAUSE SERIOUS BURNS FROM THE
COOLANT CAN OCCUR.
(2) Drain the cooling system. Refer to Group 7,
Cooling.
(3) Remove wiper module. Refer to Group 8K,
Windshield Wiper Unit Removal for procedure.
(4) Remove coolant pressure bottle.
(5) Remove intercooler hose at intake manifold
(Fig. 23).
(6) Remove intercooler hose at turbocharger inter-
cooler tube.
(7) Remove the upper radiator hose.
(8) Remove water manifold.
(9) Disconnect the heater hoses and coolant pres-
sure bottle hoses.
Fig. 22 Rocker Arm Retaining Nut
NS/GSENGINE 9 - 55
REMOVAL AND INSTALLATION (Continued)

(10) Disconnect EGR tube from EGR valve (Fig.
25).
(11) Remove exhaust pipe from turbocharger elbow
and.
(12) Disconnect oil feed line from turbo (Fig. 24).
(13) Disconnect oil drain line from turbo.
(14) Remove Intake manifold. Refer to Group 11,
Exhaust System and Intake Manifold.
(15) Remove lift eye and brake vacuum tube at
rear of exhaust manifold.(16) Remove the support strut from block to turbo-
charger exhaust elbow.
(17) Remove Exhaust manifold. Refer to Group 11,
Exhaust System and Intake Manifold.
(18) Remove oil line at pressure switch.
(19) Remove oil feed line for rocker arm assemblies
(Fig. 26).
(20) Remove Crankcase breather hose from valve
cover
(21) Remove the engine cylinder head cover.
Fig. 23 Intercooler Assembly
Fig. 24 Turbocharger
Fig. 25 EGR Valve and Tube
Fig. 26 Rocker Arm Oil Feed Lines
9 - 56 ENGINENS/GS
REMOVAL AND INSTALLATION (Continued)

(22) Remove the injector sensor wire at the con-
nector, and glow plug Connectors.
NOTE: The attachment point for the injector sensor
wire at the injector is not a connector. The connec-
tor is located in the wire 4 to 6 inches away from
the injector.
(23) Remove injector fuel lines from injectors to
pump.
(24) Remove fuel injectors with tool VM-1012A
(Fig. 27) and (Fig. 28) Refer to Group 14, Fuel Sys-
tem.
(25) Remove rocker retaining nuts (Fig. 29).
(26) Remove rocker assemblies. Place them on a
bench in the same order as removed.(27) Remove the push rods and place them on a
bench in the same order as removed.
(28) Mark cylinder heads to ensure installation in
there original position.
(29) Remove the engine cylinder head bolts with
special tool VM-1018 and VM-1019.
(30) Remove the engine cylinder heads and gasket.
NOTE: A single steel head gasket is used for 4 cyl-
inder heads (Fig. 32).
(31) Stuff clean lint free shop towels into the cyl-
inder bores.
CYLINDER HEAD GASKET
NOTE: If cylinder wall liners have not been
removed; the same thickness head gasket removed,
may be used.
CAUTION: Piston protrusion must be measured, to
determine cylinder head gasket thickness, if one or
more cylinder wall liners have been replaced.
Cylinder head gaskets are available in three thick-
ness. The different thicknesses are marked with
identification holes (one, two or none) (Fig. 32). The
gasket is to be installed DRY.DO NOT use a gas-
ket sealing compound on the gasket.
(1) Use special tool VM-1010 with dial indicator
special tool VM- 1013 (Fig. 30).
(2) Bring the piston of cylinder no. 1 exactly to top
dead center.
Fig. 27 Fuel Injector Tool VM-1012A
Fig. 28 Fuel Injector
Fig. 29 Rocker Arm Retaining Nut
NS/GSENGINE 9 - 57
REMOVAL AND INSTALLATION (Continued)

(3) Zero the dial indicator on the cylinder block
mating surface.
(4) Setup the dial indicator on the piston crown
(above the center of the piston pin) 5mm (1/8 in.)
from the edge of the piston and note the measure-
ment (Fig. 31).
(5) Repeat the procedure with the rest of the cyl-
inders.
(6) Establish the thickness of the gasket for all
four cylinder heads on the basis of the greatest pis-
ton protrusion (Fig. 32).
INSTALLATION CYLINDER HEAD
(1) Remove the shop towels from the cylinder
bores. Coat the bores with clean engine oil.
(2) Install cylinder head alignment studs
(VM-1009).
(3) After determining the correct head gasket
thickness, clean the block and head mating surfaces,
place the engine cylinder head gasket over the dow-
els.
(4) Place the engine cylinder head over the dowels.
CAUTION: Engine cylinder head bolts can be
reused up to three times.(5) Tighten the engine cylinder head bolts in
sequence according to the following procedure (Fig.
33):
a. The threads and underside heads of the bolts
should be lubricated. Use the cylinder head align-
ment studs tool number VM-1009. Position the heads
on the block and secure with the ten large center
bolts and spacers (clamps), finger tight only.
b. Ensure that the various clamps are installed
correctly and the head gasket remain in their proper
position, completely covered. Then, lubricate and
install the eight small bolts, also finger tight.
(6) Loosen assembly oil feed line for rocker arm
assemblies
(7) Install the intake and exhaust manifolds with
new gaskets, partially tightening the nuts to a max-
imum of 5 N´m (44 in. lbs.). This will align the heads
(refer to Group 11, Exhaust System and Intake Man-
ifold for the proper procedures). Install lift eye and
brake vacuum tube at this time.
(8) Then, tighten the 12mm bolts with special tool
VM-1019 in the following manner:
(9)1st Phase:Tightening Head Bolts (Fig. 33).
Central bolts (A-L): Tighten all bolts, starting with
bolt A then B-C-D-E-F-G-H-I-L, to 30 N´m. Repeat
the operation with the same torque. Following the
same sequence rotate each bolt through an angle of
Fig. 30 Measuring Piston Protrusion
Fig. 31 Piston Protrusion Chart
Fig. 32 Head Gasket Identification
9 - 58 ENGINENS/GS
REMOVAL AND INSTALLATION (Continued)