1996 CHRYSLER VOYAGER fuel pump

8W-95 SPLICE LOCATIONS
INDEX
page page
DESCRIPTION AND OPERATION
INTRODUCTION......................... 1SPLICE LOCATION INDEX.................. 1
SPLICE LOCATIONS (RHD)................ 15
DESCRIPTION AND OPERATION
INTRODUCTION
This section provides illustrations identifying the
general location of the splices in this vehicle. A spliceindex is provided. Use the wiring diagrams in each
section for splice number identification. Refer to the
index for the proper splice number.
SPLICE LOCATION INDEX
Splice Number Location Fig.
BS01 Near Split for Tail Lamps 12
BS02 Near Fuel Tank T/O 12
BS03 Near Instrument Panel T/O 9
BS05 Near Instrument Panel T/O 9
BS05 (2.5L) Near MSA Controller T/O N/S
BS06 Near Instrument Panel T/O 9
BS06 (2.5L) Near MSA Controller T/O N/S
BS08 Near Instrument Panel T/O 9
BS16 Near Right Park Lamp T/O 1
BS17 Near Split for Tail Lamps 12
BS19 Near Horn T/O 1
BS30 (2.5L) Near Generator T/O 5
BS31 Near Left Headlamp Leveling
Motor T/O1
BS31 (2.5L) In BCM T/O 5
BS32 (2.5L) In BCM T/O N/S
BS33 (2.5L) In BCM T/O N/S
BS34 (2.5L) In BCM T/O N/S
BS40 (2.5L) In Engine Harness T/O 5
BS41 (2.5L) In Engine Harness T/O N/S
CS01 Above Right Rear Door 11
CS02 Above Right Rear Door 11
CS03 Right B-Pillar 11
CS04 Right B-Pillar 11
DS01 Near LT Power WDO T/O 10
ES01 In TCM T/O 7
ES01 (2.5L) Near Battery Positive Terminal
T/ON/SSplice Number Location Fig.
ES02 (2.0L) Near Camshaft Position
Sensor T/O3
ES02 (2.4L) Near Fuel Rail T/O 4
ES02 (2.5L) Near Engine Speed Sensor
T/O5
ES02
(3.3L,3.8L)Near Transmission T/O 6
ES03 (2.0L) Near Distributor Coil T/O 2
ES03 (2.4L) Near PDC T/O 4
ES03
(3.3L,3.8L)Near Body Ground T/O 7
ES05 (2.4L) Near Knock Sensor T/O 4
ES05 (2.5L) In Fuel Injection Pump T/O 5
ES05
(3.3L,3.8L)Near Transmission T/O 6
ES06 (2.5L) Near Needle Movement
Sensor T/O5
ES06
(3.3L,3.8L)Near Transmission T/O N/S
ES07 (2.0L) Near Engine Ground T/O 2
ES07 (2.5L) Near Battery Negative
Terminal T/ON/S
ES07 (2.4L) Near Body Ground T/O 4, 7
ES07
(3.3L,3.8L)Near Battery Negative
Terminal T/O6
ES08
(3.3L,3.8L)Near Transmission T/O 6
ES09 (2.0L) In Battery Positive Terminal
T/O7
ES09 (2.4L) Near Battery Positive Terminal 4
NS/GS8W - 95 SPLICE LOCATIONS 8W - 95 - 1

Splice Number Location Fig.
ES09 (2.5L) In Battery Positive Terminal
T/ON/S
ES09
(3.3L,3.8L)In Battery Positive Terminal
T/O7
ES10 Near Knock Sensor T/O 6
ES10
(3.3L,3.8L)Near Transmission T/O 7
ES11 (2.0L) Near Battery Positive Terminal
T/O7
ES11 (2.4L) Near Battery Negative
Terminal T/O4
ES11 (2.5L) In Generator T/O N/S
ES11
(3.3L,3.8L)Near Battery Negative
Terminal7
ES12 (2.4L) Near Throttle Body T/O 4
ES12 (2.5L) Near Battery Negative
Terminal T/ON/S
ES12
(3.3L,3.8L)Near Battery Positive Terminal
T/O7
ES13 (2.4L) Near Generator T/O 4
ES13
(3.3L,3.8L)Near Battery Negative
Terminal T/O7
ES14 (2.4L) Near Generator T/O 4,7
ES14
(3.3L,3.8L)Near Battery Negative
Terminal T/O7
ES17 (2.0L) Near Camshaft Position
Sensor T/O3
ES17 (2.4L) Near Engine Ground T/O 4
ES17
(3.3L,3.8L)Near Battery Negative
Terminal T/O7
ES18 (2.0L) Near Camshaft Position
Sensor T/O3
ES18 (2.4L) Near Engine Ground T/O 4
ES18
(3.3L,3.8L)Near Engine Ground T/O 7Splice Number Location Fig.
