1996 CHRYSLER VOYAGER length

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)

(4) If inner rotor measures 7.64 mm (.301 inch) or
less replace inner rotor (Fig. 97).
(5) Slide outer rotor into pump housing, press to
one side with fingers and measure clearance between
rotor and housing (Fig. 98). If measurement is 0.39
mm (0.015 inch.) or more, replace housing only if
outer rotor is in specification.
(6) Install inner rotor into pump housing. If clear-
ance between inner and outer rotors (Fig. 99) is .203
mm (.008 inch) or more, replace both rotors.
(7) Place a straightedge across the face of the
pump housing, between bolt holes. If a feeler gauge
of .102 mm (.004 inch) or more can be inserted
between rotors and the straightedge, replace pump
assembly (Fig. 100).ONLYif rotors are in specs.
(8) Inspect oil pressure relief valve plunger for
scoring and free operation in its bore. Small marks
may be removed with 400-grit wet or dry sandpaper.
(9) The relief valve spring has a free length of
approximately 60.7 mm (2.39 inches) it should test
between 18 and 19 pounds when compressed to 40.5
mm (1.60 inches). Replace spring that fails to meet
specifications.(10) If oil pressure is low and pump is within spec-
ifications, inspect for worn engine bearings, damaged
or missing oil pick-up tube o-ring, clogged oil pick-up
tube screen, clogged oil filter and stuck open pres-
sure relief valve or other reasons for oil pressure
loss.
Fig. 96 Measuring Outer Rotor Thickness
Fig. 97 Measuring Inner Rotor Thickness
Fig. 98 Measuring Outer Rotor Clearance in
Housing
Fig. 99 Measuring Clearance Between Rotors
Fig. 100 Measuring Clearance Over Rotors
NS/GSENGINE 9 - 33
CLEANING AND INSPECTION (Continued)

CYLINDER BLOCK AND BORE
(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 C-119 (Fig. 101). The cyl-
inder bore out-of-round is 0.050 mm (.002 inch)
maximum and cylinder bore taper is 0.051 mm (0.002
inch) maximum. If the cylinder walls are badly
scuffed or scored, the cylinder block should be
rebored and honed, and new pistons and rings fitted.
Whatever type of boring equipment is used, boring
and honing operation should be closely coordinated
with the fitting of pistons and rings in order that
specified clearances may be maintained.Refer to
Honing Cylinder Bores outlined in the Stan-
dard Service Procedures for specification and
procedures.
Measure the cylinder bore at three levels in direc-
tions A and B (Fig. 101). Top measurement should be
10 mm (3/8 inch) down and bottom measurement
should be 10 mm (3/8 inch.) up from bottom of bore.
Refer to Cylinder Bore and Piston Specification
Chart for specifications.
SPECIFICATIONS
ENGINE 2.0L SOHC
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 (Federal Emission)
Clearance 17.5 mm (11/16 in.) from bottom of
skirt.....0.012 - 0.044 mm (0.0004 - 0.0017 in.)
Weight.......325-335grams (11.47 - 11.82 oz.)
Land Clearance (Diametrical) . . 0.734 - 0.797 mm
(0.029 - 0.031 in.)
Piston Length..............64mm(2.520 in.)
Piston Ring Groove Depth
No.1.......3.989 - 4.188 mm (0.157 - 0.165 in.)
Piston Ring Groove Depth
No.2.......4.462 - 4.661 mm (0.176 - 0.184 in.)
Piston Ring Groove Depth
No.3.......3.847 - 4.131 mm (0.151 - 0.163 in.)
Pistons (Low Emission VehicleÐLEV)
Clearance 10.42 mm (0.42 in.) from bottom of
skirt.....0.018 ± 0.50 mm (0.0008 ± 0.0020 in.)
Weight......320±329grams (11.29 ± 11.60 oz.)
Land Clearance (Diametrical) . . 0.758 ± 0.790 mm
(0.0299 ± 0.0312 in.)
