1996 CHRYSLER VOYAGER drain bolt

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)

(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)

(3) Drain oil.
(4) Remove oil pan bolts (Fig. 48).
(5) Remove oil pan.
INSTALLATION
(1) Install oil pan. Apply a continuous 3 mm bead
of Silicone Sealer to oil pan, install within 10 min-
utes.
(2) Install oil pan bolts and torque bolts to 11 N´m
(8 ft. lbs.).
(3) Install oil drain plug tighten to 79 N´m (58 ft.
lbs).
(4) Lower vehicle.
(5) Fill engine with proper amount of oil.
(6) Connect battery cable.
OIL PUMP
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove right splash shield.
(3) Remove both accessory drive belts. Refer to
Group 7, Cooling.
(4) Remove pump shaft support bracket assembly.
(5) Remove vibration damper. Refer to Vibration
Damper Removal in this section.
NOTE: Crankshaft damper nut is left handed
thread.
(6) Remove front cover. Refer to Timing Gear
Cover Removal in this section.
(7) Remove oil pump.
INSTALLATION
(1) Install new O-ring and lubricate with clean
engine oil.
(2) Install oil pump and tighten retaining screws
to 27.5 N´m (240 in. lbs.).(3) Install front cover. Refer to Timing Gear Cover
Installation in this section.
(4) Install pump shaft support bracket assembly.
CAUTION: Correct torque on the vibration damper
nut is important or engine damage can occur.
(5) Install vibration damper. Torque nut to 441
N´m (325 ft. lbs.)
(6) Install both accessory drive belts. Refer to
Group 7, Cooling.
(7) Install right splash shield.
OIL PUMP PRESSURE RELIEF VALVE
REMOVAL
(1) Remove oil pan.
(2) Remove clip retaining relief valve.
(3) Remove relief valve cap, spring, and plunger
(Fig. 50).
(4) Check relief valve spring length. Relief valve
spring free length is 57.5mm (2.263 in.). If spring
length is less or spring is distorted it must be
replaced.
(5) Check plunger for scoring, replace if necessary.
INSTALLATION
(1) Thoroughly clean all components and relief
valve pocket in cylinder block.
(2) Fit plunger, spring and cap into block.
(3) Compress spring and install retaining clip.
Ensure clip is completely seated in groove.
Fig. 48 Oil Pan
Fig. 49 Oil Pump Drive Gear
NS/GSENGINE 9 - 67
REMOVAL AND INSTALLATION (Continued)

DESCRIPTION...................TORQUE
Injector
Tighten to................65N´m(48ft.lbs.)
Intake Manifold Mounting
Nuts...................30N´m(264 in. lbs.)
Main Bearing Oil Delivery Union
Bolts....................54N´m(40ft.lbs.)
Oil Feed Line To Rocker Arms
Bolts.................12.7 N´m (108 in. lbs.)
Oil Feed Line to Block
Bolts.................12.7 N´m (108 in. lbs.)
Oil Feel Line to Vacuum Pump
Bolts.................16.7 N´m (145 in. lbs.)
Oil Filter
Tighten to...............9.8N´m(85in.lbs.)
Oil Filter Adaptor
Fastener.................49N´m(36ft.lbs.)
Oil Filter Base
Fastener.................49N´m(36ft.lbs.)
Oil Pan Mounting
Bolts...................12N´m(108 in. lbs.)
Oil Pickup Tube
Bolts..................11.3N´m(100 in. lbs.)
Oil Pump Mounting
Bolts.................27.5 N´m (240 in. lbs.)
Oil Pan Drain
Plug.....................54N´m(40ft.lbs.)
Power Steering Pressure Hose
Fastener................28N´m(240 in. lbs.)
Power Steering Pulley
Nut ...................170N´m(125 ft. lbs.)
Rear Crankshaft Bearing Carrier
Bolts..................10.8 N´m (95 in. lbs.)
Rocker Arm Cover
Bolts.................14.7 N´m (132 in. lbs.)
Rocker Arm Mounting
Nuts..................29.4 N´m (264 in. lbs.)
Power Steering Pump Mounting
Nuts..................24.5 N´m (216 in. lbs.)
Turbocharger Mounting
Nuts...................32N´m(288 in. lbs.)
Turbocharger Oil Delivery
Bolt..................27.5 N´m (240 in. lbs.)
Turbocharger Oil Drain
Bolts..................10.8 N´m (95 in. lbs.)
Vacuum Pump Mounting
Bolts..................10.8 N´m (95 in. lbs.)
Water Manifold Mounting
Bolts..................11.8N´m(108 in. lbs.)
Water Pump Pulley
Bolts.................27.5 N´m (240 in. lbs.)SPECIAL TOOLS
2.5L VM DIESEL
Crankshaft Pulley and Gear Remover VM.1000A
Cylinder Liner Puller VM.1001
Crankshaft Bearing Remover/Installer VM.1002
NS/GSENGINE 9 - 81
SPECIFICATIONS (Continued)