ES21 (2.0L) Near Body Ground T/O N/S
ES21 (2.4L) Near Engine Ground T/O 4
ES21
(3.3L,3.8L)Near A/C Clutch T/O 6
ES23 (2.0L) Near Radiator Fan T/O N/S
ES23 (2.4L) Near Radiator Fan T/O 4
ES23
(3.3L,3.8L)Near Engine ground T/O 7
ES24 (2.4L) Near Transmission T/O 4
ES24
(3.3L,3.8L)Near Transmission T/O 7
ES26 (2.5L) In Battery Positive Terminal
T/ON/S
ES28 (2.5L) In Battery Positive Terminal
T/ON/S
ES29 (2.5L) Near Glow Plug Relay T/O N/S
ES30 (2.5L) Near Fuel Heater T/O 5
ES31 (2.5L) Near Fuel Heater T/O 5
ES37 (2.5L) Near Oil Pressure Switch T/O 5
ES40 (2.5L) Near Fuel Injection Pump T/O 5
ES99 (2.0L) Near Knock Sensor T/O 2
FS01 (2.4L) Near ECT Sensor T/O N/S
FS01
(3.3L,3.8L)Near Injector #5 T/O N/S
FS02 (2.4L) Near Inj #2 T/O N/S
FS02
(3.3L,3.8L)Between Inj's 4 and 6 N/S
FS03 (2.4L) Between Inj #2 and #3 N/S
PS01 Near Steering Column T/O 8
PS02 Near Steering Column T/O 8
RFS01 Near Radiator Fan #2 N/S
RFS02 Near Radiator Fan #1 N/S
8W - 95 - 2 8W - 95 SPLICE LOCATIONSNS/GS
DESCRIPTION AND OPERATION (Continued)

(5) Test resistance of spark plug cables. Refer to
Group 8D, Ignition System.
(6) Test ignition coils primary and secondary resis-
tance. Replace parts as necessary. Refer to Group 8D,
Ignition System.
(7) Check fuel pump pressure at idle and different
RPM ranges. Refer to Group 14, Fuel System for
Specifications.
(8) The air filter elements should be replaced as
specified in Group 0, Lubrication and Maintenance.
(9) Inspect crankcase ventilation system as out-
lined in Group 25, Emission Control Systems.
(10) Road test vehicle as a final test.
HONING CYLINDER BORES
(1) Used carefully, the cylinder bore resizing hone
C-823 equipped with 220 grit stones, is the best tool
for this job. In addition to deglazing, it will reduce
taper and out-of-round as well as removing light
scuffing, scoring or scratches. Usually a few strokes
will clean up a bore and maintain the required lim-
its.
(2) Deglazing of the cylinder walls may be done
using a cylinder surfacing hone, Tool C-3501,
equipped with 280 grit stones, if the cylinder bore is
straight and round. 20-60 strokes depending on the
bore condition, will be sufficient to provide a satisfac-
tory surface. Inspect cylinder walls after each 20
strokes, using a light honing oil.Do not use engine
or transmission oil, mineral spirits or kerosene.
(3) Honing should be done by moving the hone up
and down fast enough to get a cross-hatch pattern.
When hone marksintersectat 50-60 degrees, the
cross hatch angle is most satisfactory for proper seat-
ing of rings (Fig. 2).(4) A controlled hone motor speed between
200-300 RPM is necessary to obtain the proper cross-
hatch angle. The number of up and down strokes per
minute can be regulated to get the desired 50-60
degree angle. Faster up and down strokes increase
the cross-hatch angle.
(5) After honing, it is necessary that the block be
cleaned again to remove all traces of abrasive.
CAUTION: Ensure all abrasives are removed from
engine parts after honing. It is recommended that a
solution of soap and hot water be used with a
brush and the parts then thoroughly dried. The bore
can be considered clean when it can be wiped
clean with a white cloth and cloth remains clean.
Oil the bores after cleaning to prevent rusting.
