1996 CHRYSLER VOYAGER weight

(25) Remove ground straps to body.
(26) Raise vehicle enough to allow engine dolly
Special Tool 6135 and cradle Special Tool 6710 with
post Special Tool 6848 and adaptor Special Tool 6909
to be installed under vehicle (Fig. 24).
(27) Loosen cradle engine mounts to allow move-
ment for positioning onto engine locating holes on the
engine. 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.
(28) Lower vehicle so the weight ofONLY THE
ENGINE AND TRANSMISSIONis on the cradle.
(29) Remove right engine mount assembly and left
transmission mount through bolt. Refer to Engine
Mounts Section of this Group.
(30) Raise vehicle slowly. It may be necessary to
move the engine/transmission assembly on the cradle
to allow for removal around body flanges.
INSTALLATION
(1) Position engine and transmission assembly
under vehicle and slowly lower the vehicle over the
engine and transmission. It may be necessary to
move the engine/transmission assembly with the cra-
dle for clearance around body flanges.
(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, 6710,
6848 and 6909.
(4) Remove Special tools 6910 and install bending
braces.
(5) Lower vehicle. Install generator and wiring
harness.
(6) Connect wiring harness on the front of the
engine.
(7) Install Air Conditioning Compressor.
(8) Install power steering pump and bracket and
accessory drive belt. Refer to Group 7. Accessory
Drive Belts Section for installation procedure.
(9) Raise vehicle and install axle shafts. Refer to
Group 2, Driveshafts for procedure.
(10) Install transmission and engine mount and
bracket assemblies. Refer to Engine Mounts in this
section for procedure.
(11) Connect exhaust system to manifold. Refer to
Group 11, Exhaust System and Intake Manifold for
procedure and torque specifications.
(12) Install left and right inner splash shields.
(13) Connect automatic transmission shifter link-
age. Refer to Group 21, Transmission for procedures.
(14) Lower vehicle and connect fuel line and
heater hoses. Remove plugs from rear heater hoses
and install, if equipped.
(15) Install ground straps. Connect engine and
throttle body connections and harnesses.
(16) Connect throttle body linkage. Refer to Group
14, Fuel System for procedure.
(17) Install radiator and fan module assembly.
Install radiator hoses. Fill cooling system. Refer to
Group 7, Cooling for procedures.
(18) Install battery tray, battery and cover.
(19) Install air cleaner and hoses.
(20) Install oil filter. Fill engine crankcase with
proper oil to correct level.
(21) Start engine and run until operating temper-
ature is reached.
(22) Adjust transmission linkage, if necessary.
CYLINDER HEAD COVER
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove air inlet resonator when removing left
head cover.
(3) When Removing left cylinder head cover,
remove dipstick tube.
(4) When removing right cylinder head cover
remove wiper unit. Refer to Wiper Unit Removal in
Group 8K.
(5) When removing right cylinder head cover,
remove accessory drive belt. Refer to Accessory Drive
Belt Removal in Group 7.
Fig. 24 Positioning Engine Cradle Support Post
MountsÐTypical
9 - 70 3.0L ENGINENS
REMOVAL AND INSTALLATION (Continued)

crankshaft seal, provides front oil pan closure, water
pump mounting.
CYLINDER HEADS:Cylinder heads are designed
to create high flow combustion chambers to improve
performance, while minimizing the change to the
burn rate of the chamber. Valve seat and guides are
inserts. A steel flanged composition type gasket is
used between head and block.
CYLINDER HEAD COVERS:The covers are
sealed with steel reinforced silicon rubber gaskets.INTAKE MANIFOLD:The intake manifold is a
tuned two-piece semi-permanent mold aluminum
casting with individual primary runners leading from
a plenum to the cylinders. The manifold is designed
to boost torque in the 3600 rpm range and contrib-
utes to the engine's broad, flat torque curve, which
was desired for excellent engine tractability, response
and usable power output.
The intake manifold is also cored with upper level
EGR passages for balanced cylinder to cylinder EGR
distribution.
VALVE TRAIN:Valve train design incorporates
the use of hydraulic roller tappets. Rocker arms are
installed on a rocker arm shaft attached to the cylin-
der head with four bolts and retainers. Viton valve
stem seals provide valve sealing. Conventional type
pushrods, retainers and valve stem locks are used.
Unique beehive style valve spring are used with
lightweight retainers for improved high RPM perfor-
mance.
EXHAUST MANIFOLDS:Exhaust manifolds are
log type with a crossover and is attached directly to
the cylinder heads.
DIAGNOSIS AND TESTING
HYDRAULIC TAPPETS
The valve train includes roller tappet assemblies,
aligning yokes and yoke retainer.
Roller tappet alignment is maintained by machined
flats on tappet body being fitted in pairs into six
Fig. 2 Engine Oiling System
Fig. 1 Engine Identification
9 - 94 3.3/3.8L ENGINENS
DESCRIPTION AND OPERATION (Continued)

