1996 CHRYSLER VOYAGER engine oil

(28) Remove radiator support bolts.It is neces-
sary to loosen the receiver/dryer to gain access
to the radiator bolts.
(29) Remove radiator and fans as an assembly.
(30) Remove accessory drive belt generator/power
steering. Refer to Group 7, for procedure.
(31) Remove both power steering lines at pump,
and cap both lines.
NOTE: It is not necessary to discharge A/C system
for engine removal.
(32) Remove A/C compressor. Secure compressor
away from engine for clearance during engine
removal.
(33) Remove Generator and adjusting bracket.
NOTE: Do not remove the mounting base from the
generator. It is aligned at the factory and cannot be
realigned in the field.
(34) Hoist vehicle.
(35) Remove exhaust pipe at turbo outlet.
(36) Remove connections at starter.
(37) Remove power steering high pressure line
bracket at rear of oil pan.
(38) Remove both driveshafts from transaxle. Refer
to Group 2, Suspension and Driveshafts.
(39) Disconnect clutch cable at transaxle.
(40) Remove reinforcement plate on lower cross-
member.
(41) Remove front and rear engine mounts. Refer
to procedure outlined in this section.
(42) Drain engine oil and remove oil filter if neces-
sary.
(43) Mount both special tool, engine support brack-
ets VM-1026 to cylinder block (Fig. 21).
(44) Using engine dolly and cradle assembly with
4 adjustable posts align posts with holes in the
engine support brackets.
(45) Lower vehicle so weight ofonly the engine
and transmissionis on the dolly and cradle assem-
bly.
(46) Remove left side splash shield to gain access
to thru bolt for left side mount.
(47) Remove right engine mount and left side
mount. Refer to procedure outlined in this section.
(48) Raise vehicle slowly. It may be necessary to
move the engine/transmission assembly on the dolly
to allow for removal around body.
(49) Reverse removal procedure for installation.
CYLINDER HEAD COVER
REMOVAL
(1) Disconnect the battery cables.
(2) Remove generator bracket.(3) Remove breather hose.
(4) Remove coolant pressure tank.
(5) Remove cylinder head cover.
INSTALLATION
(1) Install cylinder head cover, torque nuts to 23.5
N´m (208 in. lbs.).
(2) Install coolant pressure tank.
(3) Install breather hose.
(4) Install generator bracket, tighten bolts to 7
N´m (4 ft. lbs.).
(5) Connect battery cable.
ROCKER ARMS AND PUSH RODS
REMOVAL
(1) Disconnect the battery cables.
(2) Remove generator bracket.
(3) Remove breather hose.
(4) Remove coolant pressure tank.
(5) Remove cylinder head cover.
(6) Remove rocker retaining nuts (Fig. 22).
(7) Remove rocker assembly. Place them on a
bench in the same order as removed.
(8) Remove the push rods and place them on a
bench in the same order as removed.
INSTALLATION
(1) Install the push rods in the same order as
removed.
(2) Install rocker arm assemblies in the same
order as removed. Tighten the rocker arm nuts to
29.4 N´m (264 in. lbs.) torque.
Fig. 21 Engine Removal
9 - 54 ENGINENS/GS
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)

(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)

