1996 CHRYSLER VOYAGER torque

OIL PAN
REMOVAL
(1) Raise vehicle on hoist and drain engine oil.
(2) Remove front engine mount bracket from
engine and insulator mount.
(3) Remove bolts attaching bending strut to engine
and transaxle.
(4) Remove bolts attaching collar and bending
strut to engine, oil pan, and transaxle (Fig. 79).
Remove strut and collar.
(5) Remove oil pan.
(6) Clean oil pan and all gasket surfaces.
INSTALLATION
(1) Apply MopartSilicone Rubber Adhesive Seal-
ant or equivalent at the oil pump to engine block
parting line (Fig. 80).
(2) Install the oil pan gasket to the block (Fig.
81).(3) Install pan and tighten the screws to 12 N´m
(105 in. lbs.).
CAUTION: Torque procedure for the structural col-
lar and bending strut must be followed or damage
could occur to oil pan, collar, and/or bending strut.
(4) Perform the following steps for installing struc-
tural collar and bending strut. Refer to (Fig. 79):
²Step 1: Place collar into position between tran-
saxle and oil pan. Hand start only, collar to transaxle
bolt 1.
²Step 2: Install bolt 4, collar to oil pan,hand
tight only.
²Step 3: Position bending strut in place and hand
start bolt 3 into the upper transaxle hole.
²Step 4: Install bolt 2, through strut and collar.
Hand starting only.
²Step 5: Install bolt 6, strut to cylinder block,
hand tight only.
²Step 6: Install the remaining collar to oil pan
bolt 5,hand tight only.
²Step 7: Final torque collar to transaxle bolts 1 ±
3, to 101 N´m (75 ft. lbs.)
²Step 8: Install bolts 7 and 8, through strut and
into cylinder block.
²Step 9: Final torque bolts4±8to61N´m(45ft.
lbs.).
(5) Install front mount bracket to engine and front
insulator. Refer to procedure in the section.
(6) Lower vehicle and fill engine crankcase with
proper oil to correct level.
Fig. 79 Structural Collar and Bending StrutÐ
Removal and Installation
Fig. 80 Oil Pan Sealing
Fig. 81 Oil Pan Gasket Installation
NS2.4L ENGINE 9 - 45
REMOVAL AND INSTALLATION (Continued)

CRANKSHAFT
REMOVAL
NOTE: Crankshaft can not be removed when
engine is in vehicle.
(1) Remove oil filter and oil pan. Refer to proce-
dure outlined in this section.
(2) Remove Timing Belt Cover, Timing Belt and
Oil Pump. Refer to procedure outlined in this section.
(3) Remove Balance Shafts Assembly. Refer to pro-
cedure outlined in this section.
(4) Remove all main bearing cap bedplate bolts
from the engine block. Refer to procedure outlined in
this section.
(5) Using a mallet gently tap the bedplate loose
from the engine block dowel pins.
CAUTION: Do not pry up on one side of the bed-
plate. Damage may occur to cylinder block to bed-
plate alignment and thrust bearing.
(6) Bedplate should be removed evenly from the
cylinder block dowel pins to prevent damage to the
dowel pins and thrust bearing.
(7) Lift out crankshaft from cylinder block. Do not
damage the main bearings or journals when remov-
ing the crankshaft.
INSTALLATION
(1) Install the main bearing shells with the lubri-
cation groove in the cylinder block (Fig. 82).
(2) Make certain oil holes in block line up with oil
hole in bearings and bearing tabs seat in the block
tab slots.CAUTION: Do not get oil on the bedplate mating
surface. It will may effect the sealer ability to seal
the bedplate to cylinder block.
(3) Oil the bearings and journals. Install crank-
shaft.
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. 83).
(5) Install lower main bearings into main bearing
cap/bedplate. Make certain the bearing tabs are
seated into the bedplate slots. Install the main bear-
ing/bedplate into engine block.
(6) Before installing the bolts the threads should
be oiled with clean engine oil, wipe off any excess oil.
Fig. 82 Installing Main Bearing Upper Shell
Fig. 83 Main Bearing Caps/Bedplate Sealing
Fig. 84 Main Bearing Caps/Bedplate Torque
Sequence
9 - 46 2.4L ENGINENS
REMOVAL AND INSTALLATION (Continued)