MEASURING MAIN BEARING AND CONNECTING
ROD BEARING CLEARANCES
PLASTIGAGE METHOD
Engine crankshaft bearing clearances can be deter-
mined by use of Plastigage or equivalent. The follow-
ing is the recommended procedure for the use of
Plastigage:
NOTE: The total clearance of the main bearings
can only be determined by removing the weight of
the crankshaft. This can be accomplished by either
of two methods:
PREFERRED METHOD
Shimming the bearings adjacent to the bearing to
be checked in order to remove the clearance between
upper bearing shell and the crankshaft. This can be
accomplished by placing a minimum of 0.254 mm
(0.010 in.) shim (e. g. cardboard, matchbook cover,
etc.) between the bearing shell and the bearing cap
on the adjacent bearings and tightening bolts to
14-20 N´m (10-15 ft. lbs.). The number of main bear-
ing will vary from engine to engine.
Fig. 2 Cylinder Bore Cross-Hatch Pattern
Fig. 3 Plastigage Placed in Lower Shell
NSENGINE 9 - 3
GENERAL INFORMATION (Continued)

cause of low compression unless some malfunc-
tion is present.
(11) Clean or replace spark plugs as necessary
and adjust gap as specified in Group 8, Electrical.
Tighten to specifications.
(12) Test resistance of spark plug cables. Refer to
Group 8, Electrical Ignition System Secondary Cir-
cuit Inspection.
(13) Test coil output voltage, primary and second-
ary resistance. Replace parts as necessary. Refer to
Group 8, Electrical Ignition System.
(14) Check fuel pump pressure at idle and differ-
ent RPM ranges. Refer to Group 14, Fuel System for
Specifications.
(15) The air filter elements should be replaced as
specified in Group 0, Lubrication and Maintenance,.
(16) Inspect crankcase ventilation system as out
lined in Group 0, Lubrication and Maintenance. For
emission controls see Group 25, Emission Controls
for service procedures.
(17) Inspect and adjust accessory belt drives refer-
ring to Group 7, Cooling System, Accessory Drive
Belts for proper adjustments.
(18) Road test vehicle as a final test.
CYLINDER COMBUSTION PRESSURE LEAKAGE
TEST
The combustion pressure leakage test provides an
accurate means for determining engine condition.
Combustion pressure leakage testing will detect:
²Exhaust and intake valve leaks (improper seat-
ing).
²Leaks between adjacent cylinders or into water
jacket.
²Any causes for combustion/compression pressure
loss.
WARNING: DO NOT REMOVE THE RADIATOR CAP
WITH THE SYSTEM HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM COOLANT CAN
OCCUR.
Check the coolant level and fill as required. DO
NOT install the radiator cap.
Start and operate the engine until it attains nor-
mal operating temperature, then turn the engine
OFF.
Clean spark plug recesses with compressed air.
Remove the spark plugs.
Remove the oil filler cap.
Remove the air cleaner.
Calibrate the tester according to the manufactur-
er's instructions. The shop air source for testing
should maintain 483 kPa (70 psi) minimum, 1 379
kPa (200 psi) maximum and 552 kPa (80 psi) recom-
mended.Perform the test procedures on each cylinder
according to the tester manufacturer's instructions.
While testing, listen for pressurized air escaping
through the throttle body, tailpipe and oil filler cap
opening. Check for bubbles in the radiator coolant.
All gauge pressure indications should be equal,
with no more than 25% leakage.
FOR EXAMPLE:At 552 kPa (80 psi) input pres-
sure, a minimum of 414 kPa (60 psi) should be main-
tained in the cylinder.
LASH ADJUSTER (TAPPET) NOISE DIAGNOSIS
A tappet-like noise may be produced from several
items. Check the following items.
(1) Engine oil level too high or too low. This may
cause aerated oil to enter the adjusters and cause
them to be spongy.
(2) Insufficient running time after rebuilding cylin-
der head. Low speed running up to 1 hour may be
required.
(3) During this time, turn engine off and let set for
a few minutes before restarting. Repeat this several
times after engine has reached normal operating
temperature.
(4) Low oil pressure.
(5) The oil restrictor pressed into the vertical oil
passage to the cylinder head is plugged with debris.
(6) Air ingested into oil due to broken or cracked
oil pump pick up.
(7) Worn valve guides.
(8) Rocker arm ears contacting valve spring
retainer.
(9) Rocker arm loose, adjuster stuck or at maxi-
mum extension and still leaves lash in the system.
