1996 CHRYSLER VOYAGER engine

CAUTION: The vacuum pump must be centered in
the block and tighten with two bolts. Ensure that
the pump spins freely. If vacuum pump drags ordoes not spin freely loosen bolts and perform pro-
cedures again.
(28) Before installing oil pump check pump bore
depth in block (A) and pump body height (B) (Fig.
47). Difference between A and B should be
0.020-0.082 mm (.0007 to 0032 in.).
(29) Install oil pump and tighten retaining screws
to 27 N´m (20 ft. lbs.). Check for normal backlash
between pump and crankshaft gears.
(30) Install oil pump drive Gear.
(31) Install front cover. Refer to procedure in this
section.
(32) Install vibration damper. Refer to procedure
in this section.
(33) Install cylinder heads. Refer to procedure in
this section.
(34) Install rocker arms and push rods. Refer to
procedure in this section.
(35) Install cylinder head cover. Refer to procedure
in this section.
(36) Install accessary drive system.
(37) Install engine in vehicle. Refer to procedure in
this section.
(38) Fill engine with the correct amount of fluids
specified.
(39) Connect battery cable.OIL PAN
REMOVAL
(1) Disconnect battery cable.
(2) Raise vehicle on hoist.
Fig. 45 Main Bearing Carrier Alignment
Fig. 46 Measuring Crankshaft End Play
Fig. 47 Oil Pump Bore Depth
9 - 66 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)

OIL FILTER ADAPTER AND OIL COOLER
REMOVAL
(1) Remove oil filter.
(2) Remove oil cooler adapter bolt.
(3) Remove oil cooler (Fig. 51).
INSTALLATION
(1) Install oil cooler with new gasket, tighten oil
cooler adapter bolt to 60 N´m (44 ft. lbs.).(2) Install oil filter adapter to oil cooler and
tighten to 49 N´m (36. lbs.).
(3) Install oil filter and tighten to 9.8 N´m (85 in.
lbs.) and add oil.
VACUUM PUMP
REMOVAL
(1) Remove the front cover refer to front cover
removal in this section.
(2) Remove 4 bolts.
(3) Remove vacuum pump.
INSTALLATION
(1) To install the vacuum pump, align the outer
part of the gear with the inner part using a screw-
driver or similar tool, align with timing marks on
gear set and install.
(2) Install bolts and tighten to 20 N´m (15 ft. lbs.).
(3) Install front cover.
PISTONS AND CONNECTING ROD
REMOVAL
(1) Disconnect the battery cable.
(2) Remove cylinder heads, refer to cylinder head
removal in this section.
(3) Raise vehicle on host.
(4) Remove oil pan, refer to oil pan removal in this
section.
(5) Remove top carbon ridge of cylinder bores with
a reliable ridge reamer before removing pistons from
cylinder block.Be sure to keep tops of pistons
Fig. 50 Oil Pressure Relief Valve
Fig. 51 Oil Cooler
Fig. 52 Vacuum Pump
9 - 68 ENGINENS/GS
REMOVAL AND INSTALLATION (Continued)

covered during this operation. Mark piston with
matching cylinder number.
(6) Pistons and connecting rods must be removed
from top of cylinder block. Rotate crankshaft so that
each connecting rod is centered in cylinder bore.
(7) Remove connecting rod cap. Push each piston
and rod assembly out of cylinder bore.
CAUTION: During piston and rod removal. DO NOT
rotate piston and connecting rod or damage to theoil jets extending out into the cylinder bore will
occur (Fig. 56).
NOTE: Be careful not to nick crankshaft journals.
(8) After removal, install bearing cap on the mat-
ing rod.
PISTON PINÐREMOVAL
(1) Secure connecting rod in a soft jawed vice.
(2) Remove 2 clips securing piston pin (Fig. 57).
(3) Push piston pin out of piston and connecting
rod.
Fig. 53 Vacuum Pump Parts
Fig. 54 Vacuum Pump Mounting Hole
Fig. 55 Timing Marks
Fig. 56 Oil Jets
NS/GSENGINE 9 - 69
REMOVAL AND INSTALLATION (Continued)