(7) Install main bearing bedplate to engine block
bolts 11, 17 and 20 finger tight. Tighten these bolts
down together until the bedplate contacts the cylin-
der block.
(8) To ensure correct thrust bearing alignment per-
form the following steps:
²Step 1: Rotate crankshaft until number 4 pis-
ton is at TDC.
²Step 2: Move crankshaft rearward to limits of
travel.
²Step 3: Then, move crankshaft forward to lim-
its of travel.
²Step 4: Wedge an appropraite tool between the
rear of the cylinder block(NOT BED PLATE)and
the rear crankshaft counterweight. This will hold the
crankshaft in it's furthest forward position.
²Step 5: Install and tighten bolts (1-10) in
sequence shown in (Fig. 84) to 41 Nzm (30 ft. lbs.).
²Step 6: Remove wedge tool used to hold crank-
shaft.
(9) Tighten bolts (1-10) again to 41 Nzm (30 ft. lbs)
+ 1/4 turn in sequence shown in (Fig. 84).
(10) Install main bearing bedplate to engine block
bolts (11-20), and torque each bolt to 28 Nzm (20 ft.
lbs.) in sequence shown in (Fig. 84).
(11) After the main bearing bedplate is installed,
check the crankshaft turning torque. The turning
torque should not exceed 5.6 Nzm (50 in. lbs.).
OIL FILTER
CAUTION: When servicing the oil filter avoid
deforming the filter can by installing the remove/in-
stall 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) 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
filter on until the 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 procedure out-
lined in this section.
(3) Remove Oil Pan. Refer to procedure outlined in
this section.
(4) Remove Crankshaft Sprocket using Special Tool
6793 and insert C-4685-C2 (Fig. 85).
(5) Remove oil pick-up tube.
(6) Remove oil pump, (Fig. 86) and front crank-
shaft seal.
Fig. 85 Crankshaft SprocketÐRemoval
NS2.4L ENGINE 9 - 47
REMOVAL AND INSTALLATION (Continued)

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. 87). Install oil 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) Install new front crankshaft seal using Special
Tool 6780 (Fig. 88).
(6) Install crankshaft sprocket, using Special Tool
6792 (Fig. 89).
(7) Install oil pump pick-up tube.
CAUTION: Installation and torque procedure for the
collar must be followed or damage could occur to
oil pan or collar.
(8) Install oil pan and collar. Refer to procedure
outlined in this section.
(9) Install Timing Belt. Refer to procedure outlined
in this section.
Fig. 86 Oil Pump and Pick-up Tube
Fig. 87 Oil Pump Sealing
9 - 48 2.4L ENGINENS
REMOVAL AND INSTALLATION (Continued)

(2) Before installing the ring compressor, make
sure the oil ring expander ends are butted and the
rail gaps located as shown in (Fig. 92). As viewed
from top.
(3) Immerse the piston head and rings in clean
engine oil, slide the ring compressor, over the piston
(Fig. 93).Be sure position of rings does not
change during this operation.
(4) The directional stamp on the piston should
face toward the front of the engine (Fig. 90).
(5) Rotate crankshaft so that the connecting rod
journal is on the center of the cylinder bore. Insert
rod and piston assembly into cylinder bore and guide
rod over the crankshaft journal.
(6) Tap the piston down in cylinder bore, using a
hammer handle. At the same time, guide connecting
rod into position on connecting rod journal.
NOTE: The rod bearing bolts should not be reused.
(7) Before installing theNEWbolts the threads
should be coated with clean engine oil.(8) Install each bolt finger tight than alternately
torque each bolt to assemble the cap properly.
CAUTION: Do not use a torque wrench for second
part of last step.
(9) Tighten the bolts to 27 N´m PLUS 1/4 turn (20
ft. lbs. PLUS 1/4 turn).
(10) Using a feeler gauge, check connecting rod
side clearance (Fig. 94).
DISASSEMBLY AND ASSEMBLY
OIL PUMP
DISASSEMBLY
(1) To remove the relief valve, proceed as follows:
(a) Remove the threaded plug and gasket from
the oil pump (Fig. 95).
(b) Remove spring and relief valve.
(2) Remove oil pump cover screws, and lift off
cover.
(3) Remove pump rotors.
Fig. 92 Piston Ring End Gap Position
Fig. 93 PistonÐInstallation
Fig. 94 Checking Connecting Rod Side Clearance
Fig. 95 Oil Pressure Relief Valve
9 - 50 2.4L ENGINENS
REMOVAL AND INSTALLATION (Continued)

