1996 CHRYSLER VOYAGER torque

Service Limit.............0.15 mm (0.006 in.)
Valve Guide
Overall Length±Intake........44mm(1.732 in.)
Overall Length±Exhaust.......48mm(1.889 in.)
Outside Diameter...........13.055 - 13.065 mm
(0.514 - 0.5143 in.)
Inside Diameter..............8.000 - 8.018 mm
(0.314 - 315 in.)
Valve Springs
Free Length (Approx.).......49.8 mm (1.960 in.)
Service Limit............48.8 mm (1.9213 in.)
Loaded Height...............40.4 mm @ 33 kg
(1.59 in. @73 lbs.)
Perpendicularity±Intake and Exhaust . . .2É (Max.)
Service Limit.....................4É(Max.)
Oil Pump
Clearance Over Rotors (Max.) .0.077 mm (0.003 in.)
Cover Out-of-Flat (Max.).....0.076 mm (0.003 in.)
Inner Rotor Thickness (Min.) .18.92 mm (0.744 in.)
Outer Rotor (Oil Pump)
Clearance (Max.)...........0.19 mm (0.007 in.)
Diameter (Min.)...........82.45 mm (3.246 in.)
Thickness (Min.)...........18.92 mm (0.744 in.)
Tip Clearance Between Rotors (Max.) . . .0.150 mm
(0.0068 in.)
Oil Pressure
At Curb Idle Speed*...........68.9 kPa (10 psi)
At 3000 rpm.........310 - 517 kPa (45 - 75 psi)
CAUTION: * If pressure is ZERO at curb Idle, DO
NOT run engine at 3,000 rpm.
TORQUE CHART 3.0L
DESCRIPTION TORQUE
Camshaft Bearing Cap
Bolts. . .Refer to procedure outlined in this section.
Camshaft Sensor Pick Up
Bolts.....................27N´m(20ft.lbs.)
Timing Belt Cover
Outer to Inner Attaching Bolts..........4.5 N´m
(40 in. lbs.)
Inner Cover to Head/Oil Pump Bolts.....12N´m
(105 in. lbs.)
Camshaft Sprocket
Bolt......................95N´m(70ft.lbs.)
Connecting Rod Cap
Bolts..........27N´m(20ft.lbs.) Plus 1/4 Turn
Crankshaft Main Bearing Cap/Bedplate
M8 Bedplate Bolts.........34N´m(250 in. lbs.)
M11 Main Cap Bolts..................41N´m
(30 ft. lbs.) Plus 1/4 Turn
Crankshaft Vibration Damper
Bolt....................135 N´m (100 ft. lbs.)DESCRIPTION TORQUE
Cylinder Head
Bolts........Refer To Cylinder Head Installation
Cylinder Head Cover
Bolts....................12N´m(105 in. lbs.)
Engine Mount Bracket
Bolts.....................41N´m(30ft.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.)
Intake Manifold
Bolts.....................27N´m(20ft.lbs.)
Oil Filter to Engine Block Adapter
Bolts.....................55N´m(40ft.lbs.)
Oil Filter
Filter.....................20N´m(15ft.lbs.)
Oil Pan
Oil Pan Bolts.............12N´m(105 in. lbs.)
Drain Plug.................39N´m(29ft.lbs.)
Oil Pump Attaching
Bolts....................15N´m(130 in. lbs.)
Oil Pump Cover Fastener.....9N´m(104 in. lbs.)
Oil Pump Pick-up Tube Bolt . .28 N´m (250 in. lbs.)
Oil Pump Relief Valve Cap. . . .49 N´m (36 ft. lbs.)
Spark Plugs
Plugs.....................28N´m(20ft.lbs.)
Thermostat Housing
Bolts....................23N´m(200 in lbs.)
Timing Belt Tensioner
Bolt......................28N´m(20ft.lbs.)
Timing Belt Tensioner Pulley Assembly
Bolt......................41N´m(30ft.lbs.)
Water Pump Mounting
Bolts....................12N´m(105 in. lbs.)