PISTON RINGÐREMOVAL
(1) Identification (ID) mark on face of upper and
intermediate piston rings must point toward piston
crown.
(2) Using a suitable ring expander, remove upper
and intermediate piston rings (Fig. 58).
(3) Remove the upper oil ring side rail, lower oil
ring side rail and then oil ring expander from piston.
(4) Carefully clean carbon from piston crowns,
skirts and ring grooves ensuring the 4 oil holes in
the oil control ring groove are clear.
FITTING PISTON RINGS
(1) Wipe cylinder bore clean. Insert ring and push
down with piston to ensure it is square in bore. The
ring 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. 59).
Top compression ring gap .25 to .50 mm (.0098 to
.0196 in.). Second compression ring gap .25 to .35
mm (.0098 to .0137 in.). Oil control ring gap .25 to
.58 mm (.0098 to .0228 in.).
(2) If ring gaps exceed dimension given, new rings
or cylinder liners must be fitted. Keep piston rings in
piston sets.
(3) Check piston ring to groove clearance (Fig. 60).
Top compression ring gap .08 to .130 mm (.0031 to.0051 in.). Second compression ring gap .070 to .102
mm (.0027 to .0040 in.). Oil control ring gap .040 to
.072 mm (.0015 to .0028 in.).
PISTON RINGSÐINSTALLATION
(1) Install rings on the pistons using a suitable
ring expander (Fig. 58).
(2) Top compression ring is tapered and chromium
plated. The second ring is of the scraper type and
must be installed with scraping edge facing bottom of
the piston. The third is an oil control ring (Fig. 61).
Ring gaps must be positioned, before inserting piston
into the liners, as follows (Fig. 62).
(3) Top ring gap must be positioned at 30 degrees
to the right of the combustion chamber recess (look-
ing at the piston crown from above).
(4) Second piston ring gap should be positioned on
the opposite side of the combustion chamber recess.
(5) Oil control ring gap to be located 30 degrees to
the left of combustion chamber recess.
(6) When assembling pistons check that compo-
nents are installed in the same position as before dis-
Fig. 57 Piston Assembly
Fig. 58 Piston RingsÐRemoving and Installing
Fig. 59 Ring Gap Measurement
9 - 70 ENGINENS/GS
REMOVAL AND INSTALLATION (Continued)

assembly, determined by the numbers stamped on
the crown of individual pistons. Engine cylinders are
numbered starting from gear train end of the engine.
Face chamber recess side of piston towards
camshaft. Therefore, the numbers stamped on con
rod big end should also face in the same direction. To
insert piston into cylinder, use a ring compressor as
shown in (Fig. 63).
PISTON PINÐINSTALLATION
(1) Secure connecting rod in soft jawed vice.
(2) Lubricate piston pin and piston with clean oil.
(3) Position piston on connecting rod.CAUTION: Ensure combustion recess in piston
crown and the bearing cap numbers on the con-
necting rod are on the same side.
(4) Install piston pin.
(5) Install clips in piston to retain piston pin.
(6) Remove connecting rod from vice.
PISTONÐINSTALLATION
(1) Before installing pistons, and connecting rod
assemblies into the bore, be sure that compression
ring gaps are staggered so that neither is in line with
oil ring rail gap (Fig. 62).
(2) Before installing the ring compressor, make
sure the oil ring expander ends are butted and the
rail gaps located as shown in (Fig. 62).
(3) Immerse the piston head and rings in clean
engine oil, slide the ring compressor, over the piston
and tighten with the special wrench (Fig. 63).
Ensure position of rings does not change dur-
ing this operation.
Fig. 60 Piston Ring Side Clearance
Fig. 61 Piston Ring Identification
Fig. 62 Piston Ring Gap Location
Fig. 63 Installing Piston
NS/GSENGINE 9 - 71
REMOVAL AND INSTALLATION (Continued)