70É using angle torque tool. Then rotate the bolts an
additional 70É following tightening sequence.
(10) Then, tighten the 14mm bolts with special
tool VM-1018 in the following manner:
(11) Side bolts (M1-M2): Tighten M1 bolts to 30
N´m, then rotate them 85É (65). Tighten M2 bolts to
30 N´m, then rotate them 85É (65).
(12)2nd Phase:After 20 minutes of engine oper-
ation at operating temperature, allow engine to cool
down completely. Then retorque the head bolts as fol-
lows:
(13) Central bolts A-L: Starting from bolt A,
slacken and retorque it immediately to 30 N´m + 65É.
Rotate the bolt an additional 65É. Then proceed in
the same way, bolt by bolt, following alphabetical
order, as indicated.
(14) Side bolts M1-M2:Without slackening,
torque bolts M1 then bolts M2 to 90 N´m (66 ft. lbs.).
(15) Tighten intake nuts to 30 N´m (22 ft. lbs.) and
exhaust manifolds nuts to 30 N´m (22 ft. lbs.) speci-
fied torque after completing Phase 2.
(16) If the engine cylinder head is to be replaced
and the original valves used, measure the valve stem
diameter. Only standard size valves can be used with
a service replacement engine cylinder head unless
the replacement head valve stem guide bores are
reamed to accommodate oversize valve stems.
Remove all carbon buildup and reface the valves.
(17) Tighten oil feed lines for rocker arm assem-
blies and oil pressure switch to 13 N´m (112 in. lbs.).
(18) Install push rods and rocker arm assemblies,
tighten nut to 29.4 N´m (264 in. lbs.).(19) Install fuel injectors use tool VM-1012 (refer
to Group 14, Fuel System).
(20) Install valve cover, tighten nuts to 14.7 N´m
(132 in. lbs.).
(21) Connect crankcase breather hose.
(22) Connect the injector sensor wire connector,
and the glow plug connectors.
(23) Install oil feed line, tighten banjo bolts to 12.7
N´m (108 in. lbs), and oil drain line to turbo.
(24) Install water manifold tighten bolts to 12 N´m
(106 in. lbs.).
(25) Install exhaust pipe to turbo elbow, tighten
bolts to 28 N´m (250 in. lbs.).
(26) Install the support strut from block to turbo-
charger exhaust elbow.
(27) Install EGR tube to EGR valve, tighten bolts
to 26 N´m (19 ft. lbs.).
(28) Install intercooler hoses at intake manifold.
(29) Install coolant pressure bottle and hoses.
(30) Install wiper module. Refer to Group 8K,
Windshield Wiper Unit Installation for procedure.
(31) Install intercooler hose at turbocharger tube.
(32) Install fuel injector lines from the pump to
injectors, tighten nuts to 17.6 N´m (156. lbs.).
(33) Connect the upper radiator hose.
(34) Connect negative cable to battery.
(35) Fill the cooling system. Check for leaks.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN DIRECT
LINE WITH THE FAN. DO NOT PUT HANDS NEAR
THE PULLEYS, BELTS OR FAN. DO NOT WEAR
LOOSE CLOTHING.
Fig. 33 Engine Cylinder Head Bolt Tightening Sequence
NS/GSENGINE 9 - 59
REMOVAL AND INSTALLATION (Continued)

(36) Operate the engine with the radiator cap off.
Inspect for leaks and continue operating the engine
until the thermostat opens. Add coolant, if required.
VALVES AND VALVE SPRINGSÐHEAD OFF
This procedure is done with the engine cylinder
head removed from the block.
REMOVAL
(1) Remove the engine cylinder head from the cyl-
inder block. Refer to cylinder head removal in this
section.
(2) Use Valve Spring Compressor Tool and com-
press each valve spring.
(3) Remove the valve locks, retainers, and springs.
(4) Use an Arkansas smooth stone or a jewelers
file to remove any burrs on the top of the valve stem,
especially around the groove for the locks.
(5) Remove the valves, and place them in a rack in
the same order as removed.
INSTALLATION
(1) Fit each valve to its respective valve guide.
NOTE: If valves and valve seats have been refaced
refer to Service Procedures in this section. Follow
The Valve Stand Down procedure.
(2) Install lower, washer and spring.
(3) Install upper spring collar, and compress valve
spring with spring compressor tool. Install split cone
retainers.
HYDRAULIC TAPPETS
REMOVAL
(1) Remove coolant pressure bottle.
(2) Remove cylinder head cover. Refer to cylinder
head cover removal in this section.
(3) Remove rocker assembly and push rods. Iden-
tify push rods to ensure installation in original loca-
tion (Fig. 34).
(4) Remove cylinder head, intake manifold, and
exhaust manifold. Refer to cylinder head removal in
this section.
(5) Remove yoke retainer and aligning yokes (Fig.
35).
(6) Slide Hydraulic Tappet Remover/Installer Tool
through opening in block and seat tool firmly in the
head of tappet.
(7) Pull tappet out of bore with a twisting motion.
If all tappets are to be removed, identify tappets to
ensure installation in original location.
(8) If the tappet or bore in cylinder block is scored,
scuffed, or shows signs of sticking, ream the bore to
next oversize. 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 dis-
assemble a tappet on a dirty work bench.
INSTALLATION
(1) Lubricate tappets.
(2) Install tappets and yoke retainers in their orig-
inal positions. Ensure that the oil feed hole in the
side of the tappet body faces up (away from the
crankshaft).
Fig. 34 Tappet and Rocker Arm Assembly
Fig. 35 Tappet and Yoke
9 - 60 ENGINENS/GS
REMOVAL AND INSTALLATION (Continued)

