1996 CHRYSLER VOYAGER lock

(4) Wash all parts in a suitable solvent and
inspect carefully for damage or wear.
ASSEMBLY
(1) Assemble pump, using new parts as required.
Install the inner rotor with chamfer facing the
cast iron oil pump cover.
(2) Prime oil pump before installation by filling
rotor cavity with engine oil.
(3) Install cover and tighten screws to 12 N´m
(105 in. lbs.).
CAUTION: Oil pump pressure relief valve must be
installed as shown in (Fig. 95) or serious damage
may occur.
(4) Install relief valve, spring, gasket and cap as
shown in (Fig. 95). Tighten cap to 41 N´m (30 ft. lbs.)
CLEANING AND INSPECTION
CYLINDER HEAD
CLEANING
Remove all gasket material from cylinder head and
block. Be careful not to gouge or scratch the alumi-
num head sealing surface.
INSPECTION
(1) Cylinder head must be flat within 0.1 mm
(0.004 inch) (Fig. 96).
(2) Inspect camshaft bearing journals for scoring.
VALVE GUIDES
(1) Remove carbon and varnish deposits from
inside of valve guides with a reliable guide cleaner.
(2) Using a small hole gauge and a micrometer,
measure valve guides in 3 places top, middle and bot-
tom (Fig. 97). Refer to Valve Guide SpecificationChart. Replace guides if they are not within specifi-
cation.
(3) Check valve guide height (Fig. 98).
VALVE AND VALVE SPRING
VALVES
(1) Clean valves thoroughly and discard burned,
warped and cracked valves.
(2) Measure valve stems for wear. Measure stem
about 60 mm beneath the valve lock grooves.
Fig. 96 Checking Cylinder Head Flatness
Fig. 97 Checking Wear on Valve GuideÐTypical
VALVE GUIDE SPECIFICATION CHART
Valve Guide Diameter
Intake and
Exhaust Valve:5.975 - 6.000 mm
(0.2352 - 0.2362 in.)
Valve Guide Clearance
New Service
Limit
Intake Valve: 0.048 - 0.066 mm
(0.0018 - 0.0025 in.)
0.25 mm
(0.010 in.)
Exhaust Valve: 0.0736 - 0.094 mm
(0.0029 - 0.0037 in.)
Fig. 98 Valve Guide Height
NS2.4L ENGINE 9 - 51
DISASSEMBLY AND ASSEMBLY (Continued)

CYLINDER BLOCK
(1) Clean cylinder block thoroughly and check all
core hole plugs for evidence of leaking.
(2) If new core plugs are installed, refer to Engine
Core Plugs outlined in this section.
(3) Examine block and cylinder bores for cracks or
fractures.
CYLINDER BORE INSPECTION
The cylinder walls should be checked for out-of-
round and taper with Tool C119 (Fig. 107). The cyl-
inder bore out-of-round is 0.050 mm (0.002 in.)
maximum and cylinder bore taper is 0.051 mm (0.002
in.) maximum. If the cylinder walls are badly scuffed
or scored, the cylinder block should be replaced, and
new pistons and rings fitted.
Measure the cylinder bore at three levels in direc-
tions A and B (Fig. 107). Top measurement should be
10 mm (3/8 in.) down and bottom measurement
should be 10 mm (3/8 in.) up from bottom of bore.
Refer to Cylinder Bore and Piston Specification
Chart.
ADJUSTMENTS
ENGINE MOUNTS
ENGINE MOUNT INSULATOR ADJUSTMENT
(1) Remove the load on the engine motor mounts
by carefully supporting the engine and transmission
assembly with a floor jack.
(2) Loosen the right engine mount insulator verti-
cal fastener and the fore and aft fasteners, and the
front engine mount bracket to front crossmember
screws.
(3) Pry the engine right or left as required to
achieve the proper drive shaft assembly length. Refer
to Group 2, Suspension and Driveshafts for drive-
shaft identification and related assembly length mea-
suring.