Piston Length.............55.8 mm (2.197 in.)
Piston Ring Groove Depth
No.1.......3.989 - 4.188 mm (0.157 - 0.165 in.)
Piston Ring Groove Depth
No.2.......4.462 - 4.661 mm (0.176 - 0.184 in.)
Piston Ring Groove Depth
No.3.......3.847 - 4.131 mm (0.151 - 0.163 in.)
Piston Pins
Clearance in Piston..........0.008 - 0.020 mm
(0.0003 - 0.0008 in.)
In Rod (Interference).........0.018 - 0.043 mm
(0.0007 - 0.0017 in.)
Fig. 101 Checking Cylinder Bore Size
CYLINDER BORE AND PISTON
SPECIFICATION CHART
Standard Bore Max. Out-of-
RoundMax. Taper
87.5 mm
(3.445 in.)0.051 mm
(0.002 in.)0.051 mm
(0.002 in.)
Standard Piston Size
87.463 - 87.481 mm (3.4434 - 3.4441 in.)
Piston to Bore Clearance
0.012 - 0.044 mm (0.0005 - 0.0017 in.)
Measurements taken at Piston Size Location.
9 - 34 ENGINENS/GS
CLEANING AND INSPECTION (Continued)

Cylinder Block
Diameter................20.998 - 21.003 mm
(0.8267 - 0.8269 in.)
End Play............................None
Length.....74.75 - 75.25 mm (2.943 - 2.963 in.)
Piston Rings
Ring Gap Top Compression Ring . . 0.23 - 0.52 mm
(0.009 - 0.020 in.)
Ring Gap 2nd Compression Ring . . 0.49 - 0.78 mm
(0.019 - 0.031 in.)
Ring Gap Oil Control
(Steel Rails) . . . 0.23 - 0.66 mm (0.009 - 0.026 in.)
Ring Side Clearance Both Compression
Rings....0.025 - 0.065 mm (0.0010 - 0.0026 in.)
Oil Ring (Pack).............0.004 - 0.178 mm
(0.0002 - 0.0070 in.)
Ring Width Compression Rings . . . 1.17 - 1.19 mm
(0.046 - 0.047 in.)
Oil Ring (Pack).............2.854 - 3.008 mm
(0.1124 - 0.1184 in.)
Connecting Rod
Bearing Clearance...........0.026 - 0.059 mm
(0.001 - 0.0023 in.)
Piston Pin Bore Diameter.....20.96 - 20.98 mm
(0.8252 - 0.8260 in.)
Large End Bore Diameter . . . 50.991 - 51.005 mm
(2.0075 - 2.0081 in.)
Side Clearance . 0.13 - 0.38 mm (0.005 - 0.015 in.)
Total Weight (Less Bearing) . 543 grams (1.20 lbs.)
Crankshaft
Connecting Rod Journal
Diameter . .
47.9924 - 48.0076 mm (1.8894 - 1.8900 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 ..0.022 - 0.062 mm (0.0008 - 0.0024 in.)
End Play....0.09 - 0.24 mm (0.0035 - 0.0094 in.)
Main Bearing Journals
Diameter..............51.9924 - 52.0076 mm
(2.0469 - 2.0475 in.)
Out-of-Round (Max.).....0.0035 mm (0.0001 in.)
Taper (Max.)...........0.0038 mm (0.0001 in.)
ENGINE 2.0L SOHC
Rocker Arm Shaft
Rocker Arm Shaft Diameter . . 19.996 ± 19.984mm
(0.786 ± 0.7867 in.)
Rocker Arm Shaft Retainers (Width)
Intake (All)...............28.46 mm (1.12 in.)
Exhaust.............1&529.20 mm (1.14in.)
2, 3, and 4 - 40.45 mm (1.59 in.)
Rocker Arm/Hydraulic Lash Adjuster *
Rocker Arm Inside Diameter . . 20.00 ± 20.02 mm
(0.787 ± 0.788 in.)Rocker Arm Shaft Clearance . . . 0.016 ± 0.054 mm
(0.0006 ± 0.0021 in.)