(5) Drain cooling system. Refer to Group 7, Cool-
ing System for procedure.
(6) Remove heater, and upper radiator hoses at
intake manifold.
(7) Disconnect coolant temperature sensor (Fig.
14).
(8) Remove the accessory drive belt. Refer to
Accessory Drive belt Removal and Installation in
Group 7, Cooling System for procedure.
(9) Remove fasteners attaching generator bracket
to cylinder head, and block.
(10) Remove intake manifold center support
bracket bolts (Y bracket) (Fig. 15)
(11) Disconnect fuel injector harness.(12) Remove lower intake manifold fasteners (Fig.
16). Remove the manifold from engine.
(13) Inspect and clean manifold. Refer to Cleaning
and Inspection outlined in this section for proce-
dures.
INSTALLATION
If the following items were removed, install and
torque to:
²Fuel Rail Bolts 22 N´m (200 in. lbs.)
²Engine Outlet Connector Bolts 28 N´m (250 in.
lbs.)
²Coolant Temperature Sensor 7 N´m (60 in. lbs.)
²Intake Air Temperature Sensor 28 N´m (250 in.
lbs.)
(1) Using a new intake gasket, position intake
manifold on the engine and install retaining bolts.
Fig. 13 Fuel Line Quick Disconnect
Fig. 14 Coolant Temperature SensorÐ2.4L
Fig. 15 Intake Manifold Center Support Bracket
Fig. 16 Intake Manifold Fasteners
NSEXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 7
REMOVAL AND INSTALLATION (Continued)

(2) Tighten intake manifold fasteners in the fol-
lowing sequence (Fig. 16). Torque to 23 N´m (200 in.
lbs.). Repeat this procedure until all bolts are at
specified torque.
(3) Install intake manifold center support bracket
bolts (Y bracket):
²Fastener to block 54 N´m (40 ft. lbs.)
²Fastener to intake 28 N´m (250 in. lbs.)
(4) Install fuel hose quick connector fitting to
chassis tubes.Refer to Fuel Hoses, Clamps and
Quick Connect Fittings in Group 14, Fuel Deliv-
ery.Push the fitting onto the chassis tube until it
clicks into place. Pull on the fitting to ensure com-
plete insertion.
(5) Reverse removal procedures 2 through 12 for
installation.
CAUTION: When using the ASD Fuel System Test,
the ASD relay and fuel pump relay remain energized
for 7 minutes or until the test is stopped, or until
the ignition switch is turned to the Off position.
(6) With the ignition key in ON position, access
the DRB scan tool ASD Fuel System Test to pressur-
ize the fuel system. Check for leaks.
EXHAUST MANIFOLDÐ2.4L ENGINE
REMOVAL
(1) Raise vehicle and disconnect exhaust pipe from
the exhaust manifold at the flex-joint.
(2) Disconnect Oxygen Sensor lead wire at the rear
exhaust manifold (Fig. 17).
(3) Remove the bolts attaching the manifold to the
cylinder head. Remove manifold (Fig. 17).
(4) Inspect and clean manifold. Refer to Cleaning
and Inspection outlined in this section for proce-
dures.
INSTALLATION
(1) Install exhaust manifold with a new gasket
and tighten attaching nuts in the order shown in
(Fig. 17) to 20 N´m (175 in. lbs.).
(2) Attach exhaust pipe to exhaust manifold and
tighten bolt to 28 N´m (250 in. lbs.).
(3) Connect heated oxygen sensor lead (Fig. 17).
INTAKE MANIFOLDÐ3.0L ENGINE
REMOVAL
(1) Perform fuel system pressure release proce-
dure(before attempting any repairs).Refer to
Group 14 Fuel System for procedure.
(2) Disconnect negative battery cable. Drain cool-
ing system. See Cooling System, Group 7.
(3) Remove air inlet resonator to throttle body
hose.
(4) Remove throttle cable and transaxle kickdown
linkage (Fig. 18).
(5) Remove automatic idle speed (AIS) motor and
throttle position sensor (TPS) wiring connectors from
throttle body (Fig. 19).
(6) Remove vacuum hose harness from throttle
body.
(7) Remove PCV and Brake booster hoses from
Air Intake Plenum.
(8) Remove Ignition Coil from Intake Plenum
(Fig. 20).
(9) Remove wiring connectors from coolant temper-
ature sensor (Fig. 21).
(10) Remove vacuum connections from Air Intake
Plenum vacuum connector.
(11) Remove fuel hose from fuel rail (Fig. 21).
WARNING: WRAP SHOP TOWELS AROUND HOSES
TO CATCH ANY GASOLINE SPILLAGE.
Fig. 17 Exhaust Manifold Attaching PointsÐ2.4L
Engine
Fig. 18 Throttle Cable Attachment
11 - 8 EXHAUST SYSTEM AND INTAKE MANIFOLDNS
REMOVAL AND INSTALLATION (Continued)