(20) Remove rear transmission mount and bracket.
(21) Remove power steering pump and bracket
assembly.
(22) Remove wiring harness and connectors from
front of engine.
(23) Remove bending braces and install tool num-
ber 6912 on engine.
(24) Remove transmission inspection cover and
mark flexplate to torque converter.
(25) Remove driveplate to torque converter bolts.
(26) Lower the vehicle.
(27) Remove ground straps to body.
(28) Raise vehicle enough to allow engine dolly
Special Tool 6135 and cradle Special Tool 6710 with
post Special Tool 6848 and adaptor Special Tool 6909
to be installed under vehicle (Fig. 28).
(29) Loosen cradle engine mounts to allow move-
ment for positioning onto engine locating holes on the
engine. 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.
(30) Lower vehicle so the weight ofONLY THE
ENGINE AND TRANSMISSIONis on the cradle.
(31) Remove right engine mount assembly and left
transmission mount through bolt. Refer to Engine
Mounts Section of this Group.
(32) Raise vehicle slowly. It may be necessary to
move the engine/transmission assembly on the cradle
to allow for removal around body flanges.INSTALLATION
(1) Position engine and transmission assembly
under vehicle and slowly lower the vehicle over the
engine and transmission. It may be necessary to
move the engine/transmission assembly with the cra-
dle for clearance around body flanges.
(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, 6710,
6848 and 6909.
(4) Remove Special tools 6912 and install bending
braces.
(5) Lower vehicle. Install generator and wiring
harness.
(6) Connect wiring harness on the front of the
engine.
(7) Install Air Conditioning Compressor.
(8) Install power steering pump and bracket and
accessory drive belt. Refer to Accessory drive Section
Located in group 7 for installation procedure.
(9) Raise vehicle and install axle shafts. Refer to
Group 3, Differential and Driveline for procedure.
(10) Install transmission and engine mount and
bracket assemblies. Refer to Engine Mounts section
of this Group.
(11)(AWD equipped)Install propeller shaft to
power transfer unit. Refer to Group 3, Differential
and Driveline for procedure.
(12) Connect exhaust system to manifold. Refer to
Group 11, Exhaust System and Intake Manifold for
procedure and torque specifications.
(13) Install crossmember cradle plate (Fig. 27).
(14) Install left and right inner splash shields.
(15) Connect automatic transmission shifter link-
age. Refer to Group 21, Transmission for procedures.
(16) Lower vehicle and connect fuel line and
heater hoses. Remove plugs from rear heater hoses
and install, if equipped.
(17) Install ground straps. Connect engine and
throttle body connections and harnesses.
(18) Connect throttle body linkage. Refer to Group
14, Fuel System for procedure.
(19) Install radiator and fan module assembly.
Install radiator hoses. Fill cooling system. See Group
7 for filling procedure.
(20) Install battery tray, battery and cover.
(21) Install air cleaner and hoses.
(22) Install oil filter. Fill engine crankcase with
proper oil to correct level.
(23) Start engine and run until operating temper-
ature is reached.
(24) Adjust transmission linkage, if necessary.
Fig. 28 Positioning Engine Cradle Support Post
MountsÐTypical
NS3.3/3.8L ENGINE 9 - 105
REMOVAL AND INSTALLATION (Continued)