TORQUE CHART 2.4L
DESCRIPTION TORQUE
Balance Shaft Carrier to Block
Bolts.....................54N´m(40ft.lbs.)
Balance Shaft Gear Cover
Double Ended Fastener......12N´m(105 in. lbs.)
Balance Shaft Sprockets
Bolts....................28N´m(250 in. lbs.)
Balance Shaft Chain Tensioner
Bolts....................12N´m(105 in. lbs.)
Balance Shaft Carrier Cover
Fasteners................12N´m(105 in. lbs.)
Camshaft Sensor Pick Up
Bolts.....................27N´m(20ft.lbs.)
Timing Belt Cover
Outer to Inner Attaching Bolts M6.......4.5 N´m
(40 in. lbs.)
Inner Cover to Head/Oil Pump Bolts M6 . . .12 N´m
(105 in. lbs.)
Camshaft Sprocket
Bolt.....................101 N´m (75 ft. lbs.)
Connecting Rod Cap
Bolts..............................27N´m
(20 ft. lbs.) Plus 1/4 Turn
Crankshaft Main Bearing Cap/Bedplate
M8 Bedplate Bolts.........34N´m(250 in. lbs.)
Main Cap Bolts M11..................41N´m
(30 ft. lbs.) Plus 1/4 Turn
Crankshaft Damper
Bolt....................135 N´m (100 ft. lbs.)
Cylinder Head
Bolts........Refer To Cylinder Head Installation
Cylinder Head Cover
Bolts....................12N´m(105 in. lbs.)DESCRIPTION TORQUE
Engine Mount Bracket
Bolts.....................61N´m(45ft.lbs.)
Engine MountÐFront and Rear
Through Bolt...............61N´m(45ft.lbs.)
Exhaust Manifold to Cylinder Head
Bolts....................23N´m(200 in. lbs.)
Exhaust Manifold Heat Shield
Bolts....................12N´m(105 in. lbs.)
Front Torque BracketÐ2.0/2.4L Engine
Bolts.....................33N´m(24ft.lbs.)
Front Torque Bracket StrutÐ2.0/2.4L Engine
Long Bolts................110N´m(80ft.lbs.)
Short Bolt.................61N´m(45ft.lbs.)
Intake Manifold
Bolts.....................27N´m(20ft.lbs.)
Oil Filter
Filter.....................20N´m(15ft.lbs.)
Oil Pan
Oil Pan Bolts.............12N´m(105 in. lbs.)
Drain Plug.................27N´m(20ft.lbs.)
Oil Pump Attaching
Bolts....................28N´m(250 in. lbs.)
Oil Pump Cover Fastener. . . .12 N´m (105 in. lbs.)
Oil Pump Pick-up Tube Bolt . .28 N´m (250 in. lbs.)
Oil Pump Relief Valve Cap. . . .41 N´m (30 ft. lbs.)
Rear Torque Bracket
Bolts....................110N´m(80ft.lbs.)
Spark Plugs
Plugs.....................28N´m(20ft.lbs.)
Thermostat Housing
Bolts....................23N´m(200 in lbs.)
Timing Belt Tensioner Assembly
Bolts.....................61N´m(45ft.lbs.)
Water Pump Mounting
Bolts....................12N´m(105 in. lbs.)
NS2.4L ENGINE 9 - 57
SPECIFICATIONS (Continued)