(10) Faulty lash adjuster.
a. Check lash adjusters for sponginess while
installed in cylinder head. Depress part of rocker
arm over adjuster. Normal adjusters should feel very
firm. Spongy adjusters can be bottomed out easily.
b. Remove suspected lash adjusters, and disassem-
bleDo not reuse retainer caps. Do not inter-
change parts and make sure that care and
cleanliness is exercised in the handling of parts.
c. Clean out dirt and varnish with solvent.
d. Reassemble with engine oil.
e. Check for sponginess.
f. If still spongy, replace with new adjuster.
INSPECTION (ENGINE OIL LEAKS IN GENERAL)
Begin with a through visual inspection of the
engine, particularly at the area of the suspected leak.
If an oil leak source is not readily identifiable, the
following steps should be followed:
(1) Do not clean or degrease the engine at this
time because some solvents may cause rubber to
swell, temporarily stopping the leak.
9 - 8 ENGINENS
DIAGNOSIS AND TESTING (Continued)

ENGINE DIAGNOSISÐPERFORMANCE
CONDITION POSSIBLE CAUSE CORRECTION
ENGINE WILL NOT START 1. Weak battery. 1. Test battery. Charge or replace
as necessary.Refer to Group 8A,
Battery.
2. Corroded or loose battery
connections.2. Clean and tighten battery
connections. Apply a coat of light
mineral grease to terminals.
3. Faulty starter. Test starting system. Refer to Group
8B, Starting.
4. Moisture on ignition wires. 4. Remove moisture from wires.
5. Faulty ignition cables. 5. Replace any cracked or shorted
cables.
6. Faulty coil or control unit. 6. Test and replace as needed.
Refer to Group 8D, Ignition System
7. Incorrect spark plug gap. 7. Set gap. Refer to Group 8D,
Ignition System.
8. Contamination in fuel system. 8. Clean system and replace fuel
filter.
9. Faulty fuel pump. 9. Test fuel pump and replace as
needed. Refer to Group 14, Fuel
System.
ENGINE STALLS OR IDLES
ROUGH1. Idle speed too low. 1. Test minimum air flow. Refer to
Group 14, Fuel System.
2. Incorrect fuel mixture. 2. Refer to Group 14, Fuel System.
3. Intake manifold leakage. 3. Inspect intake manifold, manifold
gasket, and vacuum hoses. Refer to
Group 11, Exhaust System and
Intake Manifold.
4. Incorrect ignition wiring. 4. Install correct wiring.
5. Faulty coil(s) 5. Test and replace as necessary.
Refer to Group 8D, Ignition System.
ENGINE LOSS OF POWER 1. Dirty or incorrectly gapped plugs. 1. Clean plugs and set gap. Refer to
Group 8D, Ignition System.
2. Contamination in fuel system. 2. Clean system and replace fuel
filter.
3. Faulty fuel pump. 3. Test and replace as necessary.
Refer to Group 14, Fuel System.
4. Incorrect valve timing. 4. Correct valve timing.
5. Leaking cylinder head gasket. 5. Replace cylinder head gasket.
6. Low compression. 6. Test compression of each
cylinder.
7. Burned, warped, or pitted valves. 7. Replace valves.
8. Plugged or restricted exhaust
system.8. Install new parts, as necessary.
9. Faulty ignition cables. 9. Replace any cracked or shorted
cables.
10. Faulty coil(s). 10. Test and replace as necessary.
Refer to Group 8D, Ignition System.
9 - 10 ENGINENS
DIAGNOSIS AND TESTING (Continued)

ENGINE ASSEMBLY
REMOVAL
(1) Perform fuel pressure release procedure. Refer
to Group 14, Fuel System for procedure. Remove fuel
line to fuel rail.
(2) Disconnect battery.
(3) Remove Air cleaner and hoses.
(4) Drain cooling system. Refer to Group 7, Cooling
System for procedure.
(5) Remove upper radiator hose and remove radia-
tor fans. Refer to Group 7, Cooling System for proce-
dure.
(6) Remove lower radiator hose.
(7) Disconnect automatic transmission cooler lines
and plug, if equipped.
(8) Disconnect transmission shift linkage.
(9) Disconnect throttle body linkage.
(10) Disconnect engine wiring harness.
(11) Disconnect heater hoses.
(12) Discharge Air Conditioning System. Refer to
Group 24, Air Conditioning for procedure.
(13) Hoist vehicle and remove right inner splash
shield. Remove wheels and tires.
