1996 CHRYSLER VOYAGER remove seats

ENGINE DIAGNOSISÐMECHANICAL
CONDITION POSSIBLE CAUSES CORRECTION
NOISY VALVES 1. High or low oil level in
crankcase.1. Check for correct oil level.
2. Thin or diluted oil. 2. Change oil to correct viscosity.
3. Low oil pressure. 3. Check engine oil level.
4. Dirt in tappets/lash adjusters. 4. Replace rocker arm/hydraulic
lash adjuster assembly.
5. Worn rocker arms. 5. Inspect oil supply to rocker arms.
6. Worn tappets/lash adjusters. 6. Install new rocker arm/hydraulic
lash adjuster assembly.
7. Worn valve guides. 7. Ream and install new valves with
oversize stems.
8. Excessive runout of valve seats
on valve faces.8. Grind valve seats and valves.
9. Missing adjuster pivot. 9. Replace rocker arm/hydraulic
lash adjuster assembly.
CONNECTING ROD NOISE 1. Insuffient oil supply. 1. Check engine oil level.
2. Low oil pressure. 2. Check engine oil level. Inspect oil
pump relief valve and spring.
3. Thin or diluted oil. 3. Change oil to correct viscosity.
4. Excessive bearing clearance. 4. Measure bearings for correct
clearance. Repair as necessary.
5. Connecting rod journal
out-of-round.5. Replace crankshaft or grind
surface.
6. Misaligned connecting rods. 6. Replace bent connecting rods.
MAIN BEARING NOISE 1. Insufficient oil supply. 1. Check engine oil level.
2. Low oil pressure. 2. Check engine oil level. Inspect oil
pump relief valve and spring.
3. Thin or diluted oil. 3. Change oil to correct viscosity.
4. Excessive bearing clearance. 4. Measure bearings for correct
clearance. Repair as necessary.
5. Excessive end play. 5. Check thrust bearing for wear on
flanges.
6. Crankshaft journal out-of-round
or worn.6. Replace crankshaft or grind
journals.
7. Loose flywheel or torque
converter.7. Tighten to correct torque.
OIL PRESSURE DROP 1. Low oil level. 1. Check engine oil level.
2. Faulty oil pressure sending unit. 2. Install new sending unit.
3. Low oil pressure. 3. Check sending unit and main
bearing oil clearance.
4. Clogged oil filter. 4. Install new oil filter.
5. Worn parts in oil pump. 5. Replace worn parts or pump.
6. Thin or diluted oil. 6. Change oil to correct viscosity.
7. Excessive bearing clearance. 7. Measure bearings for correct
clearance.
8. Oil pump relief valve stuck. 8. Remove valve and inspect, clean,
or replace.
9. Oil pump suction tube loose. 9. Remove oil pan and install new
tube or clean, if necessary.
10. Oil pump cover warped or
cracked.10. Install new oil pump.
9 - 12 ENGINENS
DIAGNOSIS AND TESTING (Continued)

sealing and a chrome plated taper faced intermediate
ring for additional cylinder pressure control. There
are also standard oil control rings.
CYLINDER HEAD:Features a Dual Over Head
Camshaft (DOHC) 4 valves per cylinder cross flow
design. The valves are arranged in two inline banks,
with the ports of the bank of two intake valves per
cylinder facing toward the radiator side of engine
and ports of the bank of two exhaust valves per cyl-
inder facing toward the dash panel. Incorporates
powder metal valve guides and seats. Integral oil gal-
leys within the cylinder head supplies oil to the
hydraulic lash adjusters, camshaft and valve mecha-
nisms.
CAMSHAFTS:The nodular iron camshafts have
six bearing journals and 2 cam lobes per cylinder.
Flanges at the rear journals control camshaft end
play. Provision for cam position sensor is located on
the intake camshaft at the rear of cylinder head. A
hydrodynamic oil seal is used for oil control at the
front of the camshaft.
