1996 CHRYSLER VOYAGER service

(6) Refer to crankshaft main bearing Installation if
not in specification.
NOTE: If engine is disassembled refer to Crank-
shaft Main Bearing Removal and Installation for this
procedure.
REMOVAL AND INSTALLATION
ENGINE MOUNTÐFRONT
(1) Disconnect battery.
(2) Remove lower air dam at front fascia.
(3) Remove the bolts holding tow bracket and front
mount to the lower crossmember.(4) Remove thru bolt in engine mount (Fig. 14).
Remove mount.
(5) Reverse removal procedure for installation.
(6) Torque engine mount thru bolt to 65 N´m (48
ft. lbs.)
(7) Torque crossmember bolts for tow bracket and
engine mount to 54 N´m (40 ft. lbs.)
ENGINE MOUNTÐRIGHT
(1) Remove the right engine mount top support
bracket bolt (Fig. 15).
(2) Remove the load on the engine motor mounts
by carefully supporting the engine and transmission
assembly with a floor jack.
(3) Remove the engine mount to frame bolts.
(4) Remove the thru bolt from the mount assembly.
Remove insulator
(5) If replaceing or removing right engine mount
bracket the torque on the mounting bolts is 40 N´m
(30 ft. lbs.)
(6) Reverse removal procedure for installation.
(7) Torque engine mount top bolt (Vertical) to 101
N´m (75 ft. lbs.)
(8) Torque engine mount thru bolt (Horizontal) to
145 N´m (107 ft. lbs.)
(9) Torque engine mount to frame bolts to 68 N´m
(50 ft. lbs.)
MOUNTÐLEFT SIDE
(1) Raise vehicle on hoist and remove left front
wheel.
(2) Remove inner splash shield.
(3) Support the transmission with a transmission
jack.
(4) Remove the insulator thru bolt from the mount
(Fig. 16).
(5) Remove the transmission mount bolts and
remove mount. It may be necessary to lower trans-
mission slightly to remove mount.
(6) Reverse removal procedure for installation.
(7) Install mount. Torque transmission mount bolts
to 54 N´m (40 ft. lbs.).
(8) Align mount into frame bracket with transmis-
sion jack, install thru bolt. Torque thru bolt to 71
N´m (53 ft. lbs.).
Fig. 12 Piston Ring Side Clearance
Fig. 13 Measuring Crankshaft End Play
Fig. 14 Front Engine Mount and Tow Bracket
NS/GSENGINE 9 - 51
SERVICE PROCEDURES (Continued)

(3) Install cylinder head cover, torque nuts to 14.7
N´m (132 in. lbs.).
(4) Install coolant pressure tank.
(5) Install breather hose.
(6) Install generator bracket, tighten bolts to 7
N´m (4 ft. lbs.).
(7) Connect the service valves to the A/C compres-
sor ports, if equipped with air conditioning.
(8) Connect battery cable.
VALVE SPRINGSÐCYLINDER HEAD NOT
REMOVED
This procedure can be done with the engine cylin-
der head installed on the block.
REMOVAL
Each valve spring is held in place by a retainer
and a set of conical valve locks. The locks can be
removed only by compressing the valve spring.
(1) Remove the engine cylinder head cover, refer to
cylinder head cover removal in this section.
(2) Remove rocker arms assemblies for access to
each valve spring to be removed.
(3) Remove push rods. Retain the push rods, and
rocker arms assemblies in the same order and posi-
tion as removed.
(4) Inspect the springs and retainer for cracks and
possible signs of weakening.
(5) Install an air hose adaptor in the fuel injector
hole.
(6) Connect an air hose to the adapter and apply
air pressure slowly. Maintain at least 621 kPa (90psi) of air pressure in the cylinder to hold the valves
against their seats.
(7) Tap the retainer or tip with a rawhide hammer
to loosen the lock from the retainer. Use Valve Spring
Compressor Tool to compress the spring and remove
the locks.