(14) Loosen power steering belt for pump removal.
Refer to Group 7, Cooling System for procedure.
(15) Remove axle shafts. Refer to Group 2, Suspen-
sion and Driveshafts for procedure.
(16) Disconnect exhaust pipe from manifold.
(17) Remove front and rear engine mount brackets
from the body.
(18) Remove bending braces and front engine
mount bracket. Remove transmission inspection
cover.
(19) Mark flexplate to torque converter and
remove torque converter bolts.
(20) Install front engine mount bracket.
(21) Lower vehicle.
(22) Remove power steering pump. Set pump
aside.
(23) Remove A/C lines at compressor and cap.
(24) Remove ground straps to body.
(25) Raise vehicle enough to allow engine dolly
Special Tool 6135, cradle Special Tool 6710 with
Posts Special Tool 6848 and Adaptor Special Tool
8130 to be installed under vehicle (Fig. 27).
(26) Loosen cradle posts to allow movement for
proper positioning. Locate two rear posts (right side
of engine) into the holes on the engine bedplate.
Locate the two front posts (left side of engine) on the
front engine bracket and A/C compressor bracket
(Fig. 27). Lower vehicle and position cradle mounts
until the engine is resting on mounts. Tighten
mounts to cradle frame. This will keep mounts from
moving when removing or installing engine and
transmission.(27) Lower vehicle so the weight ofONLY THE
ENGINE AND TRANSMISSIONare on the cradle.
(28) Remove engine and transmission mount bolts.
(29) Raise vehicle slowly. It may be necessary to
move the engine/transmission assembly on the cradle
to allow for removal around the body.
INSTALLATION
(1) Position engine and transmission assembly
under vehicle and slowly lower the vehicle over the
engine and transmission.
(2) Align engine and transmission mounts to
attaching points. Install mounting bolts at the right
engine and left transmission mounts. Refer to proce-
dures outlined in this section.
(3) Slowly raise vehicle enough to remove the
engine dolly and cradle Special Tools 6135 and 6710.
(4) Install axle shafts. Refer to Group 2, Suspen-
sion and Driveshafts for procedure.
(5) Install transmission and engine braces and
splash shields.
(6) Connect exhaust system to manifold. Refer to
Group 11, Exhaust System and Intake Manifold for
procedure and torque specifications.
(7) Install power steering pump. Refer to Cooling
System Group 7, Accessory Drive Section for belt ten-
sion adjustment.
(8) Install A/C compressor hoses. Refer to Group
24, Heater and Air Conditioning for procedure.
(9) Install accessory drive belts. Refer to Group 7,
Cooling System Accessory Drive Section for belt ten-
sion adjustment.
(10) Install front and rear engine mounts. Refer to
this section for procedure.
(11) Install inner splash shield. Install wheels and
tires.
(12) Connect automatic transmission cooler lines,
and shift linkage. Refer to Group 21, Transmission
for procedures.
(13) Connect fuel line and heater hoses.
(14) Install ground straps. Connect engine and
throttle body connections and harnesses. Refer to
Group 8, Electrical for procedure.
(15) Connect throttle body linkage. Refer to Group
14, Fuel System for procedure.
(16) Install radiator fans. Install radiator hoses.
Fill cooling system. Refer to Group 7, Cooling System
for filling procedure.
(17) Connect battery.
(18) Install air cleaner and hoses.
(19) Install oil filter. Fill engine crankcase with
proper oil to correct level.
(20) Start engine and run until operating temper-
ature is reached.
(21) Adjust transmission linkage, if necessary.
9 - 26 2.4L ENGINENS
REMOVAL AND INSTALLATION (Continued)

CYLINDER HEAD
REMOVAL
(1) Perform fuel system pressure release proce-
durebefore attempting any repairs.Refer to
Group 14, Fuel System for procedure.
(2) Disconnect negative battery cable. Drain cool-
ing system. Refer to Group 7, Cooling System for pro-
cedure.
(3) Remove air cleaner and disconnect all vacuum
lines, electrical wiring and fuel lines from throttle
body.
(4) Remove throttle linkage. Refer to Group 14,
Fuel System for procedures
(5) Remove accessory drive belts. Refer to Group
7, Cooling System for procedure.
(6) Remove power brake vacuum hose from intake
manifold.
(7) Raise vehicle and remove exhaust pipe from
manifold.(8) Remove power steering pump assembly and
set aside.