(4) Tighten engine mounts and fasteners in the
following order:
(a) Right engine mount insulator vertical bolts
to 102 N´m (75 ft. lbs.) and the fore and aft bolts to
150 N´m (110 ft. lbs.).
(b) Front engine mount screws to 54 N´m (40 ft.
lbs.) the clearance between the snubbers and the
engine should be 2 mm (0.078 inch.) each side.
(c) Left engine mount through bolt to 75 N´m (55
ft. lbs.).
(5) Recheck driveshaft length.
Fig. 107 Checking Cylinder Bore Size
CYLINDER BORE AND PISTON
SPECIFICATION CHART
Standard Bore Maximum Out-
Of-RoundMaximum-
Taper
87.5 mm 0.051 mm 0.051 mm
(3.445 in.) (0.002 in.) (0.002 in.)
Standard Piston Size
87.450 - 87.468 mm (3.4434 - 3.4441 in.)
Piston To Bore Clearance
0.024 - 0.057 mm (0.0009 - 0.0022 in.)
Measurements taken at Piston Size Location.
9 - 54 2.4L ENGINENS
CLEANING AND INSPECTION (Continued)

SPECIFICATIONS
2.4L ENGINE
Type....................In-Line OHV, DOHC
Number of Cylinder.......................4
Bore.....................87.5 mm (3.445 in.)
Stroke....................101 mm (3.976 in.)
Compression Ratio......................9.4:1
Displacement.......2.4 Liters (148 Cubic Inches)
Firing Order.......................1,3,4,2
Compression Pressure...........1172-1551 kPa
(170-225 psi)
Maximum Variation Between Cylinder......25%
Lubrication. . . .Pressure Feed-Full Flow Filtration
(Direct Crankshaft Driven Pump)
Cylinder Block
Cylinder Bore Diameter. . . .87.4924 - 87.5076 mm
(3.4446 - 3.4452 in.)
Out-of-Round (Max.)........0.051 mm (0.002 in.)
Taper (Max.)..............0.051 mm (0.002 in.)
Pistons
Clearance at 14 mm (9/16 in.)
From Bottom of Skirt.........0.024 - 0.057 mm
(0.0009 - 0.0022 in.)
Weight......................332 - 346 grams
(11.85 - 12.20 oz.)
Top Land Clearance
(Diametrical)................0.614 - 0.664 mm
(0.024 - 0.026 in.)
Piston Length.............60.30 mm (2.374 in.)
Piston Ring Groove Depth
No.1........4.640 - 4.784 mm (0.182 - 0.188 in.)
No.2........4.575 - 4.719 mm (0.180 - 0.185 in.)
No.3........4.097 - 4.236 mm (0.161 - 0.166 in.)
Piston Pins
Clearance in Piston...........0.005 - 0.018 mm
In Rod (Interference)..........0.018 - 0.043 mm
(0.0007 - 0.0017 in.)
Diameter.................21.998 - 22.003 mm
(0.8660 - 0.8662 in.)
End Play.............................None
Length.....................72.75 - 73.25 mm
(2.864 - 2.883 in.)
Piston Ring Gap
Top Compression Ring...........0.25 - 0.51 mm
(0.0098 - 0.020 in.)
2nd Compression Ring...........0.23 - 0.48 mm
(0.009 - 0.018 in.)
Oil Control (Steel Rails).........0.25 - 0.64 mm
(0.0098 - 0.025 in.)
Piston Ring Side Clearance
Top and Second
Compression Rings...........0.030 - 0.080 mm
(0.0011 - 0.0031 in.)Oil Ring (Pack)..............0.012 - 0.178 mm
(0.0004 - 0.0070 in.)
Piston Ring Width
Compression Rings.............1.47 - 1.50 mm
(0.057 - 0.059 in.)
Oil Ring (Pack)................2.72 - 2.88 mm
(0.107 - 0.1133 in.)
Connecting Rod
Bearing Clearance............0.025 - 0.071 mm
(0.0009 - 0.0027 in.)