(8) Remove valve spring and retainer.
Inspect the valve stems, especially the grooves. An
Arkansas smooth stone should be used to remove
nicks and high spots.
INSTALLATION
(1) Install valve spring and retainer.
(2) Compress the valve spring with Valve Spring
Compressor Tool and insert the valve locks. Release
the spring tension and remove the tool. Tap the
spring from side-to-side to ensure that the spring is
seated properly on the engine cylinder head.
(3) Disconnect the air hose. Remove the adaptor
from the fuel injector hole and install the fuel injec-
tor.
(4) Repeat the procedures for each remaining valve
spring to be removed.
(5) Install the push rods. Ensure the bottom end of
each rod is centered in the plunger cap seat of the
hydraulic valve tappet.
(6) Install the rocker arm assemblies, at their orig-
inal location.
(7) Tighten the rocker arm assembly nut to 106
N´m (78 ft. lbs.) torque.
(8) Install the engine cylinder head cover, refer to
cylinder head cover installation in this section.
CYLINDER HEAD
REMOVAL
(1) Disconnect the battery cable.
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAIN COCK WITH THE SYSTEM HOT AND PRES-
SURIZED BECAUSE SERIOUS BURNS FROM THE
COOLANT CAN OCCUR.
(2) Drain the cooling system. Refer to Group 7,
Cooling.
(3) Remove wiper module. Refer to Group 8K,
Windshield Wiper Unit Removal for procedure.
(4) Remove coolant pressure bottle.
(5) Remove intercooler hose at intake manifold
(Fig. 23).
(6) Remove intercooler hose at turbocharger inter-
cooler tube.
(7) Remove the upper radiator hose.
(8) Remove water manifold.
(9) Disconnect the heater hoses and coolant pres-
sure bottle hoses.
Fig. 22 Rocker Arm Retaining Nut
NS/GSENGINE 9 - 55
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)

(7) Remove power steering/air conditioning pulley
nut. Remove pulley.
CAUTION: Remove old loctite from threads on
pump.
(8) Remove pump shaft support bracket assembly.
(9) Disconnect the water drain pipe hose at the
timing cover.
CAUTION: When separating the timing geat cover
from the block take care not to damage the mating
surface of the timing gear cover or block. Also take
care not to damage the timing gears or components
located inside the timing gear cover near the edge.
(10) Remove timing gear cover.
INSTALLATION
(1) Apply a continuous 3 mm bead of Silicone
Sealer to timing cover, install within 10 minutes,
tighten Torx bolts to 11 N´m (96 in. lbs) (Fig. 37).
(2) Install pump shaft support bracket assembly,
tighten nuts to 24.5 N´m (216 in. lbs.).
(3) Install Power steering/air conditioning pulley,
tighten to 170 N´m (125 ft. lbs.).
CAUTION: Correct torque on the power steering/air
conditioning pulley nut is important or engine dam-
age can occur.
(4) Connect water drain pipe hose at the timing
cover.NOTE: Before installing damper be sure O-ring on
inside center of damper is in place.
(5) Install vibration damper.
CAUTION: Correct torque on the vibration damper
nut is important or engine damage can occur.
(6) Tighten vibration damper nut to 441 N´m (325
ft. lbs.).
(7) Install accessary drive belts. Refer to Group 7,
cooling for procedure.
(8) Install splash shield.
(9) Lower vehicle.
(10) Connect battery cable.
CAMSHAFT
REMOVAL
(1) To service the camshaft (Fig. 38) the engine
must be removed from the vehicle.
(2) Remove valve cover. Refer to valve cover
removal in this section.
(3) Remove rocker arms and push rods. Identify
push rods to ensure installation in there original
location.
(4) Remove cylinder head. Refer to cylinder head
removal in this section.
(5) Remove hydraulic tappets. Refer to tappet
removal in this section.
(6) Remove vibration damper. Refer to vibration
damper removal in this section.