9 - 90 3.0L ENGINENS
SPECIFICATIONS (Continued)

3.3/3.8L ENGINE
INDEX
page page
DESCRIPTION AND OPERATION
ENGINE COMPONENTS.................. 93
ENGINE IDENTIFICATION................. 93
ENGINE LUBRICATION SYSTEM............ 93
DIAGNOSIS AND TESTING
CHECKING ENGINE OIL PRESSURE......... 96
HYDRAULIC TAPPETS.................... 94
SERVICE PROCEDURES
CRANKSHAFT END PLAY................. 99
FITTING CONNECTING ROD BEARINGS...... 97
FITTING MAIN BEARINGS................. 98
FITTING PISTONS AND RINGS............. 97
MEASURING TIMING CHAIN FOR STRETCH . . . 96
VALVE SERVICE RECONDITION........... 100
VALVE TIMING.......................... 96
REMOVAL AND INSTALLATION
CAMSHAFT BEARINGS.................. 114
CAMSHAFT........................... 113
CRANKSHAFT DAMPER................. 106
CRANKSHAFT OIL SEALÐFRONT.......... 117
CRANKSHAFT OIL SEALÐREAR........... 118
CRANKSHAFT......................... 116
CYLINDER HEAD COVER................ 107
CYLINDER HEAD....................... 108
ENGINE ASSEMBLY..................... 104
ENGINE MOUNTS...................... 102
ENGINE OIL GALLERY PLUGS............. 119OILFILTER ............................ 119
OILPAN .............................. 114
PISTON AND CONNECTING ROD.......... 115
ROCKER ARMS AND SHAFT ASSEMBLY..... 106
TAPPET REMOVAL...................... 110
TIMING CHAIN COVER................... 111
TIMING CHAIN......................... 112
VALVE STEM SEALS OR SPRINGS,
CYLINDER HEAD NOT REMOVED........ 106
VALVES AND VALVE SPRINGS............ 109
WIPER UNIT.......................... 102
DISASSEMBLY AND ASSEMBLY
HYDRAULIC TAPPETS................... 120
OIL PUMP............................ 119
CLEANING AND INSPECTION
CYLINDER HEAD....................... 120
ENGINE BLOCK AND BORE............... 121
OILPAN .............................. 121
OIL PUMP............................ 121
ADJUSTMENTS
ENGINE MOUNTS...................... 123
SPECIFICATIONS
3.3/3.8L ENGINE....................... 123
TORQUE CHART....................... 125
SPECIAL TOOLS
3.3/3.8L ENGINE....................... 127
DESCRIPTION AND OPERATION
ENGINE IDENTIFICATION
The engine identification number is located on the
rear of the cylinder block just below the cylinder
head (Fig. 1).
ENGINE LUBRICATION SYSTEM
The lubrication system is a full flow filtration pres-
sure feed type. Oil from the oil pan is pumped by a
internal gear type oil pump directly coupled to the
crankshaft. The pressure is regulated by a relief
valve located in the chain case cover. The oil is
pumped through an oil filter and feeds a main oil
galley. This oil gallery feeds oil under pressure to the
main and rod bearings, camshaft bearings. Passages
in the cylinder block feed oil to the hydraulic lifters
and rocker shaft brackets which feeds the rocker arm
pivots (Fig. 2).
ENGINE COMPONENTS
ENGINE:The 3.3L (201 Cubic Inches) and 3.8L
(231 Cubic Inches) displacement engines are 60É V
type six cylinder power plants with cast iron cylinder
blocks and aluminum cylinder heads (Fig. 3). Firing
order for these engines is 1-2-3-4-5-6. High turbu-
lence cylinder heads allow a 8.9-1 compression ratio.
CRANKSHAFT:The nodular iron crankshaft is
supported by four main bearings, with number two
being the thrust bearing. Crankshaft end sealing is
provided by front and rear rubber seals.
PISTONS:The pistons are cast aluminum alloy.
Three rings are used. Piston pins, press fitted into
place, join the pistons to forged steel connecting rods.
CAMSHAFT:The nodular iron camshaft is
mounted in four steel backed babbitt bearings. A
thrust plate located in front of the first bearing, and
bolted to the block, controls end play. Silent timing
chain drives the camshaft. This chain is enclosed by
a cast aluminum cover which also carries a front
NS3.3/3.8L ENGINE 9 - 93

crankshaft seal, provides front oil pan closure, water
pump mounting.
CYLINDER HEADS:Cylinder heads are designed
to create high flow combustion chambers to improve
performance, while minimizing the change to the
burn rate of the chamber. Valve seat and guides are
inserts. A steel flanged composition type gasket is
used between head and block.