(3) Install cylinder head, intake manifold, and
exhaust manifold. Refer to cylinder head installation
in this section.
(4) Install push rods in original positions.
(5) Install rocker arms in original positions.
(6) Install cylinder head cover. Refer to cylinder
valve cover installation in this section.
(7) Start and operate engine. Warm up to normal
operating temperature.
CAUTION: To prevent damage to valve mechanism,
engine must not be run above fast idle until all
hydraulic tappets have filled with oil and have
become quiet.
VIBRATION DAMPER
REMOVAL
(1) Disconnect the battery cable.
(2) Raise vehicle on hoist.
(3) Remove right side lower splash shield.
(4) Remove generator, power steering belt. Refer to
Group 7, Cooling.
(5) Remove water pump belt. Refer to Group 7,
Cooling.
(6) Remove engine starter. Refer to Group, 8B for
procedure
(7) Install flywheel locking tool VM.1014 to pre-
vent engine rotation.
NOTE: Crankshaft damper nut is left handed
thread.
(8) Remove vibration damper nut.
(9) Remove vibration damper. No special tool is
needed for removal.
CAUTION: If thread sealant is used it is important
to remove all the old thread sealant from the
threads on the crankshaft.
INSTALLATION
NOTE: Before installing damper be sure the O-ring
inside the center of the damper is in its grove.
(1) Install vibration damper.
CAUTION: Correct torque on the vibration damper
nut is important or engine damage can occur.
(2) Install vibration damper nut and tighten to 441
N´m (325 ft. lbs.).
(3) Remove flywheel locking tool, and install
engine starter.(4) Install both accessary drive belts. Refer to
Group 7, Cooling.
(5) Install right splash shield.
(6) Lower vehicle.
(7) Connect the battery cable.
TIMING GEAR COVER OIL SEAL
REMOVAL
(1) Disconnect the battery cable.
(2) Remove vibration damper. Refer to vibration
damper removal in this section.
(3) Pry out seal (Fig. 36).
INSTALLATION
Remove the oil seal ring. The seating diameter
must be 68.000 - 68.030 mm.
(1) Install new seal using special tool VM-1015.
(2) Install vibration damper. Refer to vibration
damper installation in this section.
(3) Connect the battery cable.
INJECTION PUMP
For removal and installation of injection pump
refer to Group 14, Fuel.
TIMING GEAR COVER
REMOVAL
(1) Disconnect the battery cable.
(2) Raise vehicle on hoist.
(3) Remove right splash shield.
(4) Remove accessary drive belts. Refer to Group 7,
Cooling.
(5) Remove vibration damper nut.
NOTE: Crankshaft damper nut is left handed
thread.
(6) Remove vibration damper.
Fig. 36 Front Cover Seal
NS/GSENGINE 9 - 61
REMOVAL AND INSTALLATION (Continued)

THRUST PLATE INSPECTION
Check the thickness (Fig. 40) of the plate at points
a-b-c-d. If the measurement is not between 3.950 -
4.050 it must be changed.
INSTALLATION
(1) Coat the camshaft journals with clean engine
oil and carefully install the camshaft complete with
thrust plate and gear. Tighten the retaining bolts to
24 N´m. Be sure to align the timing marks as shown.(2) Install hydraulic tappets and retaining yokes.
(3) Install cylinder heads.
(4) Push rods, and rocker arm assemblies. In there
original location.
(5) Install valve cover.
(6) Install Timing case cover.
(7) Install Vibration damper.
(8) Reinstall Engine.
CAMSHAFT BEARINGS
This procedure requires that the engine is removed
from the vehicle.
REMOVAL
(1) With engine completely disassembled, drive out
rear cam bearing core hole plug.
(2) Install proper size adapters and horseshoe
washers (part of Camshaft Bearing Remover/Installer
Tool) at back of each bearing shell. Drive out bearing
shells.
INSTALLATION
(1) Install new camshaft bearings with Camshaft
Bearing Remover/Installer Tool by sliding the new
camshaft bearing shell over proper adapter.
(2) Position rear bearing in the tool. Install horse-
shoe lock and by reversing removal procedure, care-
fully drive bearing shell into place.
(3) Install remaining bearings in the same man-
ner. Bearings must be carefully aligned to bring oil
holes into full register with oil passages from the
main bearing. If the camshaft bearing shell oil holes
are not in exact alignment, remove and install them
correctly. Install a new core hole plug at the rear of
camshaft.Be sure this plug does not leak.
CRANKSHAFT MAIN BEARINGS
REMOVAL
(1) Disconnect battery cable.
(2) Remove engine from vehicle, refer to engine
removal in this section.
(3) Install engine to engine stand.
(4) Remove accessary drive system.
(5) Remove cylinder head cover, refer to cylinder
head cover removal in this section.
(6) Remove rocker arm and push rods, refer to
rocker arm and push rod section in this section.
(7) Remove intake, exhaust manifold and turbo-
charger, refer to Group 11, Exhaust System and
Intake Manifold.
(8) Remove water manifold.
(9) Remove oil feed lines to rocker arms.
(10) Remove cylinder heads.
(11) Remove oil pan and oil pick-up.
(12) Remove piston and connecting rods from
crankshaft journals.
Fig. 39 Camshaft Removal
Fig. 40 Camshaft Thrust Plate
NS/GSENGINE 9 - 63
REMOVAL AND INSTALLATION (Continued)

