1996 CHRYSLER VOYAGER Service Manual

technical data USB port child seat service schedule load capacity manual transmission

Page 1257 of 1938

CHRYSLER VOYAGER 1996 Service Manual DESCRIPTION...........SPECIFICATIONS
Nominal.................63.005±63.020 mm
±0.25....................62.755±62.770 mm
±0.125...................62.880±62.895 mm
Center Bearing Diameter..........

DESCRIPTION...........SPECIFICATIONS
Nominal.................63.005±63.020 mm
±0.25....................62.755±62.770 mm
±0.125...................62.880±62.895 mm
Center Bearing Diameter...................
Nominal.................63.050±63.093 mm
±0.25....................62.800±62.843 mm
±0.125...................62.925±62.968 mm
Clearance Between Journal and Bearing:
0.030±0.088 mm..........................
Rear Journal Diameter.....................
Nominal.................79.980±80.000 mm
±0.25....................79.730±79.750 mm
±0.125...................79.855±79.875 mm
Rear Bearing Diameter.....................
Nominal.................80.045±80.070 mm
±0.25....................79.795±79.820 mm
±0.125...................79.920±79.945 mm
Clearance Between Journal and Bearing:
0.045±0.090 mm (Wear Limit: 0.200 mm).......
Connecting Rod Journal....................
Nominal.................53.940±53.955 mm
±0.25....................53.690±53.705 mm
±0.125...................53.815±53.830 mm
Connecting Rod Bearing....................
Nominal.................53.977±54.016 mm
±0.25....................53.727±53.766 mm
±0.125...................53.852±53.891 mm
Clearance Between Journal and Bearing:
0.022±0.076 mm (Wear Limit: 0.200 mm).......
Crankshaft End Play
End Play.....................0.08±0.21 mm
Adjustment.................Thrust Washers
Thrust Washers Available........2.31±2.36 mm
Thrust Washers Available........2.41±2.46 mm
Thrust Washers Available........2.51±2.56 mm
Main Bearing Carriers
Front....................67.025±67.050 mm
Center...................66.670±66.690 mm
Rear....................85.985±86.005 mm
Liners
Internal Diameter..........92.000±92.010 mm
Protrusion....................0.01±0.06 mm
Adjustment.........................Shims
Available Shims:...................0.15 mm
Available Shims:...................0.17 mm
Available Shims:...................0.20 mm
Available Shims:...................0.23 mm
Available Shims:...................0.25 mm
Cylinder Head
Minimum Thickness..........89.95±90.05 mm
Gasket.............................Steel
Gasket thickness:.......1.4260.1 mm 0 Holes
Gasket thickness:.......1.6260.1 mm 1 HolesDESCRIPTION...........SPECIFICATIONS
Gasket thickness:.......1.5260.1 mm 2 Holes
End Plates
Height.....................89.02±90.00 mm
Connecting Rods
Weight (Without the crank
bearing)..................1129±1195 grams
Small End Bearing Internal Diameter
Minimum.......................30.035 mm
Maximum......................30.050 mm
Crankshaft Bearings Standard Internal
Diameter.................53.997±54.016 mm
Pistons
Skirt Diameter............91.935±91.945 mm
(Measured at approximately 15 mm above the
bottom of the skirt)
Piston Clearance.............0.055±0.075 mm
Top of Piston to Cylinder Head....0.80±0.89 mm
Piston Protrusion.....0.53±0.62 mm Fit Gasket
(1.42), 0 Holes
Piston Protrusion.....0.73±0.82 mm Fit Gasket
(1.62), 1 Hole
Piston Protrusion.....0.63±0.72 mm Fit Gasket
(1.52), 2 Holes
Piston Pins
Type .........................Full Floating
Pin Diameter..............29.990±29.996 mm
Clearance..................0.004±0.014 mm
Piston Rings (Clearance in Groove)
Top .......................0.080±0.130 mm
Second.....................0.070±0.102 mm
Oil Control.................0.040±0.072 mm
Piston Rings (Fitted Gap)
Top .........................0.25±0.50 mm
Second......................0.20±0.35 mm
Oil Control...................0.25±0.58 mm
Camshaft
Journal Diameter Front.....53.460±53.480 mm
Bearing Clearance.............0.06±0.13 mm
Journal Diameter Center....53.460±53.480 mm
Bearing Clearance.............0.06±0.13 mm
Journal Diameter Rear......53.460±53.480 mm
Bearing Clearance.............0.06±0.13 mm
Tappets
Outside Diameter..........22.195±22.212 mm
Rocker Gear
Shaft Diameter.............21.979±22.00 mm
Bushing internal diameter . . . 22.020±22.041 mm
Assembly Clearance..........0.020±0.062 mm
Valves (Intake)
Opens........................26ÉB.T.D.C.
Closes........................58ÉA.B.D.C.
Valves (Exhaust)
Opens........................64ÉB.B.D.C.
Closes........................38ÉA.T.D.C.
NS/GSENGINE 9 - 79
SPECIFICATIONS (Continued)