CYLINDER HEAD COVERS:The covers are
sealed with steel reinforced silicon rubber gaskets.INTAKE MANIFOLD:The intake manifold is a
tuned two-piece semi-permanent mold aluminum
casting with individual primary runners leading from
a plenum to the cylinders. The manifold is designed
to boost torque in the 3600 rpm range and contrib-
utes to the engine's broad, flat torque curve, which
was desired for excellent engine tractability, response
and usable power output.
The intake manifold is also cored with upper level
EGR passages for balanced cylinder to cylinder EGR
distribution.
VALVE TRAIN:Valve train design incorporates
the use of hydraulic roller tappets. Rocker arms are
installed on a rocker arm shaft attached to the cylin-
der head with four bolts and retainers. Viton valve
stem seals provide valve sealing. Conventional type
pushrods, retainers and valve stem locks are used.
Unique beehive style valve spring are used with
lightweight retainers for improved high RPM perfor-
mance.
EXHAUST MANIFOLDS:Exhaust manifolds are
log type with a crossover and is attached directly to
the cylinder heads.
DIAGNOSIS AND TESTING
HYDRAULIC TAPPETS
The valve train includes roller tappet assemblies,
aligning yokes and yoke retainer.
Roller tappet alignment is maintained by machined
flats on tappet body being fitted in pairs into six
Fig. 2 Engine Oiling System
Fig. 1 Engine Identification
9 - 94 3.3/3.8L ENGINENS
DESCRIPTION AND OPERATION (Continued)

NOTE: Worn valve guides or cocked springs are
sometimes mistaken for noisy tappets. If such is
the case, noise may be dampened by applying side
thrust on the valve spring. If noise is not apprecia-
bly reduced, it can be assumed the noise is in the
tappet. Inspect the rocker arm push rod sockets
and push rod ends for wear.
Valve tappet noise ranges from light noise to a
heavy click. A light noise is usually caused by exces-
sive leak-down around the unit plunger which will
necessitate replacing the tappet, or by the plunger
partially sticking in the tappet body cylinder. A heavy
click is caused either by a tappet check valve not
seating, or by foreign particles becoming wedged
between the plunger and the tappet body causing the
plunger to stick in the down position. This heavy
click will be accompanied by excessive clearance
between the valve stem and rocker arm as valve
closes. In either case, tappet assembly should be
removed for inspection and cleaning.
CHECKING ENGINE OIL PRESSURE
Check oil pressure using gauge at oil pressure
switch location. Oil pressure should be 34.47 kPa (5
psi.) at idle or 205 to 551 kPa (30 to 80 psi.) at 3000
RPM.
(1) Remove pressure sending unit and install oil
pressure gauge (Fig. 5).
CAUTION: If oil pressure is 0 at idle, do not run
engine at 3000 RPM.
(2) Warm engine at high idle until thermostat
opens.
SERVICE PROCEDURES
VALVE TIMING
(1) Remove front cylinder head cover and all 6
spark plugs.
(2) Rotate engine until the #2 piston is at TDC of
the compression stroke.
(3) Install a degree wheel on the crankshaft pulley.
(4) With proper adaptor, install a dial indicator
into #2 spark plug hole. Using the indicator find TDC
on the compression stroke.
(5) Position the degree wheel to zero.
(6) Remove dial indicator from spark plug hole.
(7) Place a 5.08 mm (0.200 in.) spacer between the
valve stem tip of #2 intake valve and rocker arm pad.
Allow tappet to bleed down to give a solid tappet
effect.
(8) Install a dial indicator so plunger contacts the
#2 intake valve spring retainer as nearly perpendic-
ular as possible. Zero the indicator.
(9) Rotate the engine clockwise until the intake
valve has lifted .254 mm (0.010 in.).
CAUTION: Do not turn crankshaft any further
clockwise as intake valve might bottom and result
in serious damage.
(10) Degree wheel should read 6 degrees BTDC to
6 degrees ATDC.
MEASURING TIMING CHAIN FOR STRETCH
(1) Place a scale next to timing chain so that any
movement of chain may be measured.
(2) Place a torque wrench and socket on camshaft
sprocket attaching bolt and apply torque in direction
of crankshaft rotation to take up slack; 41 N´m (30 ft.
lb.) with cylinder head installed or 20 N´m (15 ft. lb.)
with cylinder heads removed.With a torque
applied to the camshaft sprocket bolt, crank-
shaft should not be permitted to move. It may
be necessary to block crankshaft to prevent
rotation.