Body Diameter...........22.949 ± 22.962 mm
(0.9035 ± 0.9040 in.)
Plunger Travel Minimum (Dry).........2.2mm
(0.087 in.)
Rocker Arm Ratio...................1.4to1
Cylinder Head Camshaft Bearing Diameter
No.1 ....41.20 ± 41.221 mm (1.622 ± 1.6228 in.)
No.2 ......41.6 ± 41.621 mm (1.637 ± 1.638 in.)
No.3 ......42.0 ± 42.021 mm (1.653 ± 1.654 in.)
No.4 ......42.4 ± 42.421 mm (1.669 ± 1.670 in.)
No.5 .....42.8 ± 42.821 mm (1.685 ± 1.6858 in.)
Camshaft Journal Diameter
No. 1 . . . 41.128 ± 41.147 mm (1.619 ± 1.6199 in.)
No.2 ....41.528 ± 41.547 mm (1.634 ± 1.635 in.)
No.3 ....41.928 ± 41.947 mm (1.650 ± 1.651 in.)
No.4 ....42.328 ± 42.374 mm (1.666 ± 1.668 in.)
No. 5 . . . 42.728 ± 42.747 mm (1.682 ± 1.6829 in.)
Diametrical Bearing Clearance . 0.053 ± 0.093 mm
(0.0027 ± 0.003 in.)
Max. Allowable...........0.12 mm (0.0047 in.)
End Play..........0.05 ± 0.39 mm (0.0059 in.)
Lift (Zero Lash )
Intake...................7.2mm(0.283 in.)
Exhaust.................7.03 mm (0.277 in.)
Valve Timing Exhaust Valve**
Closes (ATDC)........................5.4É
Opens (BBDC).......................43.7É
Duration...........................229.1É
Valve Timing Intake Valve **
Closes (ABDC).......................41.1É
Opens (ATDC)........................13.9É
Duration...........................207.2É
Valve Overlap..........................0É
Cylinder Head
Material....................Cast Aluminum
Gasket Thickness (Compressed).......1.15 mm
(0.045 in.)
Valve Seat
Angle................................45É
Runout (Max.)..............0.050 mm (0.002)
Width (Finish) Intake and
Exhaust.....0.75 ± 1.25 mm (0.030 ± 0.049 in.)
Valve Guide Finished
Diameter I.D. . 5.975 ± 6.000 mm (.235 ± .236 in.)
Guide Bore Diameter (Std.).....11.0±11.02 mm
(0.4330 ± 0.4338 in.)
Valves
Face Angle Intake and Exhaust.....45±45-1/2É
Head Diameter Intake.......32.12 ± 33.37 mm
(1.303 ± 1.313 in.)
Head Diameter Exhaust......28.57 ± 28.83 mm
(1.124 ± 1.135 in.)
NS/GSENGINE 9 - 35
SPECIFICATIONS (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)

HYDRAULIC TAPPETS
Before disassembling any part of the engine to cor-
rect tappet noise, check the oil pressure. If vehicle
has no oil pressure gauge, install a reliable gauge at
the pressure sending unit. The pressure should be
between 3.5 bars to 5.0 bars at 4000 RPM.
Check the oil level after the engine reaches normal
operating temperature. Allow 5 minutes to stabilize
oil level, check dipstick. The oil level in the pan
should never be above the FULL mark or below the
ADD OIL mark on dipstick. Either of these 2 condi-
tions could be responsible for noisy tappets.
OIL LEVEL HIGH
If oil level is above the FULL mark, it is possible
for the connecting rods to dip into the oil. With the
engine running, this condition could create foam in
the oil pan. Foam in oil pan would be fed to the
hydraulic tappets by the oil pump causing them to
lose length and allow valves to seat noisily.
OIL LEVEL LOW
Low oil level may allow oil pump to take in air.