Page 1258 of 1938

CHRYSLER VOYAGER 1996 Service Manual DESCRIPTION...........SPECIFICATIONS
Valve Face Angle
Intake.......................55É30± 55É50
Exhaust.....................45É25± 45É35
Valve Head Diameter
Intake.....................40.05�

DESCRIPTION...........SPECIFICATIONS
Valve Face Angle
Intake.......................55É30'± 55É50'
Exhaust.....................45É25'± 45É35'
Valve Head Diameter
Intake.....................40.05±40.25 mm
Exhaust.....................33.8±34.0 mm
Valve Head Stand Down
Intake.......................1.08±1.34 mm
Exhaust.....................1.99±1.25 mm
Valve Stem Diameter
Intake.....................7.940±7.960 mm
Exhaust....................7.922±7.940 mm
Valve Clearance in Guide
Intake.....................0.040±0.075 mm
Exhaust....................0.060±0.093 mm
Valve Guide
Inside Diameter...............8.0±8.015 mm
Fitted Height.................13.5±14.0 mm
Valve Spring
Free Length.....................44.65 mm
Fitted Length.....................38.6 mm
Load at Fitted Length............3466% Kg
Load at Top of Lift.............92.564% Kg
Number of Coils............5.33 Valve Timing
Oil Pressure
at 4000 rpm.....3.0to4.5bar(Oil at 90±100ÉC)
Pressure Relief Valve Opens..........6.38 bar
Pressure Relief Valve±Free Length.....57.5 mm
Oil Pump
Outer Rotor End Float..........0.03±0.09 mm
Inner Rotor End Float..........0.03±0.09 mm
Outer Rotor to Body Diameter
Clearance..................0.130±0.230 mm
Rotor Body to Drive Gear Clearance (Pump Not
Fitted)......................3.27±3.73 mm
TORQUE
DESCRIPTION...................TORQUE
Generator Mounting Bracket
Bolts....................47N´m(35ft.lbs.)
Camshaft Thrust Plate Retaining Bolts
Bolt.....................24N´m(18ft.lbs.)
Cylinder Head
Bolts . . See Cylinder Head Installation Procedure
Connecting Rod
Bolts...........29.5 N´m +60É (22 ft. lbs. +60É)
Crankshaft Bearing Carrier
Bolts....................44N´m(32ft.lbs.)
Crankshaft damper (Pulley)
Nut ...................441N´m(325 ft. lbs.)
EGR Valve to Intake Manifold
Tube ....................26N´m(19ft.lbs.)DESCRIPTION...................TORQUE
EGR Tube to EGR Valve
Bolts....................26N´m(19ft.lbs.)
Engine MountÐFront
Support Bracket Engine Bolts . 68 N´m (50 ft. lbs.)
Support Bracket Transmission
Bolts...................101N´m(75ft.lbs.)
Support Cushion Crossmember
Bolts....................54N´m(40ft.lbs.)
Support Cushion Thru Bolt . . . 65 N´m (48 ft. lbs.)
Engine MountÐRear
Support Bracket Transmission
Bolts...................101N´m(75ft.lbs.)
Support Bracket to Engine
Bracket.................101N´m(75ft.lbs.)
Support Cushion Thru Bolt . . . 68 N´m (50 ft. lbs.)
Engine MountÐLeft
Transmission Mounting Bolts . 54 N´m (40 ft. lbs.)
Support Cushion Thru Bolt . . . 71 N´m (53 ft. lbs.)
Engine MountÐRight
Mount to Frame Rail Bolts . . . 68 N´m (50 ft. lbs.)
Mount Bolt (Horizontal) . . . 145 N´m (107 ft. lbs.)
Mount Bolt (Vertical).......101N´m(75ft.lbs.)
Right Engine Mount Bracket
Bolts....................40N´m(30ft.lbs.)
Exhaust Pipe to Turbocharger
Bolts...................28N´m(250 in. lbs.)
Exhaust Manifold Outlet to Turbo
Nuts....................32N´m(24ft.lbs.)
Exhaust Elbow to Turbo
Bolts....................30N´m(22ft.lbs.)
Exhaust Manifold Mounting
Nuts....................30N´m(22ft.lbs.)
Flywheel
Bolts.....SeeRear Crankshaft Seal Installation
Procedure
Engine Adaptor Plate
Bolts....................47N´m(35ft.lbs.)
Front Timing Gear Cover
Bolts....................11N´m(96in.lbs.)
Fuel Filter
Nuts...................28N´m(250 in. lbs.)
Glow Plugs
Plugs..................14N´m(120 in. lbs.)
Idler Pulley Pump Support Bracket
Nuts...................26N´m(228 in. lbs.)
Idler Pulleys (left handed threads)
Bolts....................47N´m(35ft.lbs.)
Injector Pump fuel lines
Nuts..................17.6 N´m (156 in. lbs.)
Injector Pump Gear
Lock Nut..........................86N´m
Injector Pump Mounting
Nuts..................27.5 N´m (240 in. lbs.)
9 - 80 ENGINENS/GS
SPECIFICATIONS (Continued)