VALVES:4 valves per cylinder are actuated by
roller cam followers which pivot on stationary
hydraulic lash adjusters. All valves have 6 mm diam-
eter chrome plated valve stems. The valve sizes are
34.8 mm (1.370 inch.) diameter intake valves and
30.5 mm (1.20 inch.) diameter exhaust valves. Viton
rubber valve stem seals are integral with the spring
seats. Valve springs, spring retainers, and locks are
conventional.
INTAKE MANIFOLD:The intake manifold is a
two piece aluminum casting, attached to the cylinder
head with ten screws. This long branch fan design
enhances low and midspeed torque, while minimizing
undesirable inlet noise.
EXHAUST MANIFOLD:The exhaust manifold is
made of cast iron for strength and high tempera-
tures.
ENGINE LUBRICATION:Refer to Group 0
Lubrication and Maintenance for recommended oil to
be used in various engine application. 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 cylin-
der block, supplying main and rod bearings with fur-
ther routing. Pistons are lubricated from rod bearing
throw off and lubricating slots on 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.DIAGNOSIS AND TESTING
CHECKING ENGINE OIL PRESSURE
(1) Remove oil pressure sending unit and install
gauge assembly C-3292.
(2) Run engine until thermostat opens.
CAUTION: If oil pressure is 0 at idle, Do Not Run
engine at 3000 RPM
(3) Oil Pressure:Curb Idle25 kPa (4 psi) mini-
mum3000 RPM170/550 kPa (25/80 psi).
(4) If oil pressure is 0 at idle. Shut off engine,
check for pressure relief valve stuck open or a
clogged oil pickup screen.
SERVICE PROCEDURES
FITTING PISTONS
Piston and cylinder wall must be clean and dry.
Piston diameter should be measured 90 degrees to
piston pin about 14 mm (9/16 inch.) from the bottom
of the skirt as shown in (Fig. 3). Cylinder bores
should be measured halfway down the cylinder bore
and transverse to the engine crankshaft center line
shown in (Fig. 2). Refer to Cylinder Bore and Piston
Specification Chart.
Correct piston to bore clearance must be estab-
lished in order to assure quiet and economical oper-
ation.
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, 70ÉF (21ÉC).
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. 4).
Refer to specification in Piston Ring Specification
Chart.
(2) Check piston ring to groove side clearance (Fig.
5). Refer to specification in Piston Ring Specification
Chart.
9 - 16 2.4L ENGINENS
DESCRIPTION AND OPERATION (Continued)

OPTIONAL CRANKSHAFT END PLAY CHECK
(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.DO NOTloosen main bear-
ing cap.
(2) Use a feeler gauge between number three
thrust bearing and machined crankshaft surface to
determine end play.
VALVE SERVICE RECONDITION
VALVE REMOVAL
(1) With cylinder head removed, compress valve
springs using Special Tool C-3422-B or equivalent.
(2) Remove valve retaining locks, valve spring
retainers, valve stem seals and valve springs.
(3) Before removing valves,remove any burrs
from valve stem lock grooves to prevent dam-
age to the valve guides.Identify valves to insure
installation in original location.
VALVE INSPECTION
(1) Clean valves thoroughly and discard burned,
warped and cracked valves.
(2) Measure valve stems for wear. Measure stem
about 60 mm beneath the valve lock grooves.
(3) If valve stems are worn more than 0.05 mm
(0.002 in.), replace valve.
VALVE GUIDES
(1) Remove carbon and varnish deposits from
inside of valve guides with a reliable guide cleaner.
(2) Using a small hole gauge and a micrometer,
measure valve guides in 3 places top, middle and bot-
tom (Fig. 15). Refer to Valve Guide Specification
Chart. Replace guides if they are not within specifi-
cation.
(3) Check valve guide height (Fig. 16).
TESTING VALVE SPRINGS
(1) Whenever valves have been removed for inspec-
tion, reconditioning or replacement, valve springs
should be tested. As an example, the compression
length of the spring to be tested is 33.34 mm (1 5/16inches). Turn tool table until surface is in line with
the 33.34 mm (1 5/16 in.) mark on the threaded stud
and the zero mark on the front. Place spring over
stud on the table and lift compressing lever to set
tone device (Fig. 17). Pull on torque wrench until
ping is heard. Take reading on torque wrench at this
instant. Multiply this reading by two. This will give
the spring load at test length. Fractional measure-
ments are indicated on the table for finer adjust-
ments. Discard the springs that do not meet
specifications. The Following specifications apply to
both intake and exhaust valve springs;
²Valve Closed Nominal TensionÐ 76 lbs. @ 38.0
mm (1.50 in.)
