1996 CHRYSLER VOYAGER service

(5) Turn crankshaft two full turns in clockwise
direction.Turn smoothly and in clockwise direc-
tion ONLY.
(6) Align the timing marks on the sprockets and
tighten the timing belt tensioner locking bolt to 25
N´m (250 in. lbs.) torque.
(7) Reassembly belt covers, engine bracket, insula-
tor, crankshaft pulleys, accessories and accessory
drive belts in reverse order.
OIL PAN
Oil pan to crankcase sealing is provided with
MopartSilicone Rubber Adhesive Sealant or equiva-
lent gasket material. See Form-In-Place Gaskets in
Standard Service Procedures.
(1) Apply sealant as shown in (Fig. 42).
(2) Install pan and tighten screws to 6 N´m (50 in.
lbs.) in sequence shown in (Fig. 43).
Fig. 41 Positioning Belt Tensioner
Fig. 42 Oil Pan Sealing
Fig. 43 Oil Pan Screw Tightening Sequence
Fig. 40 Timing Belt Tensioner
NS3.0L ENGINE 9 - 77
REMOVAL AND INSTALLATION (Continued)

REAR CRANKSHAFT SEAL
REAR CRANKSHAFT SEAL RETAINER
(1) Install rear crankshaft oil seal in housing with
Special Tool MD-998718 (Fig. 62).
(2) Apply Mopar Silicone Rubber Adhesive Sealant
or equivalent to oil seal housing (Fig. 63) per proce-
dure detailed in form-in-place gasket section in Stan-
dard Service Procedures.(3) Apply light coating of engine oil to the entire
circumference of oil seal lip.
(4) Install seal assembly on cylinder block and
tighten bolts to 12 N´m (104 in. lbs.)
FRONT CRANKSHAFT OIL SEAL
(1) Install oil pump gasket and oil pump case (Fig.
65) and (Fig. 64).
CAUTION: Install bolts, depending on length in
locations shown in (Fig. 64).
(2) Using front crankshaft oil seal installer Special
Tool MD-998717 install oil seal in oil pump (Fig. 65).
Fig. 62 Rear Crankshaft Oil SealÐInstallation
Fig. 61 Crankshaft Main Bearing Cap
Fig. 63 Apply Sealant to Oil Seal Housing
NS3.0L ENGINE 9 - 83
REMOVAL AND INSTALLATION (Continued)

CLEANING AND INSPECTION
TIMING BELT
INSPECTION
(1) Remove the upper front outer timing belt cover
by loosening the three attaching bolts (Fig. 75).
(2) Inspect both sides of the timing belt drive &
back. Replace belt if any of the following conditions
exist:²Rubber back side is glossy, hardened back with-
out resilience and leaves no indent when pressed
with fingernail.
²Cracks on rubber back.
²Cracks or peeling of canvas.
²Cracks on rib root.
²Missing teeth.
²The sides are normal if they are sharp as if cut
by a knife (Fig. 74).
NOTE: If none of the above conditions are seen on
the belt, the belt cover can be installed.
CYLINDER HEAD
CLEANING AND INSPECTION
(1) Before cleaning, check for leaks, damage and
cracks.
(2) Clean cylinder head and oil passages.
(3) Check cylinder head for flatness (Fig. 76).
(4) Cylinder head must be flat within:
²Standard dimension = less than 0.05 mm (.002
in.)
²Service Limit = 0.2 mm (.008 in.)
²Grinding Limit = Maximum of 0.2 mm (.008 in.)
is permitted.
Fig. 73 Rocker Arm and Shafts
Fig. 72 Number One Camshaft Bearing Cap
9 - 86 3.0L ENGINENS
DISASSEMBLY AND ASSEMBLY (Continued)