Page 1259 of 1938

CHRYSLER VOYAGER 1996 Service Manual DESCRIPTION...................TORQUE
Injector
Tighten to................65N´m(48ft.lbs.)
Intake Manifold Mounting
Nuts...................30N´m(264 in. lbs.)
Main Bearing Oil Delivery Union
Bolts....

Page 1260 of 1938

CHRYSLER VOYAGER 1996 Service Manual Crankshaft Remover/Installer Sleeve VM.1004
Torque Angle Gauge VM.1005
Cylinder Head Bolt Wrench VM.1006A
Cylinder Head Guide Studs VM.1009
Cylinder Liner Protrusion Tool VM.1010
Injector Socket Remov

Page 1261 of 1938

CHRYSLER VOYAGER 1996 Service Manual Dial Indicator Gauge VM.1013
Flywheel Locking Tool VM.1014
Timing Cover Oil Seal Installer VM.1015
Cylinder Retainers VM.1016
Cylinder Head Bolt Wrench M12 VM.1018
NS/GSENGINE 9 - 83
SPECIAL TOOLS (Co

Page 1262 of 1938

CHRYSLER VOYAGER 1996 Service Manual Adapter Cylinder Leakage Tester VM.1021
Cylinder Head Bolt Wrench M14 VM.1019
Support Brackets Engine Removal/Installation
VM.1026
9 - 84 ENGINENS/GS
SPECIAL TOOLS (Continued)

Page 1263 of 1938

CHRYSLER VOYAGER 1996 Service Manual EXHAUST SYSTEM AND INTAKE MANIFOLD
CONTENTS
page page
GENERAL INFORMATION
CATALYTIC CONVERTERS................. 1
EXHAUST FLEX-JOINT COUPLING........... 2
EXHAUST GAS RECIRCULATION (EGR)....... 2
EXHA