²Valve Open Nominal TensionÐ 136 lbs. @ 29.75
mm (1.17 in.)
(2) Inspect each valve spring for squareness with a
steel square and surface plate, test springs from both
ends. If the spring is more than 1.5 mm (1/16 inch)
out of square, install a new spring.
REFACING VALVES AND VALVE SEATS
(1) The intake and exhaust valve seats and valve
face have a 45 and a 45 1/2 degree angles.
Fig. 15 Checking Wear on Valve GuideÐTypical
VALVE GUIDE SPECIFICATION CHART
Valve Guide Diameter
Intake and
Exhaust Valve:5.975 - 6.000 mm
(0.2352 - 0.2362 in.)
Valve Guide Clearance
New Service
Limit
Intake Valve: 0.048 - 0.066 mm
(0.0018 - 0.0025 in.)
0.25 mm
(0.010 in.)
Exhaust Valve: 0.0736 - 0.094 mm
(0.0029 - 0.0037 in.)
Fig. 16 Valve Guide Height
NS2.4L ENGINE 9 - 21
SERVICE PROCEDURES (Continued)

need to be reground to prevent seal damage when
the valve is installed.
VALVE INSTALLATION
(1) Coat valve stems with clean engine oil and
insert in cylinder head.
(2) Install new valve stem seals on all valves using
a valve stem seal tool (Fig. 21). The valve stem seals
should be pushed firmly and squarely over valve
guide.CAUTION: When oversize valves are used, the cor-
responding oversize valve seal must also be used.
Excessive guide wear may result if oversize seals
are not used with oversize valves.
(3) Install valve springs and retainers. Compress
valve springs only enough to install locks, taking
care not to misalign the direction of compression.
Nicked valve stems may result from misalignment of
the valve spring compressor.
CAUTION: When depressing the valve spring
retainers with valve spring compressor the locks
can become dislocated. Check to make sure both
locks are in their correct location after removing
tool.
(4) Check the valve spring installed height B after
refacing the valve and seat (Fig. 20). Make sure mea-
surements are taken from top of spring seat to the
bottom surface of spring retainer. If height is greater
than 38.75 mm (1.525 in.), install a .762 mm (0.030
inch.) spacer under the valve spring seat to bring
spring height back within specification.
(5) Install rocker arm shafts as previously
described in this section.
(6) Checking dry lash. Dry lash is the amount of
clearance that exists between the base circle of an
installed cam and the rocker arm roller when the
adjuster is drained of oil and completely collapsed.
Specified dry lash is 1.17 mm (0.046 in.) for intake
and 1.28 mm (0.050 in.) for exhaust. After performing
dry lash check, refill adjuster with oil and allow 10
minutes for adjuster/s to bleed down before rotating
cam.
REMOVAL AND INSTALLATION
ENGINE MOUNTÐFRONT
REMOVAL
(1) Support the engine and transaxle assembly
with a floor jack so it will not rotate.
(2) Remove the front engine mount through bolt
from the insulator and front crossmember mounting
bracket (Fig. 22).
(3) Remove six screws from air dam to allow
access to the front mount screws.
(4) Remove the front engine mount screws and
remove the insulator assembly.
(5) Remove the front mounting bracket, if neces-
sary (Fig. 22).
INSTALLATION
(1) Reverse removal procedure for installation and
tighten fasteners in this order. For engine mount
Fig. 19 Refacing Valve Seats
Fig. 20 Checking Spring Installed Height and Valve
Tip Height Dimensions
Fig. 21 Valve Stem Oil Seal Special Tool C4745
NS2.4L ENGINE 9 - 23
SERVICE PROCEDURES (Continued)

dure of 0.15 mm (0.005 in.), 0.40 mm (0.015 in.)
and 0.80 mm (0.030 in.) so the valve guides may
be reamed true in relation to the valve seat.