(7) Remove power steering pulley.
(8) Remove pump shaft support bracket.
(9) Remove timing gear cover. Refer to timing gear
cover removal in this section.
(10) Remove camshaft.
Fig. 37 Front Cover Sealer Location
Fig. 38 Camshaft Assembly
9 - 62 ENGINENS/GS
REMOVAL AND INSTALLATION (Continued)

a catalytic converter. Failure of the catalytic con-
verter can occur due to temperature increases caused
by unburned fuel igniting when passing through the
converter.
The use of the catalysts also involves some non-au-
tomotive problems. Unleaded gasoline must be used
to avoid poisoning the catalyst core. Do not allow
engine to operate at fast idle for extended periods
(over 5 minutes). This condition may result in exces-
sive exhaust system and floor pan temperatures.
EXHAUST GAS RECIRCULATION (EGR)
To assist in the control of oxides of nitrogen (NOx)
in engine exhaust, all engines are equipped with an
exhaust gas recirculation system. The use of exhaust
gas to dilute incoming air/fuel mixtures lowers peak
flame temperatures during combustion, thus limiting
the formation of NOx.
Exhaust gases are taken from opening in the
exhaust manifold passage to the intake manifold.
REFER TO SECTION 25 FOR A COMPLETE
DESCRIPTION, DIAGNOSIS AND SERVICE PRO-
CEDURES ON THE EXHAUST GAS RECIRCULA-
TION SYSTEM AND COMPONENTS.
HEAT SHIELDS
Heat shields (Fig. 2) are needed to protect both the
vehicle and the floor pan from the high temperatures
developed near the catalytic converter and muffler.
Avoid application of rust prevention com-
pounds or undercoating materials to exhaust
system floor pan heat shields on cars so
equipped. Light over spray near the edges is
permitted. Application of coating will greatlyreduce the efficiency of the heat shields result-
ing in excessive floor pan temperatures and
objectionable fumes.
EXHAUST FLEX-JOINT COUPLING
A exhaust flex-joint coupling (Fig. 3) is used to
secure the catalytic converter to the engine manifold.
This living joint actually moves back and forth as the
engine moves, preventing breakage that could occur
from the back-and-forth motion of a transverse
mounted engine.
The exhaust flex-joint has four bolts, four flag nuts
and a gasket that are separate parts from the
exhaust flex-joint. The flex-joint is welded to the cat-
alytic converter.
Fig. 2 Heat Shields
Fig. 3 Flex-Joint
11 - 2 EXHAUST SYSTEM AND INTAKE MANIFOLDNS
GENERAL INFORMATION (Continued)

INSTALLATION
(1) Install new upper intake manifold gasket.
NOTE: Center outboard fastener is a double stud.
(2) Tighten upper intake manifold fasteners start-
ing at center and progressing outward in both direc-
tions. Tighten bolts to 28 N´m (250 in. lbs.). Repeat
this procedures until all fasteners are at specified
torque.
(3) Install dipstick tube. Seal tube to cylinder
block using MopartStud N' Bearing Mount Adhe-
sive. Tighten dipstick tube fastener to 12 N´m (105
in. lbs.)
(4) Install dipstick.
(5) Install upper bolt in intake manifold to front
support bracket (Fig. 11). Torque to 28 N´m (250 in.
lbs.).
(6) Install two top bolts at intake manifold to rear
support bracket making sure bracket to manifold
spacer is in place (Fig. 10). Tighten bolts to 28 N´m
(250 in. lbs.)
(7) Install throttle cables in bracket.
(8) Install throttle cable and speed control cable (if
equipped) to throttle lever.
(9) Install vacuum lines for power brake booster
and speed control vacuum reservoir at upper intake
manifold fittings.
(10) Install vacuum lines for purge solenoid and
PCV valve.
(11) Install electrical connectors for MAP sensor,
throttle position sensor, and idle air control motor.(12) Install air intake tube and resonator box to
throttle body.