(9) Disconnect coil pack wiring connector and
remove coil pack and plug wires from engine.
(10) Remove cam sensor and fuel injectors wiring
connectors.
(11) Remove timing belt and camshaft sprocket.
Refer to procedure outlined in this section.
(12) Remove timing belt idler pulley and rear tim-
ing belt cover.
(13) Remove cylinder head cover using procedure
outlined in this section.
(14) Remove camshafts and cam followers. Refer to
procedures outlined in this section for procedures.
(15) Remove cylinder head bolts and remove cyl-
inder head from engine block.
(16) Inspect and clean cylinder head. Refer to
Cleaning and Inspection outlined in this section for
procedures.
INSTALLATION
NOTE: The Cylinder head bolts should be exam-
ined BEFORE reuse. If the threads are necked
down, the bolts should be replaced (Fig. 49).
Necking can be checked by holding a scale or
straight edge against the threads. If all the threads
do not contact the scale the bolt should be replaced.
(1) Before installing the bolts, the threads should
be coated with engine oil.
(2) Tighten the cylinder head bolts in the
sequence shown in (Fig. 50). Using the 4 step torque
turn method, tighten according to the following val-
ues:
²First All to 34 N´m (25 ft. lbs.)
²Second All to 68 N´m (50 ft. lbs.)
²Third All to 68 N´m (50 ft. lbs.)
CAUTION: Do not use a torque wrench for the fol-
lowing step.
²Fourth Turn an additional 1/4 Turn,
(3) Install camshafts and cam followers. Refer to
procedures outlined in this section for procedures.
Fig. 47 Valve SpringÐRemoval/Installation
Fig. 48 Valve Stem Seal/Valve Spring Seat
Fig. 49 Checking Bolts for Stretching (Necking)
9 - 34 2.4L ENGINENS
REMOVAL AND INSTALLATION (Continued)

(4) Install cylinder head cover using procedure out-
lined in this section.
(5) Install rear timing belt cover and timing belt
idler pulley.
(6) Install timing belt and camshaft sprocket.
Refer to procedure outlined in this section.
(7) Install cam sensor and fuel injectors wiring
connectors.
(8) Install coil pack and plug wires onto the
engine. Connect coil pack wiring connector.
(9) Install power steering pump assembly.
(10) Raise vehicle and install the exhaust pipe to
the manifold.
(11) Install power brake vacuum hose to the intake
manifold.
(12) Install accessory drive belts. Refer to Group 7,
Cooling System for procedure.
(13) Install throttle linkage. Refer to Group 14,
Fuel System for procedures.
(14) Install air cleaner and connect all vacuum
lines, electrical wiring and fuel lines to the throttle
body.
(15) Fill cooling system. Refer to Group 7, Cooling
System for procedure. Connect negative battery
cable.
VALVES AND VALVE SPRINGS
REMOVAL
(1) With cylinder head removed, compress valve
springs using a universal valve spring compressor.
(2) Remove valve retaining locks, valve spring
retainers, valve stem seals and valve springs.(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.
(4) Inspect and clean the valves. Refer to Cleaning
and Inspection outlined in this section for procedure.
INSTALLATION
(1) Coat valve stems with clean engine oil and
insert in cylinder head.
(2) Install new valve stem seals on all valves
using a valve stem seal tool (Fig. 51). The valve stem
seals should be pushed firmly and squarely over
valve guide.
CAUTION: When oversize valves are used, the cor-
responding oversize valve seal must also be used.
Excessive guide wear may result if oversize seals
are not used with oversize valves.
(3) Install valve springs and retainers. Compress
valve springs only enough to install locks, taking
care not to misalign the direction of compression.
Nicked valve stems may result from misalignment of
the valve spring compressor.
CAUTION: When depressing the valve spring
retainers with valve spring compressor the locks
can become dislocated. Ensure both locks are in
the correct location after removing tool.
(4) Check the valve spring installed height B after
refacing the valve and seat (Fig. 52). Make sure mea-
surements are taken from top of spring seat to the
bottom surface of spring retainer. If height is greater
than 38.75 mm (1.525 in.), install a .762 mm (0.030
in.) spacer under the valve spring seat to bring
spring height back within specification.
Fig. 50 Cylinder Head Tightening Sequence
Fig. 51 Valve Stem Oil Seal Tool
NS2.4L ENGINE 9 - 35
REMOVAL AND INSTALLATION (Continued)