Piston Pin Bore Diameter......20.96 - 20.98 mm
(0.8252 - 0.8260 in.)
Large End Bore Diameter. . . .53.007 - 52.993 mm
(2.0868 - 2.0863)
Side Clearance..............0.013 - 0.0150 mm
(0.0051 - 0.0150 in.)
Total Weight (Less Bearing).........565.8 grams
(19.96 oz.)
Crankshaft
Connecting Rod
Journal Diameter..........49.984 - 50.000 mm
(1.967 - 1.9685 in.)
Out-of-Round (Max.)......0.0035 mm (0.0001 in.)
Taper (Max.)............0.0038 mm (0.0001 in.)
Main Bearing Diametrical
Clearance No.1-5...........0.018 - 0.058 mm
(0.0007 - 0.0023 in.)
End Play.....................0.09 - 0.24 mm
(0.0035 - 0.0094 in.)
Main Bearing Journals
Diameter.................59.992 - 60.008 mm
(2.361 - 2.3625 in.)
Out-of-Round (Max.)......0.0035 mm (0.0001 in.)
Taper (Max.)...............0.0038 (0.0001 in.)
Hydraulic Lash Adjusters
Body Diameter.............15.901 - 15.913 mm
(0.626 - 0.6264 in.)
Plunger Travel Minimum (Dry)..........3.0 mm
(0.118 in.)
Camshaft
Bearing Bore
Diameters No. 1±6..........26.020 - 26.041 mm
(1.024 - 1.025 in.)
Diametrical Bearing Clearance . .0.069 - 0.071 mm
(0.0027 - 0.003 in.)
End Play...................0.050 - 0.170 mm
(0.0019 - 0.0066 in.)
Bearing Journal
Diameter No. 1±6..........25.951 - 25.970 mm
(1.021 - 1.022 in.)
Lift (Zero Lash) Intake.......8.25 mm (0.324 in.)
Lift (Zero Lash) Exhaust.....6.52 mm (0.256 in.)
Valve Timing ± Intake Valve
Closes (ABDC)..........................51É
Opens (BTDC)...........................1É
NS2.4L ENGINE 9 - 55

TORQUE CHART 2.4L
DESCRIPTION TORQUE
Balance Shaft Carrier to Block
Bolts.....................54N´m(40ft.lbs.)
Balance Shaft Gear Cover
Double Ended Fastener......12N´m(105 in. lbs.)
Balance Shaft Sprockets
Bolts....................28N´m(250 in. lbs.)
Balance Shaft Chain Tensioner
Bolts....................12N´m(105 in. lbs.)
Balance Shaft Carrier Cover
Fasteners................12N´m(105 in. lbs.)
Camshaft Sensor Pick Up
Bolts.....................27N´m(20ft.lbs.)
Timing Belt Cover
Outer to Inner Attaching Bolts M6.......4.5 N´m
(40 in. lbs.)
Inner Cover to Head/Oil Pump Bolts M6 . . .12 N´m
(105 in. lbs.)
Camshaft Sprocket
Bolt.....................101 N´m (75 ft. lbs.)
Connecting Rod Cap
Bolts..............................27N´m
(20 ft. lbs.) Plus 1/4 Turn
Crankshaft Main Bearing Cap/Bedplate
M8 Bedplate Bolts.........34N´m(250 in. lbs.)
Main Cap Bolts M11..................41N´m
(30 ft. lbs.) Plus 1/4 Turn
Crankshaft Damper
Bolt....................135 N´m (100 ft. lbs.)
Cylinder Head
Bolts........Refer To Cylinder Head Installation
Cylinder Head Cover
Bolts....................12N´m(105 in. lbs.)DESCRIPTION TORQUE
Engine Mount Bracket
Bolts.....................61N´m(45ft.lbs.)
Engine MountÐFront and Rear
Through Bolt...............61N´m(45ft.lbs.)
Exhaust Manifold to Cylinder Head
Bolts....................23N´m(200 in. lbs.)