(2) Attach exhaust pipe to exhaust manifold and
tighten bolts to 28 N´m (250 in. lbs.)
(3) Attach crossover pipe to exhaust manifold and
tighten bolt to 69 N´m (51 ft. lbs.)
(4) Install rear exhaust manifold heat shield (Fig.
29).
(5) Connect heated oxygen sensor lead (Fig. 28).
(6) Install front exhaust manifold and attach
exhaust crossover.
(7) Install front exhaust manifold heat shield and
tighten attaching screws to 15 N´m (130 in. lbs.) (Fig.
31).
INTAKE MANIFOLDÐ3.3/3.8L ENGINE
REMOVAL
(1) Remove windshield wiper module. Refer to
Group 8K Windshield Wiper and Washer Systems for
procedure.
(2) Perform fuel system pressure release proce-
dure(before attempting any repairs).Refer to
Group 14 Fuel System for procedure.
(3) Drain cooling system. See Cooling System,
Group 7 for procedure.(4) Remove air inlet resonator to throttle body
hose assembly.
(5) Remove throttle cable. Refer to Group 14 Fuel
Systems for procedure. Remove wiring harness from
throttle cable bracket.
(6) Remove automatic idle speed (AIS) motor and
throttle position sensor (TPS) wiring connectors from
throttle body (Fig. 33).
(7) Remove EGR transducer connector.
(8) Remove vacuum hose harness from throttle
body (Fig. 33).
(9) Remove PCV and brake booster hoses from air
intake plenum.
Fig. 30 Crossover Pipe
Fig. 31 Front Exhaust Manifold Heat Shield
Fig. 32 Identify Exhaust Manifold Gaskets
Fig. 33 Electrical and Vacuum Connection to
Throttle Body
11 - 12 EXHAUST SYSTEM AND INTAKE MANIFOLDNS
REMOVAL AND INSTALLATION (Continued)

FRAME
INDEX
page page
REMOVAL AND INSTALLATION
FRONT CROSSMEMBER MOUNT BUSHINGS . . . 5
FRONT CROSSMEMBER................... 3SPECIFICATIONS
FRAME AND BODY OPENING DIMENSIONS.... 5
REMOVAL AND INSTALLATION
FRONT CROSSMEMBER
The front suspension crossmember must be
installed in the design location to achieve proper
front end suspension alignment. If the crossmember
is removed without applying reference marks on the
frame rails, align the crossmember according to the
dimensions provided in this group.
NOTE: If the caged nuts in the frame rails become
damaged and cannot be reused, a replacement nut
can be obtained through a MoparTParts supplier.
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove steering column lower cover from
instrument panel. Refer to Group 8E, Instrument
Panel and Systems.
(3) Remove knee blocker reinforcement. Refer to
Group 8E, Instrument Panel and Systems.
(4) Position steering so front wheels are straight
ahead.
CAUTION: Do not rotate steering wheel after disen-
gaging lower coupling from steering gear, damage
to airbag clock spring can result.
(5) Remove clinch bolt holding steering column
coupling to steering gear shaft (Fig. 1).
(6) Remove steering column coupling from tele-
scoping steering gear shaft.
(7) Hoist and support vehicle on safety stands.
(8) Position a drain pan under power steering
pump and oil return hose coupling.
(9) Using a hose pinch-off pliers (C-4390), pinch
power steering oil return hose off between the cross-
member coupling and the pump.
(10) Loosen hose clamp at the crossmember cou-
pling.
(11) Disconnect return hose from metal tube.
(12) While holding pressure relief valve nut on
back of power steering pump, Remove flare nut hold-
ing high pressure hose to back of pump.(13) Separate high pressure hose from pump.
(14) Allow power steering fluid to drain into pan.
(15) Remove bolts holding anti-lock brake sensor
leads to crossmember.
(16) Position anti-lock brake leads out of the way.
(17) Disconnect stabilizer bar links from ends of
stabilizer bar. Refer to Group 2, Suspension.
(18) Disconnect lower ball joints from lower control
arms. Refer to Group 2, Suspension.
(19) Remove bolt holding rear engine mount to
crossmember (Fig. 2).
(20) Using paint or grease pencil, mark outline of
crossmember on frame rails to aid installation.
(21) Support crossmember on suitable lifting
device (Fig. 4).
(22) Remove bolts holding crossmember to front
frame rails (Fig. 3).
(23) Remove crossmember from vehicle (Fig. 4).
Fig. 1 Steering Coupling Boot
NSFRAME AND BUMPERS 13 - 3