1996 CHRYSLER VOYAGER height

Service Tappets Available........Std., 0.025 mm
(0.001), 0.20 mm (0.008 in.),
0.762 mm (0.030 in.)
Cylinder Head
Gasket Thickness (Compressed)........1.78 mm
(0.070 in.)
Cylinder Head Valve Seat
Angle±Intake and Exhaust...........45-45.5É
Runout (Max)............0.0762 mm (0.003 in.)
Width (Finish)±Intake...........1.75 - 2.25 mm
(0.069 - 0.088 in.)
Width (Finish)±Exhaust.........1.50 - 2.00 mm
(0.057 - 0.078 in.)
Valve Guides
Type..................Powdered Metal Inserts
Guide Bore Diameter...........7.975 - 8.00 mm
(0.314 - 0.315 in.)
ValvesÐIntake
Face Angle...........................44.5É
Head Diameter..............45.5 mm (1.79 in.)
Length (Overall)..........127.005 - 128.036 mm
(5.000 - 5.041 in.)
Minimum Valve Length
After Tip Grinding...................124.892
(4.916 in.)
Lift (Zero Lash)...........10.16 mm (0.400 in.)
Stem Diameter (Standard)......7.935 - 7.953 mm
(0.312 - 0.313 in.)
Valve Tip Height (From
Cylinder Head Surface)......49.541 - 51.271 mm
(1.950 - 2.018 in.)
Stem-to-Guide Clearance.......0.025 - 0.095 mm
(0.001 - 0.003 in.)
Max. Allowable (Rocking Method). . . .0.247 mm
(0.010 in.)
Valves for Service
(Oversize Stem Diameters).......Std., 0.015 mm
(0.005 in.), 0.40 mm (0.015 in.),
0.80 mm (0.030 in.)
ValvesÐExhaust
Face Angle.............................45É
Head Diameter.............37.5 mm (1.476 in.)
Length Overall..............127.825 - 128.465
(5.032 - 5.058 in.)
Minimum Valve Length
After Tip Grinding.......125.512 mm (4.941 in.)
Lift (Zero Lash)............10.16 mm (0.40 in.)
Valve Tip Height (From
Cylinder Head Surface)......49.541 - 51.271 mm
(1.950 - 2.018 in.)
Stem Diameter (Standar).......7.906 - 7.924 mm
(0.3112 - 0.3119 in.)
Stem to Guide Clearance.......0.051 - 0.175 mm
(0.002 - 0.006 in.)Max. Allowable (Rocking Method)......0.414 mm
(0.016 in.)
Valves for Service (Oversize
Stem Diameters)......Std., 0.015 mm (0.005 in.),
0.40 mm (0.015 in.), 0.80 mm (0.030 in.)
Valve Springs
Free Length (Approx.).......48.5 mm (1.909 in.)
Wire Diameter.............4.75 mm (0.187 in.)
Number of Coils.........................6.8
Spring Tension (Valve Closed).......95-100lbs.
@ 1.57 in.
Spring Tension (Valve Open).......207 - 229 lbs.
@ 1.169 in.
Installed Height (Spring
Seat to Bottom of Retainer)......41.2 - 42.7 mm
(1.622 - 1.681 in.)
Oil Pump
Pump Type...............Rotary Full Pressure
Clearance Over Rotors
(Inner & Outer Max.)........0.10 mm (0.004 in.)
Cover Out-of-Flat (Max.).....0.025 mm (0.001 in.)
Inner Rotor Thickness (Min.) . .7.64 mm (0.301 in.)
Outer Rotor Thickness (Min.) . .7.64 mm (0.301 in.)
Outer Rotor Diameter (Min.) .79.95 mm (3.148 in.)
Outer Rotor Clearance.......0.39 mm (0.015 in.)
Tip Clearance Between Rotors (Max.). . . .0.20 mm
(0.008 in.)
Oil Pressure
Minimum Pressure at Idle (Engine
Fully Warmed Up)*...........34.47 kPa (5 psi)
At 3000 rpm.........205 - 551 kPa (30 - 80 psi)
Oil Filter Bypass Valve Setting......62-103kPa
(9 - 15 psi)
Oil Filter Type.....................Full Flow
Oil Pressure Switch Actuating
Pressure (Min.)...........14-28kPa(2 - 4 psi)
CAUTION: * If pressure is ZERO at curb Idle, DO
NOT run engine at 3,000 rpm.