(3) Holding a scale even, with dimension reading
as shown (Fig. 6), along edge of chain links. Apply
torque in the reverse direction to 41 N´m (30 ft. lbs.)
with cylinder heads installed, or 20 N´m (15 ft. lbs.)
with cylinder heads removed. Check amount of chain
movement.
(4) Install a new timing chain, if its movement
exceeds 3.175 mm (1/8 inch).
(5) If chain is not satisfactory, refer to Timing
Chain Removal and Installation in this section.
Fig. 5 Checking Oil Pump Pressure
9 - 96 3.3/3.8L ENGINENS
DIAGNOSIS AND TESTING (Continued)

with an old bearing half. Do not file the rods or
bearing caps.
(1) Follow procedure specified in the Standard Ser-
vice Procedure Section for Measuring Main Bearing
Clearance and Connecting Rod Bearing Clearance
(Fig. 11).
NOTE: The rod bearing bolts should be examined
before reuse. If the threads are necked down the
bolts should be replaced (Fig. 13). Necking can be
checked by holding a scale or straight edge againstthe threads. If all the threads do not contact the
scale the bolt should be replaced.
(2) Before installing the nuts the threads should
be oiled with engine oil.
(3) Install nuts finger tight on each bolt then alter-
nately torque each nut to assemble the cap properly.
(4) Tighten the nuts to 54 N´m PLUS 1/4 turn (40
ft. lbs. PLUS 1/4 turn).
(5) Using a feeler gauge, check connecting rod side
clearance (Fig. 12). Refer to Connecting Rod Specifi-
cation Chart.
FITTING MAIN BEARINGS
CRANKSHAFT OIL CLEARANCE
Measure the journal outside diameter as shown in
(Fig. 14). Refer to Crankshaft Specification Chart.
PISTON RING SPECIFICATION CHART
Ring Position Ring Gap Wear Limit Groove Clearance Maximum Clearance
Upper Ring 0.30 - 0.55 mm
(0.012 - 0.022 in.)1.0 mm (0.039 in.) 0.030 - 0.085 mm
(0.001 - 0.003 in.)0.10 mm (0.004 in.)
Intermediate Ring 0.30 - 0.55 mm
(0.012 - 0.022 in.)1.0 mm (0.039 in.) 0.030 - 0.095 mm
(0.001 - 0.0037 in.)0.10 mm (0.004 in.)
Oil Control Ring 0.25 - 1.00 mm
(0.010 - 0.039 in.)1.88 mm (0.074 in.) 0.014 - 0.266 mm
(0.0005 - 0.009 in.)0.266 mm (0.009 in.)
Fig. 9 Check Gap on Piston Rings
Fig. 10 Measuring Piston Ring Side Clearance
Fig. 11 Checking Connecting Rod Bearing
Clearance
9 - 98 3.3/3.8L ENGINENS
SERVICE PROCEDURES (Continued)

PLASTIGAGE (OIL CLEARANCE)
MEASUREMENT
(1) Remove oil from journal and bearing shell.
(2) Install crankshaft.
(3) Cut plastigage to same length as width of the
bearing and place it in parallel with the journal axis
(Fig. 15).
(4) Install the main bearing cap carefully and
tighten the bolts to specified torque.
CAUTION: Do not rotate crankshaft or the plasti-
gage will be smeared.(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. 15). Refer to
Crankshaft Specification Chart for proper clearances.
If the clearance exceeds the specified limits, replace
the main bearing(s) and if necessary, have the crank-
shaft machined to next undersize.
CAUTION: Do not rotate crankshaft or the Plasti-
gage may be smeared.
CRANKSHAFT END PLAY
DIAL INDICATOR METHOD
(1) Mount a dial indicator to front of engine, locat-
ing probe on nose of crankshaft (Fig. 16).
Fig. 12 Checking Connecting Rod Side Clearance
CONNECTING ROD SPECIFICATION CHART
Connecting Rod Bearing Clearance
New Part: 0.019 - 0.073 mm
(0.0008 - 0.0029 in.)
Wear Limit: 0.074 mm
(0.003 in.)
Connecting Rod Side Clearance
New Part: 0.13 - 0.32 mm
(0.005 - 0.013 in.)
Wear Limit: 0.38 mm
(0.015 in.)
Fig. 13 Check for Stretched (Necked) Bolts
CRANKSHAFT SPECIFICATION CHART
Crankshaft End-Play
New Part: 0.09 - 0.24 mm
(0.0036 - 0.0095 in.)