EXHAUST SYSTEM AND INTAKE MANIFOLD
CONTENTS
page page
GENERAL INFORMATION
CATALYTIC CONVERTERS................. 1
EXHAUST FLEX-JOINT COUPLING........... 2
EXHAUST GAS RECIRCULATION (EGR)....... 2
EXHAUST SYSTEM....................... 1
HEAT SHIELDS.......................... 2
DESCRIPTION AND OPERATION
INTAKE/EXHAUST MANIFOLDÐ2.4L ENGINE . . 3
INTAKE/EXHAUST MANIFOLDÐ3.0L ENGINE . . 3
INTAKE/EXHAUST MANIFOLDÐ3.3/3.8L
ENGINES............................. 3
DIAGNOSIS AND TESTING
EXHAUST SYSTEM....................... 3REMOVAL AND INSTALLATION
EXHAUST MANIFOLDÐ2.4L ENGINE........ 8
EXHAUST MANIFOLDÐ3.0L ENGINE....... 11
EXHAUST MANIFOLDSÐ3.3/3.8L ENGINE . . . 16
EXHAUST PIPES, MUFFLERS AND TAILPIPES . 4
INTAKE MANIFOLD LOWERÐ2.4L ENGINE.... 6
INTAKE MANIFOLDÐ3.0L ENGINE.......... 8
INTAKE MANIFOLDÐ3.3/3.8L ENGINE...... 12
UPPER INTAKE MANIFOLDÐ2.4L ENGINE.... 4
CLEANING AND INSPECTION
EXHAUST MANIFOLD.................... 17
INTAKE MANIFOLD...................... 17
SPECIFICATIONS
TORQUE CHART........................ 18
GENERAL INFORMATION
EXHAUST SYSTEM
The exhaust systems are produced in several con-
figurations, depending on engine and vehicle (Fig. 1).
AWD vehicles have a catalytic converter mounted
heat shield. The tailpipes, mufflers, and resonators
are tuned to each vehicle/powertrain combination.
CATALYTIC CONVERTERS
There is no regularly scheduled maintenance on
any Chrysler catalytic converter. If damaged, the con-
verter must be replaced.CAUTION: Due to exterior physical similarities of
some catalytic converters with pipe assemblies,
extreme care should be taken with replacement
parts. There are internal converter differences
required in some parts of the country.
The combustion reaction caused by the catalyst
releases additional heat in the exhaust system. Caus-
ing temperature increases in the area of the reactor
under severe operating conditions. Such conditions
can exist when the engine misfires or otherwise does
not operate at peak efficiency.Do notremove spark
plug wires from plugs or by any other means short
out cylinders of the exhaust system if equipped with
Fig. 1 Exhaust SystemÐTypical (All Vehicles)
NSEXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 1

Page 1264 of 1938

CHRYSLER VOYAGER 1996 Service Manual a catalytic converter. Failure of the catalytic con-
verter can occur due to temperature increases caused
by unburned fuel igniting when passing through the
converter.
The use of the catalysts also in

a catalytic converter. Failure of the catalytic con-
verter can occur due to temperature increases caused
by unburned fuel igniting when passing through the
converter.
The use of the catalysts also involves some non-au-
tomotive problems. Unleaded gasoline must be used
to avoid poisoning the catalyst core. Do not allow
engine to operate at fast idle for extended periods
(over 5 minutes). This condition may result in exces-
sive exhaust system and floor pan temperatures.
EXHAUST GAS RECIRCULATION (EGR)
To assist in the control of oxides of nitrogen (NOx)
in engine exhaust, all engines are equipped with an
exhaust gas recirculation system. The use of exhaust
gas to dilute incoming air/fuel mixtures lowers peak
flame temperatures during combustion, thus limiting
the formation of NOx.
Exhaust gases are taken from opening in the
exhaust manifold passage to the intake manifold.
REFER TO SECTION 25 FOR A COMPLETE
DESCRIPTION, DIAGNOSIS AND SERVICE PRO-
CEDURES ON THE EXHAUST GAS RECIRCULA-
TION SYSTEM AND COMPONENTS.
HEAT SHIELDS
Heat shields (Fig. 2) are needed to protect both the
vehicle and the floor pan from the high temperatures
developed near the catalytic converter and muffler.
Avoid application of rust prevention com-
pounds or undercoating materials to exhaust
system floor pan heat shields on cars so
equipped. Light over spray near the edges is
permitted. Application of coating will greatlyreduce the efficiency of the heat shields result-
ing in excessive floor pan temperatures and
objectionable fumes.
EXHAUST FLEX-JOINT COUPLING
A exhaust flex-joint coupling (Fig. 3) is used to
secure the catalytic converter to the engine manifold.
This living joint actually moves back and forth as the
engine moves, preventing breakage that could occur
from the back-and-forth motion of a transverse
mounted engine.
The exhaust flex-joint has four bolts, four flag nuts
and a gasket that are separate parts from the
exhaust flex-joint. The flex-joint is welded to the cat-
alytic converter.
Fig. 2 Heat Shields
Fig. 3 Flex-Joint
11 - 2 EXHAUST SYSTEM AND INTAKE MANIFOLDNS
GENERAL INFORMATION (Continued)

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