After reaming guides, the seat runout should be
measured and resurfaced if necessary. See
Refacing Valves and Valve Seats.VALVE GUIDES
NOTE: Replace cylinder head if guide does not
clean up with 0.80 mm (0.030 in.) oversize reamer,
or if guide is loose in cylinder head.
REFACING VALVES AND VALVE SEATS
The intake and exhaust valves have a 44-1/2 to 45
degree face angle. The valve seats have a 45 to 45-1/2
degree face angle. The valve face and valve seat
angles are shown in (Fig. 19).
VALVES
(1) Inspect the remaining margin after the valves
are refaced Refer to Valve Dimension Chart.
VALVE SEATS
CAUTION: Remove metal from valve seat only. Do
not remove metal from cylinder head (Fig. 20).
(1) When refacing valve seats, it is important that
the correct size valve guide pilot be used for reseat-
ing stones. A true and complete surface must be
obtained.
(2) Measure the concentricity of valve seat using
dial indicator. Total runout should not exceed 0.051
mm (0.002 in.) total indicator reading.
(3) Inspect the valve seat using Prussian blue to
determine where the valve contacts the seat. To do
this, coat valve seatLIGHTLYwith Prussian blue
then set valve in place. Rotate the valve with light
pressure. If the blue is transferred to the center of
valve face, contact is satisfactory. If the blue is trans-
ferred to top edge of valve face, lower valve seat with
a 15 degree stone. If the blue is transferred to the
bottom edge of valve face raise valve seat with a 65
degrees stone.
Fig. 18 Intake and Exhaust Valves
VALVE GUIDE SPECIFICATION CHART
Intake Valve Exhaust Valve
Dial Indicator
Reading
(Maximum):0.247 mm
(0.009 in.)0.414 mm
(0.016 in.)
Valve Guide
Reamer
OversizeValve Guide Size
0.15 mm
(0.005 in.)8.125 - 8.150 mm
(0.3198 - 0.3208 in.)
0.40 mm
(0.015 in.)8.375 - 8.400 mm
(0.3297 - 0.3307 in.)
0.80 mm
(0.030 in.)8.775 - 8.800 mm
(0.3454 - 0.3464 in.)
VALVE SPECIFICATION CHART
Intake Valve (Minimum)
Stem Diameter: 7.935 mm (0.3124 in.)
Face Angle: 44.5É
Valve Margin: 0.794 mm (0.031 in.)
Head Diameter: 45.5 mm (1.79 in.)
Length: 127.2 mm (5.008 in.)
Exhaust Valve (Minimum)
Stem Diameter: 7.906 mm (0.3112 in.)
Face Angle: 44.5É
Valve Margin: 1.191 mm (0.0469 in.)
Head Diameter: 37.5 mm (1.476 in.)
Length: 127.82 (5.032 in.)
Fig. 19 Valve Seats
NS3.3/3.8L ENGINE 9 - 101
SERVICE PROCEDURES (Continued)

NOTE: Valve seats which are worn or burned can
be reworked, provided that correct angle and seat
width are maintained. Otherwise cylinder head must
be replaced.
(4) When seat is properly positioned the width of
intake seats should be 1.75 to 2.25 mm (0.69 to 0.088
in.) The width of the exhaust seats should be 1.50 to
2.00 mm (0.059 to 0.078 in.) (Fig. 19).
(5) Check the valve spring installed height after
refacing the valve and seat (Fig. 22).
TESTING VALVE SPRINGS
Whenever valves have been removed for inspection,
reconditioning or replacement, valve springs should
be tested (Fig. 21).As an example;the compression
length of the spring to be tested is 33.34 mm (1-5/16
inches). Turn table of Tool C-647 until surface is in
line with the 33.34 mm (1-5/16 inch) mark on the
threaded stud and the zero mark on the front. Place
spring over stud on the table and lift compressing
lever to set tone device. Pull on torque wrench until
ping is heard. Take reading on torque wrench at this
instant. Multiply this reading by two. This will give
the spring load at test length. Fractional measure-
ments are indicated on the table for finer adjust-
ments. Refer to specifications to obtain specified
height and allowable tensions. Discard the springs
that do not meet specifications.