Exhaust Manifold Heat Shield
Bolts....................12N´m(105 in. lbs.)
Front Torque BracketÐ2.0/2.4L Engine
Bolts.....................33N´m(24ft.lbs.)
Front Torque Bracket StrutÐ2.0/2.4L Engine
Long Bolts................110N´m(80ft.lbs.)
Short Bolt.................61N´m(45ft.lbs.)
Intake Manifold
Bolts.....................27N´m(20ft.lbs.)
Oil Filter
Filter.....................20N´m(15ft.lbs.)
Oil Pan
Oil Pan Bolts.............12N´m(105 in. lbs.)
Drain Plug.................27N´m(20ft.lbs.)
Oil Pump Attaching
Bolts....................28N´m(250 in. lbs.)
Oil Pump Cover Fastener. . . .12 N´m (105 in. lbs.)
Oil Pump Pick-up Tube Bolt . .28 N´m (250 in. lbs.)
Oil Pump Relief Valve Cap. . . .41 N´m (30 ft. lbs.)
Rear Torque Bracket
Bolts....................110N´m(80ft.lbs.)
Spark Plugs
Plugs.....................28N´m(20ft.lbs.)
Thermostat Housing
Bolts....................23N´m(200 in lbs.)
Timing Belt Tensioner Assembly
Bolts.....................61N´m(45ft.lbs.)
Water Pump Mounting
Bolts....................12N´m(105 in. lbs.)
NS2.4L ENGINE 9 - 57
SPECIFICATIONS (Continued)

3.0L ENGINE
INDEX
page page
DESCRIPTION AND OPERATION
ENGINE COMPONENTS.................. 61
ENGINE IDENTIFICATION NUMBER......... 61
ENGINE LUBRICATION................... 61
DIAGNOSIS AND TESTING
CHECKING ENGINE OIL PRESSURE......... 62
SERVICE PROCEDURES
AUTO LASH ADJUSTER................... 62
CHECKING CRANKSHAFT END PLAY........ 65
FITTING CONNECTING ROD BEARINGS...... 63
FITTING MAIN BEARING.................. 63
VALVE SERVICE RECONDITION............ 66
REMOVAL AND INSTALLATION
CAMSHAFT SEAL....................... 72
CAMSHAFT............................ 71
CRANKSHAFT.......................... 81
CYLINDER HEAD COVER................. 70
CYLINDER HEAD........................ 73
ENGINE ASSEMBLY...................... 69
ENGINE MOUNTS....................... 68
FRONT CRANKSHAFT OIL SEAL............ 83OIL FILTER AND ADAPTOR................ 84
OILPAN ............................... 77
OIL PUMP............................. 84
PISTON AND CONNECTING ROD........... 78
REAR CRANKSHAFT SEAL................ 83
ROCKER ARMS......................... 72
TIMING BELT........................... 75
DISASSEMBLY AND ASSEMBLY
ROCKER ARMS AND SHAFTS.............. 85
CLEANING AND INSPECTION
CYLINDER BORE........................ 87
CYLINDER HEAD........................ 86
OIL PUMP............................. 87
TIMING BELT........................... 86
ADJUSTMENTS
ENGINE MOUNTS....................... 88
SPECIFICATIONS
3.0L ENGINE........................... 89
TORQUE CHART 3.0L.................... 90
SPECIAL TOOLS
3.0L ENGINE........................... 91
DESCRIPTION AND OPERATION
ENGINE IDENTIFICATION NUMBER
The engine identification number is located on the
rear of the cylinder block just below the cylinder
head (Fig. 1).
ENGINE LUBRICATION
System is a full flow filtration, pressure feed type.
The oil pump is mounted behind the timing belt
cover. The pump inner rotor is driven by the crank-
shaft. The engine oil pan contains a baffle plate to
control oil level fluctuation during engine operation.