When air is fed to the tappets, they lose length which
allows valves to seat noisily. Any leaks on intake side
of oil pump through which air can be drawn will cre-
ate the same tappet action. Check the lubrication
system from the intake strainer to the pump cover,
including the relief valve retainer cap. When tappet
noise is due to aeration, it may be intermittent or
constant, and usually more than 1 tappet will be
noisy. When oil level and leaks have been corrected,
operate the engine at fast idle. Run engine for a suf-
ficient time to allow all of the air inside the tappets
to be bled out.
TAPPET NOISE DIAGNOSIS
(1) To determine source of tappet noise, operate
engine at idle with cylinder head covers removed.
(2) Feel each valve spring or rocker arm to detect
noisy tappet. The noisy tappet will cause the affected
spring and/or rocker arm to vibrate or feel rough in
operation.
NOTE: Worn valve guides or cocked springs are
sometimes mistaken for noisy tappets. If such is
the case, noise may be dampened by applying side
thrust on the valve spring. If noise is not apprecia-
bly reduced, it can be assumed the noise is in the
tappet. Inspect the rocker arm push rod sockets
and push rod ends for wear.
(3) Valve tappet noise ranges from light noise to a
heavy click. A light noise is usually caused by exces-
sive leak down around the unit plunger or by the
plunger partially sticking in the tappet body cylinder.
The tappet should be replaced. A heavy click iscaused by a tappet check valve not seating or by for-
eign particles becoming wedged between the plunger
and the tappet body. This will cause the plunger to
stick in the down position. This heavy click will be
accompanied by excessive clearance between the
valve stem and rocker arm as valve closes. In either
case, tappet assembly should be removed for inspec-
tion and cleaning.
(4) The valve train generates a noise very much
like a light tappet noise during normal operation.
Care must be taken to ensure that tappets are mak-
ing the noise. In general, if more than one tappet
seems to be noisy, its probably not the tappets.
SERVICE PROCEDURES
CHECKING OIL LEVEL
To assure proper engine lubrication, the engine oil
must be maintained at the correct level. Check the
oil level at regular intervals, such as every fuel stop.
The best time to check the oil level is about 5 min-
utes after a fully warmed-up engine is shut off, or
before starting the vehicle after it has sat overnight.
Checking the oil while the vehicle is on level
ground, will improve the accuracy of the oil level
readings (Fig. 4).
CHANGING ENGINE OIL AND FILTER
Change engine oil and filter at mileage and time
intervals described in the Maintenance Schedule.
Fig. 4 Checking Engine Oil
NS/GSENGINE 9 - 47
DIAGNOSIS AND TESTING (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)

retainer and plunger spring. Check valve could be
flat or ball.
Assemble tappets in reverse order.
CLEANING AND INSPECTION
CYLINDER HEAD COVERS
Remove any original sealer from the cover sealing
surface of the engine cylinder head.
Remove all residue from the sealing surface using
a clean, dry cloth.
ROCKER ARMS AND PUSH RODS
CLEANING
Clean all the components (Fig. 69) with cleaning
solvent.
Use compressed air to blow out the oil passages in
the rocker arms and push rods.
INSPECTION
Inspect the pivot surface area of each rocker arm.
Replace any that are scuffed, pitted, cracked or
excessively worn.
Inspect the valve stem tip contact surface of each
rocker arm and replace any rocker arm that is deeply
pitted.
Inspect each push rod end for excessive wear and
replace as required. If any push rod is excessively
worn because of lack of oil, replace it and inspect the
corresponding hydraulic tappet for excessive wear.
Inspect the push rods for straightness by rolling
them on a flat surface or by shining a light between
the push rod and the flat surface.
A wear pattern along the length of the push rod is
not normal. Inspect the engine cylinder head for
obstruction if this condition exists.
Fig. 66 Liner Clamp Location
Fig. 67 Flywheel
Fig. 68 Crankshaft Seal
9 - 74 ENGINENS/GS
DISASSEMBLY AND ASSEMBLY (Continued)