(4) Face chamber recess side of piston towards
camshaft.
(5) Install connecting rod bolt protectors on rod
bolts.
(6) Rotate crankshaft so that the connecting rod
journal is on the center of the cylinder bore. Insert
rod and piston into cylinder bore and guide rod over
the crankshaft journal.
CAUTION: During piston and rod installation. DO
NOT rotate piston and connecting rod or damage to
the oil jets extending out into the cylinder bore will
occur (Fig. 56).
(7) Tap the piston down in cylinder bore, using a
hammer handle. At the same time, guide connecting
rod into position on connecting rod journal.
(8) Install rod caps. Install nuts on cleaned and
oiled rod bolts and tighten nuts to 29.5 N´m (22 ft.
lb.) plus 60É.
CYLINDER LINER
REMOVAL
(1) Remove cylinder heads (refer to cylinder head
removal in this section).
(2) Remove Oil pan (refer to oil pan removal in
this section).
(3) Remove pistons (refer to piston removal in this
section).
(4) Use tool VM-1001 to remove liners (Fig. 64).
(5) Remove shims from cylinder liner or cylinder
block recess. Keep shims with each cylinder liner.
INSTALLATION
(1) Carefully clean residualsealerfrom liner and
crankcase, and degrease the crankcase where it
comes into contact with the liners. Referring to (Fig.
65), install the liners in the crankcase as shown (A),
rotating them back and forth by 45É in order to guar-
antee correct positioning.
(2) Measure the liner recess relative to block deck
with a dial indicator mounted on a special tool
VM-1010 A.All the measurements must be taken
on camshaft side. Zero dial gauge on block deck.
(3) Move dial gauge to cylinder liner record read-
ing on dial gauge.
(4) Remove liner and special tool.
(5) Then select the correct shim thickness to give
proper protrusion (0.01 - 0.06 mm).
(6) Fit the shim and the O-rings onto the liner.
(7) Lubricate the lower liner location in the block.
Apply LOCTITE 275 to the corner of the liner seat.
Apply LOCTITE 275 uniformly to the upper part of
the liner at area.
(8) Fit the liners in the crankcase making sure
that the shim is positioned correctly in the seat. Lockthe liners in position using special tool (VM-1016)
and bolts (Fig. 66). Clean the residual LOCTITE on
the upper surface of the block deck.
(9) Recheck the liner protrusion. It should be 0.01
- 0.06 mm.
NOTE: A period of six hours must elapse between
the liners being installed and engine start-up. If
engine assembly is not continued after liner instal-
lation, the liners need to be clamped for twelve
hours minimum.
(10) Refer to Cylinder Head Removal and Installa-
tion procedure in this section. To measure piston pro-
trusion for installation of proper head gasket
thickness.
CRANKSHAFTÐREMOVAL
Refer to CRANKSHAFT MAIN BEARING
REMOVAL in this section.
REAR CRANKSHAFT OIL SEAL
REMOVAL
(1) Remove transmission. Refer to Group 21,
Transmission for removal procedure.
(2) Remove flywheel.
Fig. 64 Cylinder LinerÐRemoval
9 - 72 ENGINENS/GS
REMOVAL AND INSTALLATION (Continued)

NOTE: Inspect O-ring in flywheel (Fig. 67).
(3) Remove rear crankshaft oil seal from retainer
(Fig. 68).
CAUTION: When removing seal from retainer take
care not to damage retainer.
INSTALLATION
(1) Install crankshaft oil seal.
CAUTION: Use NEW flywheel bolt for the following
procedure.
(2) Install new O-ring on flywheel. Install fly-
wheel. The 6 flywheel bolts must be tightened as fol-
lows:
a. Torque the 6 flywheel bolts to 60 N´m (44 ft.
lbs.).b. Loosen 2 of the 6 bolts, 180É apart. Torque the 2
bolts to 20 N´m (180 in. lbs.). Then using a torque
angle gauge rotate the 2 bolts 65É additional.
c. Loosen the next 2 bolts, 180É apart and follow
the same procedure.
d. Loosen the last 2 bolts, 180É apart and follow
the same procedure.
(3) Install Transmission. Refer to procedure in
Group 21, Transmission.
DISASSEMBLY AND ASSEMBLY
HYDRAULIC TAPPETS
DISASSEMBLE AND ASSEMBLE
(1) Pry out plunger retainer spring clip.
(2) Clean varnish deposits from inside of tappet
body above plunger cap.
(3) Invert tappet body and remove plunger cap,
plunger, check valve, check valve spring, check valve
Fig. 65 Cylinder LinerÐInstallation
NS/GSENGINE 9 - 73
REMOVAL AND INSTALLATION (Continued)