REMOVAL AND INSTALLATION
WIPER UNIT
When performing work on the upper engine.
Refer to Section 8K, Windshield Wipers and
Washers for removal of the Wiper Unit.
ENGINE MOUNTS
RIGHT SIDE MOUNT
REMOVAL
NOTE: Right mount should only be serviced as an
assembly to prevent noise, vibration and harshness
concerns.
(1) Remove the purge duty solenoid and wiring
harness from engine mount.
(2) Remove the two right engine mount insulator
vertical fasteners and loosen the horizontal fastener,
Do Notremove the large nut on the end of the core
from frame rail (Fig. 23).
(3) Remove the load on the engine motor mounts
by carefully supporting the engine and transmission
assembly with a floor jack.
Fig. 20 Refacing Valve SeatsFig. 21 Testing Valve Springs
Fig. 22 Checking Valve Installed Height
ITEM DESCRIPTION
A Valve Stem Height
B Valve Installed Height
9 - 102 3.3/3.8L ENGINENS
SERVICE PROCEDURES (Continued)

(3) Before removing valves,remove any burrs
from valve stem lock grooves to prevent dam-
age to the valve guides.Identify valves to insure
installation in original location.
VALVE INSTALLATION
(1) Coat valve stems with clean engine oil and
insert them in cylinder head.
(2) Check valve tip to spring seat dimensions A
after grinding the valve seats or faces. Grind valve
tip to give 49.541 to 51.271 mm (1.950 to 2.018 in.)
over spring seat when installed in the head (Fig. 41).
Check valve tip for scoring, if necessary, the tip
chamfer should be reground to prevent seal damage
when the valve is installed.
(3) Install valve spring seat spacer on head (Fig.
42).
(4) Install new cup seals on all valve stems and
over valve guides (Fig. 41). Install valve springs and
valve retainers (Fig. 42).
(5) Compress valve springs with Valve Spring
Compressor Tool C-3422-B, with adapter 6412 install
locks and release tool.If valves and/or seats are
reground, measure the installed height of
springs dimension B, make sure measurementsare taken from top of spring seat to the bottom
surface of spring retainer. If height is greater
than 1-19/32 inches, (40.6 mm), install a 1/32
inch (.794 mm) spacer in head counterbore to
bring spring height back to normal 1-17/32 to
1-19/32 inch (39.1 to 40.6 mm).TAPPET REMOVAL
(1) Refer to Cylinder Head Removal in this section.
Cylinder Head must be removed to gain access to
tappets for service.
(2) Remove yoke retainer and aligning yokes.
(3) Use Tool C-4129 to remove tappets from their
bores. If all tappets are to be removed, identify tap-
pets to insure installation in original location.
NOTE: If the tappet or bore in cylinder block is
scored, scuffed, or shows signs of sticking, ream
the bore to next oversize and replace with oversize
tappet.
CAUTION: The plunger and tappet bodies are not
interchangeable. The plunger and valve must
always be fitted to the original body. It is advisable
to work on one tappet at a time to avoid mixing of
parts. Mixed parts are not compatible. Do not disas-
semble a tappet on a dirty work bench.
INSTALLATION
(1) Lubricate tappets.
(2) Install tappets in their original positions.
(3) With roller tappets, install aligning yokes (Fig.
43).
(4) Install yoke retainer and torque screws to 12
N´m (105 in. lbs.) (Fig. 43).
(5) Install cylinder heads. Refer to cylinder head
installation of this section for procedure.
Fig. 40 Compress Valve Springs with Special Tool
C-3422-B with Adapter 6412
Fig. 41 Checking Valve Installed Height
Fig. 42 Valve Seal and SpringÐInstallation
9 - 110 3.3/3.8L ENGINENS
REMOVAL AND INSTALLATION (Continued)

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)