1996 CHRYSLER VOYAGER service

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)

(2) Move crankshaft all the way to the rear of its
travel.
(3) Zero the dial indicator.
(4) Move crankshaft all the way to the front and
read the dial indicator. Refer to Crankshaft Specifi-
cation Chart.
FEELER GAUGE METHOD
(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 damage
any bearing surface.Do notloosen main bearing
cap.
(2) Use a feeler gauge between number 2 thrust
bearing and machined crankshaft surface to deter-
mine end play. Refer to Crankshaft Specification
Chart.
VALVE SERVICE RECONDITION
VALVE INSPECTION
(1) Clean valves thoroughly and discard burned,
warped and cracked valves.
(2) Measure valve stems for wear. Refer to Valve
Dimension Chart.
CAUTION: Valve stems are chrome plated and
should not be polished.
(3) Remove carbon and varnish deposits from
inside of valve guides with a reliable guide cleaner.
(4) Measure valve stem guide clearance as follows:
a. Install valve into cylinder head so it is 14 mm
(0.551 in.) off the valve seat. A small piece of hose
may be used to hold valve in place.
b. Attach dial indicator Tool C-3339 to cylinder
head and set it at right angle of valve stem being
measured (Fig. 17).
(5) Move valve to and from the indicator. Refer to
Valve Guide Specification Chart.
(6) Ream the guides for valves with oversized
stems if dial indicator reading is excessive or if the
stems are scuffed or scored.
(7) Service valves with oversize stems and over
size seals are available in 0.15 mm (0.005 in.), 0.40
mm, (0.015 in.) and 0.80 mm (0.030 in.) oversize.
NOTE: Oversize seals must be used with oversize
valves.
(8) Refer to Valve Guide Specification Chart for
reamer size to accommodate the oversize valve
stems.
(9) Slowly turn reamer by hand and clean guide
thoroughly before installing new valve.Do not
attempt to ream the valve guides from standard
directly to 0.80 mm (0.030 in.) Use step proce-
Fig. 15 Measuring Bearing Clearance with
Plastigage
Fig. 16 Checking Crankshaft End Play
Fig. 17 Measuring Valve Guide Wear
9 - 100 3.3/3.8L ENGINENS
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)

(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.
(7) The notch or groove on top of piston must be
pointing toward front of engine (Fig. 60).
(8) Install rod caps. Install nuts on cleaned and
oiled rod bolts and tighten nuts to 54 N´m (40 ft. lb.)
Plus 1/4 turn.
(9) Repeat procedure for each piston and rod
installation.
(10) Install cylinder heads and oil pan.
(11) Fill engine crankcase with proper oil to cor-
rect level.
(12) Connect negative cable to battery.
CRANKSHAFT
MAIN BEARINGS
Bearing caps are not interchangeable and should
be marked at removal to insure correct assembly
(Fig. 62). Upper and lower bearing halves are NOT
interchangeable. Lower main bearing halves of 1, 3
and 4 are interchangeable. Upper main bearing
halves of 1, 3 and 4 are interchangeable.
CRANKSHAFT MAIN JOURNALS
The crankshaft journals should be checked for
excessive wear, taper and scoring. (Fig. 61) Limits of
taper or out-of-round on any crankshaft journals
should be held to 0.025 mm (0.001 in.). Journal
grinding should not exceed 0.305 mm (0.012 in.)
under the standard journal diameter. Do NOT grind
thrust faces of Number 2 main bearing. Do NOT nick
crank pin or bearing fillets. After grinding, remove
rough edges from crankshaft oil holes and clean out
all passages.
CAUTION: With the nodular cast iron crankshafts
used it is important that the final paper or cloth pol-ish after any journal regrind be in the same direc-
tion as normal rotation in the engine.
Upper and lower Number 2 bearing halves are
flanged to carry the crankshaft thrust loads and are
NOT interchangeable with any other bearing halves
in the engine (Fig. 63). All bearing cap bolts removed
during service procedures are to be cleaned and oiled
before installation. Bearing shells are available in
standard and the following undersizes: 0.025 mm
(0.001 in.) and 0.254 mm (0.010 in). Never install an
undersize bearing that will reduce clearance below
specifications.
REMOVAL
(1) Remove oil pan and identify bearing caps
before removal.
(2) Remove bearing caps one at a time. Remove
upper half of bearing by inserting Special Main Bear-
ing Tool C-3059. (Fig. 64) into the oil hole of crank-
shaft.
Fig. 60 Piston I.D. NotchesFig. 61 Measure Crankshaft Journal O.D.
Fig. 62 Main Bearing Cap Identification
9 - 116 3.3/3.8L ENGINENS
REMOVAL AND INSTALLATION (Continued)

Install new gasket and tighten screws to 12 N´m (105
in. lbs.).
OIL FILTER
CAUTION: When servicing the oil filter (Fig. 71)
avoid deforming the filter can by installing the
remove/install 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) Using Tool C-4065, turn filter counterclockwise
to remove from base. Properly discard filter.
(2) Wipe base clean, then inspect gasket contact
surface.
(3) Lubricate gasket of new filter with clean
engine oil.
(4) Install new filter until gasket contacts base.
Tighten filter 1 turn or 20 N´m (15 ft. lbs.). Use filter
wrench if necessary.
(5) Start engine and check for leaks.
ENGINE OIL GALLERY PLUGS
REMOVAL
Using a blunt tool such as a drift and a hammer,
strike the bottom edge of the cup plug. With the cup
plug rotated, grasp firmly with pliers or other suit-
able tool and remove plug (Fig. 72).CAUTION: Do not drive cup plug into the casting
as restricted cooling can result and cause serious
engine problems.
INSTALLATION
Thoroughly clean inside of cup plug hole in cylin-
der block or head. Be sure to remove old sealer.
Lightly coat inside of cup plug hole with Loctite Stud
N' Bearing Mount or equivalent. Make certain the
new plug is cleaned of all oil or grease. Using proper
drive plug, drive plug into hole so that the sharp
edge of the plug is at least 0.5 mm (0.020 in.) inside
the lead-in chamfer.
DISASSEMBLY AND ASSEMBLY
OIL PUMP
It is necessary to remove the oil pan, oil pickup
and chain case cover to service the oil pump rotors.
The oil pump pressure relief valve can be serviced by
removing the oil pan and oil pickup tube. Refer to
Timing Chain Cover Removal and Installation of this
section for procedures.
DISASSEMBLY
(1) To remove the relief valve, proceed as follows:
Fig. 70 Rear Crankshaft Oil SealÐInstallation
Fig. 71 Oil Filter
Fig. 72 Core Hole Plug Removal
NS3.3/3.8L ENGINE 9 - 119
REMOVAL AND INSTALLATION (Continued)