NS3.3/3.8L ENGINE 9 - 125
SPECIFICATIONS (Continued)

INSTALLATION
(1) Install crankshaft damper using M12-1.75 x
150 mm bolt, washer, thrust bearing and nut from
Special Tool 6792. Install crankshaft damper bolt and
tighten to 142 N´m (105 ft. lbs.) (Fig. 84).
(2) Install accessory drive belts. Refer to Group 7,
Cooling System Accessory Drive section for proce-
dure.
DISASSEMBLY AND ASSEMBLY
OIL PUMP
(1) To remove the relief valve, proceed as follows:
(2) Remove the threaded plug and gasket from the
oil pump (Fig. 85).
CAUTION: Oil pump pressure relief valve must be
installed as shown in (Fig. 85) or serious damage
may occur.
(3) Remove spring and relief valve (Fig. 85).(4) Remove oil pump cover screws, and lift off
cover.
(5) Remove pump rotors.
(6) Wash all parts in a suitable solvent and inspect
carefully for damage or wear (Fig. 86).
VALVE SERVICE WITH THE CYLINDER HEAD
REMOVED
REMOVAL
(1) With cylinder head removed, compress valve
springs using Special Tool C-3422-B or equivalent.
(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.
VALVE INSPECTION
(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.
(3) If valve stems are worn more than 0.05 mm
(.002 in.), replace valve.
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. 87). Refer to Valve Guide Specification
Chart for specifications. Replace guides if they are
not within specification.
(3) Check valve guide height (Fig. 88).
TESTING VALVE SPRINGS
(1) Whenever valves have been removed for inspec-
tion, reconditioning or replacement, valve springs
Fig. 84 Crankshaft DamperÐInstallation
Fig. 85 Oil Pressure Relief Valve
Fig. 86 Oil Pump
NS/GSENGINE 9 - 29
REMOVAL AND INSTALLATION (Continued)

should be tested Special Tool C-647. As an example,
the compression length of the spring to be tested is
33.34 mm (1-5/16 inches). Turn tool table until sur-
face is in line with the 33.34 mm (1-5/16 inch) mark
on the threaded stud and the zero mark on the front.
Place spring over stud on the table and lift compress-
ing lever to set tone device (Fig. 89). Pull on torque
wrench until ping is heard. Take reading on torque
wrench at this instant. Multiply this reading by two.
This will give the spring load at test length. Frac-
tional measurements are indicated on the table for
finer adjustments. Discard the springs that do not
meet specifications. The Following specifications
apply to both intake and exhaust valve springs.²Valve Closed Nominal ForceÐ 67 lbs. @ 39.8 mm
(1.57 in.)
²Valve Open Nominal ForceÐ 160 lbs. @ 32.6 mm
(1.28 in.)
(2) Verify springs are not distorted with a steel
square and surface plate, check springs from both
ends. If the spring is more than 1.5 mm (1/16 inch)
out of square, install a new spring.
REFACING VALVES AND VALVE SEATS
(1) The intake and exhaust valve seats and valve
face have a 45 degree angle.
(2) Inspect the remaining margin after the valves
are refaced (Fig. 90). Intake valves with less than
0.95 mm (1/32 inch.) margin and Exhaust valves
with less than 1.05 mm (3/64 inch) margin should be
discarded.
(3) When refacing valve seats, it is important that
the correct size valve guide pilot be used for reseat-
ing stones. A true and complete surface must be
obtained. For valve specifications see Valve Specifica-
tion Chart.
(4) Measure the concentricity of valve seat and
valve guide using a valve seat runout dial indicator.
Fig. 87 Checking Wear on Valve GuideÐTypical
VALVE GUIDE SPECIFICATION CHART
Valve Guide
DiameterIntake Valve Exhaust Valve
5.975 - 6.000 mm
(0.2352 - 0.2362
in.)5.975 - 6.000 mm
(0.2352 - 0.2362 in.)
Valve Guide Clearance
Intake Valve Exhaust Valve
New: 0.023 - 0.066 mm
(0.001 - 0.0025 in.)0.051 - 0.094 mm
(0.002 - 0.0037 in.)
Service Limit: 0.25 mm (0.010 in.)