3.0L ENGINE
INDEX
page page
DESCRIPTION AND OPERATION
ENGINE COMPONENTS.................. 61
ENGINE IDENTIFICATION NUMBER......... 61
ENGINE LUBRICATION................... 61
DIAGNOSIS AND TESTING
CHECKING ENGINE OIL PRESSURE......... 62
SERVICE PROCEDURES
AUTO LASH ADJUSTER................... 62
CHECKING CRANKSHAFT END PLAY........ 65
FITTING CONNECTING ROD BEARINGS...... 63
FITTING MAIN BEARING.................. 63
VALVE SERVICE RECONDITION............ 66
REMOVAL AND INSTALLATION
CAMSHAFT SEAL....................... 72
CAMSHAFT............................ 71
CRANKSHAFT.......................... 81
CYLINDER HEAD COVER................. 70
CYLINDER HEAD........................ 73
ENGINE ASSEMBLY...................... 69
ENGINE MOUNTS....................... 68
FRONT CRANKSHAFT OIL SEAL............ 83OIL FILTER AND ADAPTOR................ 84
OILPAN ............................... 77
OIL PUMP............................. 84
PISTON AND CONNECTING ROD........... 78
REAR CRANKSHAFT SEAL................ 83
ROCKER ARMS......................... 72
TIMING BELT........................... 75
DISASSEMBLY AND ASSEMBLY
ROCKER ARMS AND SHAFTS.............. 85
CLEANING AND INSPECTION
CYLINDER BORE........................ 87
CYLINDER HEAD........................ 86
OIL PUMP............................. 87
TIMING BELT........................... 86
ADJUSTMENTS
ENGINE MOUNTS....................... 88
SPECIFICATIONS
3.0L ENGINE........................... 89
TORQUE CHART 3.0L.................... 90
SPECIAL TOOLS
3.0L ENGINE........................... 91
DESCRIPTION AND OPERATION
ENGINE IDENTIFICATION NUMBER
The engine identification number is located on the
rear of the cylinder block just below the cylinder
head (Fig. 1).
ENGINE LUBRICATION
System is a full flow filtration, pressure feed type.
The oil pump is mounted behind the timing belt
cover. The pump inner rotor is driven by the crank-
shaft. The engine oil pan contains a baffle plate to
control oil level fluctuation during engine operation.
ENGINE COMPONENTS
BLOCK:The cylinder block is a light weight
design created by reducing thickness in many parts
and a short 10 mm (3/8 in.) block skirt. High rigidity
is provided with ribs cast in the outer wall, a full
length water jacket, and a mono-block or beam type,
main bearing cap. This single unit four bearing cap
is designed to control vibration of the cylinder block
partition walls.
CRANKSHAFT:A six throw, five weight crank-
shaft is supported by four main bearings with num-
ber three being the thrust bearing. The six separate
connecting rod throws pins reduce torque fluctua-tions while a torsional vibration damper is used to
control torsion caused vibration of the crankshaft.
Rubber lipped seals are used at front and rear. The
Fig. 1 Engine Identification
NS3.0L ENGINE 9 - 61

CAUTION: Do not rotate crankshaft or the plasti-
gage will be smeared.
(4) Install the main bearing cap carefully and
tighten the bolts to specified torque.(5) Carefully remove the bearing cap and measure
the width of the plastigage at the widest part using
the scale on the plastigage package (Fig. 9). Refer to
Crankshaft Clearance Specification Chart for proper
clearances. Also see Measuring Main and Connecting
Rod Bearing Clearance in Standard Service Proce-
dures.
CRANKSHAFT BEARING INSTALLATION
When the bearings need replacing, select and
install the proper bearing by the following procedure.
(1) Measure the crankshaft journal diameter and
confirm its classification from the following. In the
case of a bearing supplied as a service part, its iden-
tification color is painted at the position show in (Fig.
10).
NOTE: Service replacement parts have identifica-
tion marks, but factory-assembled parts have no
identification marks. Service crankshaft identifica-
tion may have marks or paint at counterweights.
Refer to Crankshaft Size Classification Chart.
Fig. 6 Measure Crankshaft Journal O.D.
Fig. 7 Measure Main Bearing I.D.
CRANKSHAFT SPECIFICATION CHART
Crankshaft End-Play
New Part: 0.05 - 0.25 mm
(0.002 - 0.001 in.)
Wear Limit: 0.30 mm (0.012 in.)
Main Bearing Oil Clearance
New Part: 0.018 - 0.036 mm
(0.0007 - 0.0014 in.)
Wear Part: 0.10 mm (0.0039 in.)
Crankshaft Main Bearing Journal
Standard Diameter: 59.980 mm (2.361 in.)
Crankshaft Connecting Rod Journal
Standard Diameter: 50.00 mm (1.968 in.)
Fig. 8 Measure Oil Clearance with Plastigage
Fig. 9 Measuring Clearance
9 - 64 3.0L ENGINENS
SERVICE PROCEDURES (Continued)