SPECIFICATIONS
3.0L ENGINE
Type.........................60É V-6 SOHC
Number of Cylinders.......................6
Bore.....................91.1 mm (3.587 in.)
Stroke.....................76mm(2.992 in.)
Compression Ratio.....................8.85:1
Displacement..............3.0L (181 Cubic in.)
Firing Order....................1±2±3±4±5±6
Basic Ignition Timing.........Refer to Emission
Control Information Label on Vehicle
Compression Pressure...............1227 kPa
(178 psi) @ 250 RPM
Maximum Variation Between Cylinders......25%
Valve Timing
Intake Valve±Open.................19É BTDC
Intake Valve±Closed................59É ABDC
Exhaust Valve±Open................59É BBDC
Exhaust Valve±Closed...............19É ATDC
Cylinder Block
Cylinder Bore Diameter......91.1 mm (3.587 in.)
Top Surface Flatness........0.05 mm (0.002 in.)
Service Limit.............0.1 mm (0.0039 in.)
Grinding Limit of Top Surface*..........0.2 mm
(0.008 in.)
*Includes/Combined with cylinder Head Grinding
Pistons
Piston Diameter.................91.06 - 91.09
Piston to Cylinder Clearance......0.03 - 0.05 mm
(0.0012 - 0.002 in.)
Piston Ring End Gap No. 1......0.30 - 0.45 mm
(0.012 - 0.018 in.)
Service Limit..............0.8 mm (0.031 in.)
Piston Ring End Gap No. 2......0.45 - 0.60 mm
(0.018 - 0.024 in.)
Service Limit..............0.8 mm (0.031 in.)
Piston Ring End Gap Oil Control . .0.20 - 0.60 mm
(0.008 - 0.024 in.)
Service Limit..............1.0 mm (0.039 in.)
Ring Side Clearance No. 1......0.030 - 0.090 mm
(0.002 - 0.0035 in.)
Service Limit..............1.0 mm (0.039 in.)
Ring Side Clearance No. 2......0.040 - 0.085 mm
(0.0016 - 0.0033 in.)
Service Limit..............1.0 mm (0.039 in.)
Oversize Service Pistons.........0.25 - 0.50 mm
(0.010 - 0.020 in.),
0.75 - 1.00 mm (0.030 - 0.039 in.)
Connecting Rods
Bearing Clearance............0.018 - 0.036 mm
(0.0007 - 0.0014 in.)
Side Clearance................0.10 - 0.25 mm
(0.004 - 0.010 in.)Wear Limit.................0.4 mm (0.015 in.)
Length±Center to Center.......140.9 - 141.0 mm
(5.547 - 5.551 in.)
Parallelism±Twist..........0.05 mm (0.0019 in.)
Torsion...................0.1 mm (0.0039 in.)
Crankshaft
Main Journal Diameter.......59.980 - 60.0 mm
(2.361 - 2.362 in.)
Connecting Rod
Journal Diameter..........49.980 - 50.000 mm
(1.968 - 1.969 in.)
Out-of-Round (Max.).........0.03 mm (0.001 in.)
Taper (Max.).............0.005 mm (0.0002 in.)
Main and Rod
Bearing Clearance...........0.018 - 0.036 mm
(0.0007 - 0.0014 in.)
Undersize Service
Bearings................0.25 - 0.50 - 0.75 mm
(0.010 - 0.020 - 0.030 in.)
End Play.......0.05 - 0.25 mm (0.002 - 0.010 in.)
Service Limit..............0.3 mm (0.012 in.)
Cylinder Head
Flatness of Gasket Surface. . . .0.05 mm (0.002 in.)
Grinding Limit of
Gasket Surface.............0.2 mm (0.008 in.)
Cylinder Head Valve Seat
Angle±Intake and Exhaust..........44É - 44É.3'
Contact Width...................0.9 - 1.3 mm
(0.035 - 0.051 in.)
Sinkage±Service Limit........0.2 mm (0.078 in.)
Guide Bore Diameter (Std).......7.95 - 7.98 mm
(0.313 - 0.314 in.)
Valves
Face Angle......................45É - 45É 30'
Head Diameter Intake.........48.64 - 48.90 mm
(1.915 - 1.925 in.)
Head Diameter Exhaust.......40.01 - 40.26 mm
(1.575 - 1.585 in.)
Length Intake (Overall).....103.0 mm (4.055 in.)
Length Exhaust (Overall). . . .102.7 mm (4.043 in.)
Valve Margin±Intake.........1.2 mm (0.047 in.)
Service Limit..............0.7 mm (0.027 in.)
Valve Margin±Exhaust........2.0 mm (0.079 in.)
Service Limit..............1.5 mm (0.059 in.)
Valve Stem Tip Height......49.02 mm (1.929 in.)
Stem Diameter±Intake........7.960 - 7.975 mm
(0.313 - 0.314 in.)
Stem Diameter±Exhaust.......7.930 - 7.950 mm
(0.312 - 0.3125 in.)
Stem-to-Guide Clearance±Intake . . .0.03 - 0.06 mm
(0.001 - 0.002 in.)
Service Limit.............0.10 mm (0.004 in.)
Stem-to-Guide Clearance±
Exhaust.....................0.05 - 0.09 mm
(0.0019 - 0.003 in.)
NS3.0L ENGINE 9 - 89

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

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)

FITTING PISTONS AND RINGS
FITTING PISTONS
The piston and cylinder wall must be clean and
dry. Piston diameter should be measured 90 degrees
to piston pin at size location shown in (Fig. 8). Cyl-
inder bores should be measured halfway down the
cylinder bore and transverse to the engine crankshaft
center line shown in (Fig. 7). Refer to Cylinder Bore
and Piston Specification Chart.Pistons and cylin-
der bores should be measured at normal room
temperature, 70ÉF (21ÉC).
FITTING RINGS
(1) Wipe cylinder bore clean. Insert ring and push
down with piston to ensure it is square in bore. Thering gap measurement must be made with the ring
positioning at least 12 mm (0.50 in.) from bottom of
cylinder bore. Check gap with feeler gauge (Fig. 9).
Refer to Piston Ring Specification Chart.
(2) Check piston ring to groove clearance: (Fig. 10).
Refer to Piston Ring Specification Chart.
FITTING CONNECTING ROD BEARINGS
Fit all rods on one bank until complete.
The bearing caps are not interchangeable and
should be marked at removal to insure correct
assembly.
The bearing shells must be installed with the
tangs inserted into the machined grooves in the rods
and caps. Install cap with the tangs on the same side
as the rod.
Limits of taper or out-of-round on any crankshaft
journals should be held to 0.025 mm (0.001 in.).
Bearings are available in 0.025 mm (0.001 in.) and
0.250 mm (0.010 in.) undersize.Install the bear-
ings in pairs. Do not use a new bearing half
Fig. 6 Measuring Timing Chain Wear and Stretch
Fig. 7 Checking Cylinder Bore Size
CYLINDER BORE AND PISTON
SPECIFICATION CHART
EngineStandard
BoreMaximum
Out-Of-
RoundMaximum
Taper
3.3L 92.993 -
93.007 mm0.076 mm 0.51 mm
(3.661 -
3.6617 in.)(0.003 in.) (0.002 in.)
3.8L 95.993 -
96.007 mmSame Same
3.7792 -
3.780 in.
Standard Piston Size
3.3L 92.950 - 92.968 mm (3.6594 - 3.6602 in.)
3.8L 95.950 - 95.968 mm (3.7776 - 3.7783 in.)
Piston to Bore Clearance: 0.025 - 0.057 mm
(0.0009 - 0.0022 in.)
Measurements taken at Piston Size Location.
Fig. 8 Piston Measurements
NS3.3/3.8L ENGINE 9 - 97
SERVICE PROCEDURES (Continued)