Wear Limit: 0.38 mm
(0.015 in.)
Main Bearing Clearance
New Part: 0.011 - 0.059 mm
(0.0005 - 0.0024 in.)
Wear Limit: 0.076 mm
(0.003 in.)
Crankshaft Main Bearing Journal
Standard Size: 63.992 - 64.013 mm
(2.5194 - 2.5202 in.)
Crankshaft Connecting Rod Journal
Standard Size: 57.989 - 58.005 mm
(2.2831 - 2.2837 in.)
Fig. 14 Measure Crankshaft Journal O.D.
NS3.3/3.8L ENGINE 9 - 99
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)

(20) Remove rear transmission mount and bracket.
(21) Remove power steering pump and bracket
assembly.
(22) Remove wiring harness and connectors from
front of engine.
(23) Remove bending braces and install tool num-
ber 6912 on engine.
(24) Remove transmission inspection cover and
mark flexplate to torque converter.
(25) Remove driveplate to torque converter bolts.
(26) Lower the vehicle.
(27) Remove ground straps to body.
(28) Raise vehicle enough to allow engine dolly
Special Tool 6135 and cradle Special Tool 6710 with
post Special Tool 6848 and adaptor Special Tool 6909
to be installed under vehicle (Fig. 28).
(29) Loosen cradle engine mounts to allow move-
ment for positioning onto engine locating holes on the
engine. Lower vehicle and position cradle mounts
until the engine is resting on mounts. Tighten
mounts to cradle frame. This will keep mounts from
moving when removing or installing engine and
transmission.
(30) Lower vehicle so the weight ofONLY THE
ENGINE AND TRANSMISSIONis on the cradle.
(31) Remove right engine mount assembly and left
transmission mount through bolt. Refer to Engine
Mounts Section of this Group.
(32) Raise vehicle slowly. It may be necessary to
move the engine/transmission assembly on the cradle
to allow for removal around body flanges.INSTALLATION
(1) Position engine and transmission assembly
under vehicle and slowly lower the vehicle over the
engine and transmission. It may be necessary to
move the engine/transmission assembly with the cra-
dle for clearance around body flanges.
(2) Align engine and transmission mounts to
attaching points. Install mounting bolts at the right
engine and left transmission mounts. Refer to proce-
dures outlined in this section.
(3) Slowly raise vehicle enough to remove the
engine dolly and cradle Special Tools 6135, 6710,
6848 and 6909.
(4) Remove Special tools 6912 and install bending
braces.
(5) Lower vehicle. Install generator and wiring
harness.
(6) Connect wiring harness on the front of the
engine.
(7) Install Air Conditioning Compressor.
(8) Install power steering pump and bracket and
accessory drive belt. Refer to Accessory drive Section
Located in group 7 for installation procedure.
(9) Raise vehicle and install axle shafts. Refer to
Group 3, Differential and Driveline for procedure.
(10) Install transmission and engine mount and
bracket assemblies. Refer to Engine Mounts section
of this Group.
(11)(AWD equipped)Install propeller shaft to
power transfer unit. Refer to Group 3, Differential
and Driveline for procedure.
(12) Connect exhaust system to manifold. Refer to
Group 11, Exhaust System and Intake Manifold for
procedure and torque specifications.
(13) Install crossmember cradle plate (Fig. 27).
(14) Install left and right inner splash shields.
(15) Connect automatic transmission shifter link-
age. Refer to Group 21, Transmission for procedures.
(16) Lower vehicle and connect fuel line and
heater hoses. Remove plugs from rear heater hoses
and install, if equipped.
(17) Install ground straps. Connect engine and
throttle body connections and harnesses.
(18) Connect throttle body linkage. Refer to Group
14, Fuel System for procedure.
(19) Install radiator and fan module assembly.
Install radiator hoses. Fill cooling system. See Group
7 for filling procedure.
(20) Install battery tray, battery and cover.
(21) Install air cleaner and hoses.
(22) Install oil filter. Fill engine crankcase with
proper oil to correct level.
(23) Start engine and run until operating temper-
ature is reached.
(24) Adjust transmission linkage, if necessary.
Fig. 28 Positioning Engine Cradle Support Post
MountsÐTypical
NS3.3/3.8L ENGINE 9 - 105
REMOVAL AND INSTALLATION (Continued)