(13) Connect negative cable to battery.
INTAKE MANIFOLD LOWERÐ2.4L ENGINE
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL SYSTEM COMPONENTS.
SERVICE VEHICLES IN WELL VENTILATED AREAS
AND AVOID IGNITION SOURCES. NEVER SMOKE
WHILE SERVICING THE VEHICLE
To release fuel pressure, refer to the Fuel Delivery
System Pressure Release section of Group 14 Fuel
System for procedure.
REMOVAL
(1) Perform fuel system pressure release proce-
durebefore attempting any repairs.
(2) Remove upper intake manifold. Refer to proce-
dure in this section.
CAUTION: Cover intake manifold to prevent foreign
material from entering engine.
(3) Disconnect electrical connector from intake air
temperature sensor (Fig. 12).
(4) Remove fuel hose quick connect fitting from
the chassis tube (Fig. 13).Refer to Fuel Hoses,
Clamps and Quick Connect Fittings in the Fuel
Delivery Section of this Group.
WARNING: WRAP A SHOP TOWEL AROUND
HOSES TO CATCH ANY GASOLINE SPILLAGE.
Fig. 11 Intake Manifold Front Support Bracket and
Map Sensor
Fig. 12 Intake Air Temperature Sensor
11 - 6 EXHAUST SYSTEM AND INTAKE MANIFOLDNS
REMOVAL AND INSTALLATION (Continued)

FUEL SYSTEM
CONTENTS
page page
FUEL DELIVERY SYSTEM................... 4
FUEL INJECTION SYSTEM................. 29GENERAL INFORMATION................... 1
GENERAL INFORMATION
INDEX
page page
GENERAL INFORMATION
CRUISING RANGE........................ 3
E-85 GENERAL INFORMATION.............. 2
ETHANOL FUEL (E-85).................... 2
FUEL REQUIREMENTS.................... 1
FUEL REQUIREMENTS.................... 2GASOLINE/OXYGENATE BLENDS............ 2
INTRODUCTION......................... 1
PCM REPLACEMENT..................... 1
REPLACEMENT PARTS.................... 3
STARTING.............................. 2
GENERAL INFORMATION
INTRODUCTION
Throughout this group, references may be made to
a particular vehicle by letter or number designation.
A chart showing the breakdown of these designations
is included in the Introduction Section at the front of
this service manual.
The Evaporation Control System, is also considered
part of the fuel system. The system reduces the emis-
sion of fuel vapor into the atmosphere.
The description and function of the Evaporation
Control System is found in Group 25 of this manual.
PCM REPLACEMENT
USE THE DRB SCAN TOOL TO REPROGRAM
THE NEW PCM WITH THE VEHICLES ORIGI-
NAL IDENTIFICATION NUMBER (VIN) AND
THE VEHICLES ORIGINAL MILEAGE. IF THIS
STEP IS NOT DONE A DIAGNOSTIC TROUBLE
CODE (DTC) MAY BE SET.
FUEL REQUIREMENTS
Your vehicle was designed to meet all emission reg-
ulations and provide excellent fuel economy when
using high quality unleaded gasoline.
Use unleaded gasolines having a minimum posted
octane of 87.
If your vehicle develops occasional light spark
knock (ping) at low engine speeds this is not harm-
ful. However; continued heavy knock at high speeds
can cause damage and should be reported to your
dealer immediately. Engine damage as a result of
heavy knock operation may not be covered by the
new vehicle warranty.
In addition to using unleaded gasoline with the
proper octane rating, those that contain detergents,
corrosion and stability additives are recommended.
Using gasolines that have these additives will help
improve fuel economy, reduce emissions, and main-
tain vehicle performance.
Poor quality gasoline can cause problems such as
hard starting, stalling, and stumble. If you experi-
ence these problems, try another brand of gasoline
before considering service for the vehicle.
NSFUEL SYSTEM 14 - 1