Fig. 88 Valve Guide Height
Fig. 89 Valve Spring Testing
Fig. 90 Intake and Exhaust Valve Refacing
9 - 30 ENGINENS/GS
DISASSEMBLY AND ASSEMBLY (Continued)

Total runout should not exceed. 0.051 mm (0.002
inch.) (total indicator reading).
(5) Inspect the valve seat with Prussian blue to
determine where the valve contacts the seat. To do
this, coat valve seatLIGHTLYwith Prussian blue
then set valve in place. Rotate the valve with light
pressure. If the blue is transferred to the center of
valve face, contact is satisfactory. If the blue is trans-
ferred to top edge of the valve face, lower valve seat
with a 15 degrees stone. If the blue is transferred to
the bottom edge of valve face raise valve seat with a
65 degrees stone.
²Intake valve seat diameter is 33 mm (1.299 in.)
²Exhaust valve seat diameter is 28 mm (1.102
in.)
(6) Valve seats which are worn or burned can be
reworked, provided that correct angle and seat width
are maintained. The intake valve seat must be ser-
viced when the valve seat width is 2.0 mm (0.079 in.)
or greater. The exhaust valve seat must be serviced
when the valve seat width is 2.5 mm (0.098 in.) or
greater. Otherwise the cylinder head must be
replaced.
(7) When seat is properly positioned the width of
intake and exhaust seats should be 0.75 to 1.25 mm
(0.030 to 0.049 in.) (Fig. 91).
(8) Check valve tip to spring seat dimensions A
after grinding the valve seats or faces. Grind valve
tip to 43.51 - 44.57 mm (1.71 - 1.75 in.) for exhaust
valve and 45.01 - 46.07 mm (1.77 - 1.81 in.) for
intake valve over spring seat when installed in the
head (Fig. 92). The valve tip chamfer may need to be
reground to prevent seal damage when the valve is
installed.
CLEANING
Clean all valve guides, valves and valve spring
assemblies thoroughly with suitable cleaning solution
before reassembling.
VALVE 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. 93). The valve stem seals
should be pushed firmly and squarely over valve
guide.
CAUTION: If oversize valves are used, there is only
one oversize valve available. The same stem seal is
used on both the standard and oversize valve.
(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.
VALVE SPECIFICATION CHART
Face Angle
Intake and
Exhaust:45 - 45 1/2É
Head Diameter
Intake: 33.12 - 33.37 mm (1.303 - 1.313 in.)
Exhaust: 28.57 - 28.83 mm (1.124 - 1.135 in.)
Length (Overall)
Intake: 114.69 - 115.19 mm (4.515 - 4.535 in.)
Exhaust: 116.94 - 117.44 mm (4.603 - 4.623 in.)
Stem Diameter
Intake: 5.934 - 5.952 mm (0.2337 - 0.2344 in.)
Exhaust: 5.906 - 5.924 mm (0.2326 - 0.2333 in.)
Valve Margin
Intake: 1.15 - 1.48 mm (0.0452 - 0.0582 in.)
Exhaust: 1.475 - 1.805 mm (0.0580 - 0.0710 in.)
Fig. 91 Valve Seat Refacing
Fig. 92 Spring Installed Height and Valve Tip to
Spring Seat Dimensions
NS/GSENGINE 9 - 31
DISASSEMBLY AND ASSEMBLY (Continued)

CAUTION: When depressing the valve spring
retainers with valve spring compressor the locks
can become dislocated. Check to make sure both
locks are in their correct location after removing
tool.
(4) Check the valve spring installed height B after
refacing the valve and seat (Fig. 92). Make sure mea-
surements are taken from top of spring seat to the
bottom surface of spring retainer. If height is greater
than 40.18 mm (1.58 in.), install a 0.762 mm (0.030
in.) spacer under the valve spring seat to bring
spring height back within specification.
(5) Install rocker arm shafts as previously
described in this section.
(6) Checking dry lash. Dry lash is the amount of
clearance that exists between the base circle of an
installed cam and the rocker arm roller when the
adjuster is drained of oil and completely collapsed.
Specified dry lash is 1.17 mm (0.046 in.) for intake
and 1.28 mm (0.050 in.) for exhaust. After performing
dry lash check, refill adjuster with oil and allow 10
minutes for adjuster/s to bleed down before rotating
cam.
CLEANING AND INSPECTION
CYLINDER HEAD AND CAMSHAFT JOURNALS
INSPECTING CYLINDER HEAD
Cylinder head must be flat within 0.1 mm (0.004
inch) (Fig. 94).