ENGINE COMPONENTS
BLOCK:The cylinder block is a light weight
design created by reducing thickness in many parts
and a short 10 mm (3/8 in.) block skirt. High rigidity
is provided with ribs cast in the outer wall, a full
length water jacket, and a mono-block or beam type,
main bearing cap. This single unit four bearing cap
is designed to control vibration of the cylinder block
partition walls.
CRANKSHAFT:A six throw, five weight crank-
shaft is supported by four main bearings with num-
ber three being the thrust bearing. The six separate
connecting rod throws pins reduce torque fluctua-tions while a torsional vibration damper is used to
control torsion caused vibration of the crankshaft.
Rubber lipped seals are used at front and rear. The
Fig. 1 Engine Identification
NS3.0L ENGINE 9 - 61

front seal is retained in the oil pump case and the
rear is retained in a block-mounted housing.
PISTONS:Are aluminum alloy with a steel strut,
short height, and thin wall so as to be autothermic
and light weight. The piston head with valve
recesses, in combination with the cylinder head,
forms a compact spherical head with clearance for
total valve lift with pistons at top dead center. The
piston skirt, top and second ring lands are finished to
a tapered roughness for oil retention and high resis-
tance to scuffing. Piston pins, pressed into place, join
the pistons to the connecting rods.
CYLINDER HEAD:The alloy cylinder heads fea-
ture cross-flow type intake and exhaust ports. Valve
guides and inserts are hardened cast iron. Valves of
heat resistance steel are arranged in a V with each
camshaft on center. To improve combustion speed the
chambers are a compact spherical design with a
squish area of approximately 30 percent of the piston
top area. The cylinder heads are common to either
cylinder bank by reversing the direction of installa-
tion.
CAMSHAFTS:Two overhead camshafts provide
valve actuation, one front (radiator side of cylinder
bank) and one rear. The front camshaft is provided
with a distributor drive and is longer. Both cam-
shafts are supported by four bearing journals, thrust
for the front camshaft is taken at journal two and
the rear at journal three. Front and rear camshaft
driving sprockets are interchangeable. The sprockets
and the engine water pump are driven by a single
notched timing belt.
ROCKER ARM SHAFTS:The shafts are retained
by the camshaft bearing journal caps. Four shafts are
used, one for each intake and exhaust rocker arm
assembly on each cylinder head. The hollow shafts
provide a duct for lubricating oil flow from the cylin-
der head to the valve mechanisms.
ROCKER ARMS:Are of light weight die-cast with
roller type follower operating against the cam shaft.
The valve actuating end of the rocker arms are
machined to retain hydraulic lash adjusters, elimi-
nating valve lash adjustment.
VALVES:Are made of heat resistant steel, valve
springs are especially designed to be short. The valve
spring wire cross-section is oval shaped and provides
the same spring tension as longer springs. Valve
spring retainers, locks and seals are conventional.
INTAKE MANIFOLD:The aluminum alloy mani-
fold is a cross type with long runners to improve
inertia. The runners, attaching below at the cylinder
head, also attach above and support an air plenum.
The air plenum chamber absorbs air pulsations cre-
ated during the suction phase of each cylinder.
EXHAUST MANIFOLDS:Both manifolds are a
log style made of ductile cast iron. Exhaust gasses,collected from the front cylinder bank, leave the front
manifold through an end outlet and are fed through
an upper crossover tube to the rear manifold. The
collected exhaust from both manifolds are combined,
and exit to the exhaust pipe through an articulated
joint.
DIAGNOSIS AND TESTING
CHECKING ENGINE OIL PRESSURE
Check oil pressure using gauge at oil pressure
switch location. Oil pressure should be 41 kPa ( 6
psi.) at idle or 241 to 517 kPa (35 to 75 psi.) at 3000
RPM.
(1) Remove pressure sending unit and install oil
pressure gauge. (Fig. 2).
CAUTION: If oil pressure is 0 at idle, Do Not Run
engine at 3000 RPM.
(2) Warm engine at high idle until thermostat
opens.