(13) Remove pistons and connecting rods from
block.
(14) Remove vibration damper. Refer to procedure
in this section.
(15) Remove front cover. Refer to procedure in this
section.
(16) Remove oil pump drive gear.
(17) Install special tool VM-1004 onto crankshaft
over gear (Fig. 41).
(18) Remove main bearing oil feed and carrier
locators from block.
(19) Remove flywheel and adaptor plate from
engine block.
(20) Remove thrust bearings from rear main bear-
ing carrier (Fig. 42).
(21) Slide crankshaft and bearing carriers rear-
ward to rear of block. If you encounter difficulty in
removing the complete assembly as previously
described, slide the assembly rearward sufficiently to
gain access to the main bearing carrier bolts. Mark
the carriers for assembly and remove the bolts, two
for each carrier (Fig. 43).
(22) Separate the two halves of each carrier,
remove from the crankshaft and temporarily re-as-
semble the carriers (Fig. 44). Withdraw the crank-
shaft through the rear of the crankcase.
INSTALLATION
NOTE: Assemble engine according to sequence
described, thus saving time and preventing dam-
ages to engine components. Clean parts with a suit-
able solvent and dry them with compressed airbefore assembly. Use new gaskets where applicable
and torque wrenches for correct tightening of com-
ponents.
(1) Thoroughly clean crankcase and oil passages,
and blow dry with compressed air.
(2) Install new main bearing shells in each of the
carrier halves. Assemble the carriers to the crank-
shaft journals, ensuring that the carriers are
installed in their original locations. Secure each car-
rier with the two bolts tightening evenly to 42 N´m
(31 ft. lbs.) (Fig. 44).
(3) Slide special tool (VM-1002) over the crank-
shaft gear and, insert the crankshaft and carrier
assembly into the crankcase in the same manner
used for removal.
(4) Align the holes in the lower carriers, with the
center of the crankcase webs (Fig. 45).
(5) Secure each carrier assembly to the crankcase
with the main bearing oil feed and carrier locators
and tighten them to 54 N´m (40 ft. lbs).
(6) Install rear main bearing carrier onto crank-
shaft ensuring arrow on bearing carrier aligns with
vertical web in center of crankcase.
(7) Install rear oil seal.
(8) Install new O-rings in adaptor plate.
(9) Install adaptor plate and tighten bolts to 47
N´m (35 ft. lbs.).
(10) Install bolts to main bearing carrier and
tighten to 26.5 N´m (20 ft. lbs.).
(11) Position flywheel and O-ring on crankshaft
and align bolt holes.
NOTE: For purposes of checking crankshaft end
play used flywheel bolts may be used. Final assem-
bly requires new flywheel bolts.
(12) Install 2 flywheel bolts, 180É apart, and
tighten bolts to 20 N´m plus 60É (15 ft. lbs.) plus 60É.
(13) Attach dial indicator to engine block.
(14) Move crankshaft toward front of engine and
zero indicator.
(15) Move crankshaft toward the rear of engine
and record measurement.
(16) Subtract specified crankshaft end play from
figure obtained. Crankshaft end play 0.08 to 0.21 mm
(0.0032 to 0.0083 in.).
(17) Select thrust washers which will give correct
end play.
(18) Remove tools and flywheel.
(19) Lubricate thrust washer halves and fit them
into the rear main bearing carrier.
(20) To verify correct end play, install 2 flywheel
bolts 180É apart, and tighten bolts to 20 N´m plus 60É
(15 ft. lbs. plus 60É).
(21) Measure crankshaft end play with a dial
gauge. Crankshaft end play should not exceed 0.08-
Fig. 41 Crankshaft Special Tool VM.1004
9 - 64 ENGINENS/GS
REMOVAL AND INSTALLATION (Continued)