Inspect cylinder head camshaft bearings for wear.
Check camshaft journals for scratches and worn
areas. If light scratches are present, they may be
removed with 400 grit sand paper. If deep scratches
are present, replace the camshaft and check the cyl-
inder head for damage. Replace the cylinder head if
worn or damaged. Check the lobes for pitting and
wear. If the lobes show signs of wear, check the cor-
responding rocker arm roller for wear or damage.Replace rocker arm/hydraulic lash adjuster if worn or
damaged. If lobes show signs of pitting on the nose,
flank or base circle; replace the camshaft.
CLEANING
Remove all gasket material from cylinder head and
block. Be careful not to gouge or scratch the alumi-
num head sealing surface.
OIL PUMP
(1) Clean all parts thoroughly. Mating surface of
the oil pump should be smooth. Replace pump cover
if scratched or grooved.
(2) Lay a straightedge across the pump cover sur-
face (Fig. 95). If a 0.076 mm (0.003 inch.) feeler
gauge can be inserted between cover and straight
edge, cover should be replaced.
(3) Measure thickness and diameter of outer rotor.
If outer rotor thickness measures 7.64 mm (0.301
inch.) or less (Fig. 96), or if the diameter is 79.95 mm
(3.148 inches) or less, replace outer rotor.
Fig. 93 Valve Stem Oil Seal Tool
Fig. 94 Checking Cylinder Head Flatness
Fig. 95 Checking Oil Pump Cover Flatness
9 - 32 ENGINENS/GS
DISASSEMBLY AND ASSEMBLY (Continued)

Valve Margin
Intake.....1.15 ± 1.48 mm (0.0452 ± 0.0582 in.)
Exhaust....1.475 ± 1.805 mm (0.058 ± 0.071 in.)
Valve Length (Overall)
Intake....114.69 ± 115.19 mm (4.515 ± 4.535 in.)
Exhaust . . 109.59 ± 110.09 mm (4.603 ± 4.623 in.)
Valve Stem Tip Height
Intake.......45.01 ± 46.07 mm (1.77 ± 1.81 in.)
Exhaust......43.51 ± 44.57 mm (1.71 ± 1.75 in.)
Stem Diameter
Intake.....5.934 ± 5.952 mm (0.234 ± 0.234 in.)
Exhaust....5.906 ± 5.924 mm (0.233 ± 0.233 in.)
Stem to Guide Clearance
Intake . . . 0.048 ± 0.066 mm (0.0018 ± 0.0025 in.)
Exhaust . 0.0736 ± 0.094 mm (0.0029 ± 0.0037 in.)
Max. Allowable Intake.....0.076 mm (0.003 in.)
Max. Allowable Exhaust....0.101 mm (0.004 in.)
Valve Springs
Free Length (Approx.)......44.4 mm (1.747 in.)
Nominal Force (Valve closed) . 91 N´m @ 39.8 mm
(67 ft. lbs. @ 1.57 in.)
Nominal Force (Valve open) . 239 N´m @ 32.6 mm
(176 lbs. @ 1.28 in.)
Installed Height..........40.18 mm (1.580 in.)
* SERVICE AS AN ASSEMBLY WITH ROCKER
ARM.
** ALL READINGS IN CRANKSHAFT DEGREES,
AT 0.5 mm (0.019 in.) OF VALVE LIFT.
TORQUE CHART 2.0L SOHC
DESCRIPTION...................TORQUE
Camshaft Sensor Pick Up
Bolts...................9.6N´m(85in.lbs.)
Camshaft Sprocket
Bolt....................115N´m(85ft.lbs.)
Connecting Rod Cap
Bolts.........27N´m(20ft.lbs.) Plus 1/4 Turn
CollarÐOil Pan to Transaxle
Step 1: Collar to Oil Pan Bolts . 3 N´m (30 in. lbs.)
Step 2: Collar to Transaxle
Bolts...................108N´m(80ft.lbs.)
Step 3: Collar to Oil Pan
Bolts....................54N´m(40ft.lbs.)
Crankshaft Main Bearing Cap/Bedplate
M8 Bedplate Bolts..........30N´m(22ft.lbs.)
M11 Main Cap Bolts........81N´m(60ft.lbs.)
Crankshaft Damper
Bolt...................142N´m(105 ft. lbs.)