SERVICE PROCEDURES
AUTO LASH ADJUSTER
The automatic lash adjusters are precision units
installed in machined openings in the valve actuating
ends of the rocker arms. Do not disassemble the auto
lash adjuster.
FUNCTION CHECK
Check auto adjusters for free play by inserting a
small wire through the air bleed hole in the rocker
arm andvery lightlypushing the auto adjuster ball
check down (Fig. 3). While lightly holding the check
ball down move the rocker up and down to check for
free play. If there is no play replace the adjuster.
Fig. 2 Checking Engine Oil Pressure
9 - 62 3.0L ENGINENS
DESCRIPTION AND OPERATION (Continued)

VALVE SERVICE RECONDITION
(1) With suitable valve spring compressor, remove
spring retainer locks, retainer, valve spring, spring
seat and valve (Fig. 12).
(2) Remove valve stem seals with suitable tool
(Fig. 13). Do not reuse valve stem seals.
VALVES
(1) Check valve stem tip for pitting or depression
at point A (Fig. 14).
(2) Check for wear and ridge wear at Point B.
(3) Check for even contact (at face center) with
valve seat, Point C.
(4) Check margin (Fig. 14). Replace valve if mar-
gin is out of specification. Refer to Valve Specification
Chart.
(5) Check valve guide height (Fig. 15).
(6) Measure valve stem to guide clearance. Refer
to Valve Specification Chart.
(7) Measure Valve spring free length and square-
ness (Fig. 16). Refer to Valve Specification Chart.
Fig. 12 Remove Valves
Fig. 13 Remove Valve Stem Seals
Fig. 14 Valve Inspection
Fig. 15 Valve Guide Height
9 - 66 3.0L ENGINENS
SERVICE PROCEDURES (Continued)

VALVE SEAT
Inspect the valve seat with Prussian blue to deter-
mine where the valve contacts the seat. To do this,
coat valve seatLIGHTLYwith Prussian blue then
set valve in place. Rotate the valve with light pres-
sure. If the blue is transferred to the center of valve
face, contact is satisfactory. If the blue is transferred
to top edge of the valve face, lower valve seat with a
15 degrees stone. If the blue is transferred to the bot-
tom edge of valve face raise valve seat with a 65
degree stone (Fig. 17).
INSTALLATION
(1) Install valve spring seat.
(2) Using suitable tool install seal by tapping
lightly until seal is in place (Fig. 18).
(3) Install valve spring with the enamelled ends
facing the rocker arms (Fig. 19).
CAUTION: During reassembly, compressing the
valve spring more than necessary to install valve
spring retainer locks can cause the retainer to be
forced against the stem seal and damaging it.
VALVE SPECIFICATION CHART
Valve Dimensions
INTAKE VALVE (MINIMUM)
Stem Diameter: 7.960 mm (0.313 in.)
Face Angle: 45É
Valve Margin: 0.700 mm (0.028 in.)
Length: 103.0 mm (4.055 in.)
EXHAUST VALVE (MINIMUM)
Stem Diameter: 7.930 mm (0.312)
Face Angle: 45É
Valve Margin: 1.50 mm (0.059 in.)
Length: 102.70 mm (4.043 in.)
Valve Guide
ClearanceNew Service
Limit
Intake: 0.03 - 0.06 mm
(0.001 - 0.002 in.)0.10 mm
(0.004 in.)
Exhaust: 0.05 - 0.09 mm
(0.002 - 0.0035 in.)0.15 mm
(0.006 in.)
Valve Springs New Service
Limit
Free Length: 49.8 mm (1.960 in.) 48.8 mm
(1.921 in.)
Squarness: 2É Maximum 4É Maximum
Spring Tension: 33 Kg @ 40.4 mm
(73 lbs. @ 1.59 in.)
Fig. 16 Valve Spring
Fig. 17 Valve Seat Reconditioning
Fig. 18 Install Valve Stem Seals
Fig. 19 Installed Valve Spring Position
NS3.0L ENGINE 9 - 67
SERVICE PROCEDURES (Continued)