Cylinder Head
Bolts.......Refer To Cylinder Head Installation
Cylinder Head Cover
Bolts...................12N´m(105 in. lbs.)
Engine Mount BracketÐRight
Bolts....................61N´m(45ft.lbs.)DESCRIPTION...................TORQUE
Engine Mounting
Bolts.......Refer to Engine Mount Installation
Exhaust Manifold to Cylinder Head
Bolts...................23N´m(200 in. lbs.)
Exhaust Manifold Heat Shield
Bolts...................12N´m(105 in. lbs.)
Intake Manifold
Bolts...................12N´m(105 in. lbs.)
Oil Filter Adapter
Fastener.................80N´m(60ft.lbs.)
Oil Filter.................20N´m(15ft.lbs.)
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.)
Rocker Arm Shaft
Bolts...................28N´m(250 in. lbs.)
Spark Plugs...............28N´m(20ft.lbs.)
Thermostat Housing
Bolts...................23N´m(200 in lbs.)
Timing Belt Cover
Bolts M6................12N´m(105 in. lbs.)
Timing Belt Mechanical Tensioner Assembly
Bolts...................28N´m(250 in. lbs.)
Timing Belt Hydraulic Tensioner
Pulley Bolt...............68N´m(50ft.lbs.)
Pivot Bracket Bolt..........31N´m(23ft.lbs.)
Tensioner Bolts............31N´m(23ft.lbs.)
Water Pump Mounting
Bolts...................12N´m(105 in. lbs.)
SPECIAL TOOLS
ENGINE 2.0L SOHC
Puller 1026
9 - 36 ENGINENS/GS
SPECIFICATIONS (Continued)

VALVE STAND DOWN
Valve stand down is to maintain the adequate com-
pression ratio.
(1) Invert cylinder head.
(2) Fit each valve to its respective valve guide.
(3) Using a straight edge and feeler gauge (Fig. 9),
check valve head stand down: Inlet valve head stand
down .80 to 1.2 mm (.031 to .047 in.) and exhaust
valve stand down .79 to 1.19 mm (.031 to .047 in).
(4) If valve head stand down is not in accordance
with above, discard original valves, check stand down
with new valves and recut valve seat inserts to
obtain correct stand down.
VALVE GUIDE HEIGHT
(1) Valve Guides height requirement.
(2) Measurement A (Fig. 10): 13.50 - 14.00 mm.
VALVE STEM-TO-GUIDE CLEARANCE
MEASUREMENT
(1) Measure and record internal diameter of valve
guides. Valve guide internal diameter is 8.0 to 8.015
mm (.3149 to .3155 in.).
(2) Measure valve stems and record diameters.
Intake valve stem diameter 7.94 to 7.96 mm (.3125 to
.3133 in). Exhaust valve stem diameter 7.92 to 7.94
mm (.3118 to .31215 in).(3) Subtract diameter of valve stem from internal
diameter of its respective valve guide to obtain valve
stem clearance in valve guide. Clearance of inlet
valve stem in valve guide is .040 to .075 mm (.0015
to .0029 in). Clearance of exhaust valve stem in valve
guide is .060 to .095 mm (.0023 to .0037 in).
(4) If valve stem clearance in valve guide exceeds
tolerances, new valve guides must be installed.
FITTING PISTON RING
(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 (Fig. 11). Check gap with feeler gauge.
Top compression ring gap .25 to .50mm (.0098 to
.0196 in.). Second compression ring gap .25 to .35mm
(.0098 to .0137 in.). Oil control ring gap .25 to .58mm
(.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. 12).
Top compression ring gap .08 to .130mm (.0031 to
.0051 in.). Second compression ring gap .070 to
.102mm (.0027 to .0040 in.). Oil control ring gap .040
to .072mm (.0015 to .0028 in.).
CRANKSHAFT END PLAY
(1) Attach dial indicator to engine block (Fig. 13).
(2) Move crankshaft toward front of engine and
zero indicator.
(3) Move crankshaft toward the rear of engine and
record measurement.
(4) Subtract specified crankshaft end float from
figure obtained. Crankshaft end float 0.08 to
0.21mm.
(5) Select thrust washer which will give correct
end float.
Fig. 9 Checking Valve Stand Down
Fig. 10 Valve Guide Height
Fig. 11 Ring Gap Measurement
9 - 50 ENGINENS/GS
SERVICE PROCEDURES (Continued)

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)