(3) Slowly rotate crankshaft clockwise, forcing out
upper half of bearing shell.
INSTALLATION
NOTE: Only one main bearing should be selec-
tively fitted while all other main bearing caps are
properly tightened.
When installing a new upper bearing shell, slightly
chamfer the sharp edges from the plain side.
(1) Start bearing in place, and insert Main Bearing
Tool C-3059 into oil hole of crankshaft (Fig. 64).
(2) Slowly rotate crankshaft counterclockwise slid-
ing the bearing into position. Remove Special Main
Bearing Tool C-3059.
(3) Install each main cap and tighten bolts finger
tight.
(4) Tighten number 1, 3 and 4 main cap bolts to 41
N´m + 1/4 Turn (30 ft. lbs.+ 1/4 Turn).(5) Rotate the crankshaft until number 6 piston is
at TDC.
(6) To ensure correct thrust bearing alignment the
following procedure must be done:
a. Move crankshaft all the way to the rear of its
travel.
b. Then, move crankshaft all the way to the front
of its travel.
c. Wedge a appropriate tool between the rear of
the cylinder block and rear crankshaft counter-
weight. This will hold the crankshaft in it's most for-
ward position.
d. Tighten the #2 Thrust Bearing cap bolts to 41
N´m + 1/4 Turn (30 ft. lbs.+ 1/4 Turn). Remove the
holding tool.
(7) Install oil pan.
(8) Fill engine crankcase with proper oil to correct
level.
CRANKSHAFT OIL SEALÐFRONT
REMOVAL
(1) Disconnect negative cable from battery.
(2) Raise vehicle on hoist. Remove right wheel and
inner splash shield.
(3) Remove drive belt. Refer to Group 7, Cooling
System for procedure.
(4) Remove crankshaft damper (Fig. 65).
(5) Using Tool 6341A to remove oil seal (Fig. 66).
Be careful not to damage that crankshaft seal sur-
face of cover.
INSTALLATION
(1) Install new seal by using Tool C-4992 (Fig. 67).
(2) Place seal into opening with seal spring
towards the inside of engine. Install seal until flush
with cover.
(3) Install crankshaft pulley using plate L-4524.
Thrust Bearing/washer and 5.9 inch screw (Fig. 68).
Fig. 63 Main Bearing Identification
Fig. 64 Removing and Installing Upper Main Bearing
With Special Tool C-3059
Fig. 65 Crankshaft DamperÐRemoval
NS3.3/3.8L ENGINE 9 - 117
REMOVAL AND INSTALLATION (Continued)

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.
SPECIFICATIONS
3.3/3.8L ENGINE
Type.........................60É V-6 Engine
Bore±3.3L..................93.0 mm (3.66 in.)
Bore±3.8L.................96.0 mm (3.779 in.)
Stroke±3.3L...............81.0 mm (3.188 in.)
Stroke±3.8L...............87.0 mm (3.425 in.)
Compression Ratio±3.3L.................8.9:1
Compression Ratio±3.8L.................9.6:1
Displacement±3.3L..........3.3L (201 Cubic in.)
Displacement±3.8L..........3.8L (231 Cubic in.)
Brake Horsepower±3.3L........158 @ 4850 RPM
Brake Horsepower±3.8L........180 @ 4400 RPM
Torque±3.3L............203 lb. ft. @ 3600 RPM
Torque±3.8L............240 lb. ft. @ 3600 RPM
Firing Order....................1±2±3±4±5±6
Compression Pressure.Refer to Engine Performance
in Standard Service Procedures.
Cylinder Number (Front to Rear)
Front Bank...........................2,4,6
Rear Bank............................1,3,6
Cylinder Block
Cylinder Bore (Standard)±3.3L.........93.0 mm
(3.66 in.)
Cylinder Bore (Standard)±3.8L.........96.0 mm
(3.779 in.)
Out-of-Round (Max.)........0.076 mm (0.003 in.)
Taper (Max.)..............0.051 mm (0.002 in.)
Cylinder Bore Oversize (Max.).........0.508 mm
(0.020 in.)
Tappet Bore Diameter.....22.9896 - 23.0099 mm
(0.9051 - 0.9059 in.)
Pistons
Type Material.......Aluminum Alloy Tin Coated
Clearance at Size Location......0.025 - 0.057 mm
(0.001 - 0.0022 in.)
Weight (Standard Only)±3.3L......38165 grams
(13.439460.1764 oz.)
Weight (Standard Only)±3.8L......43865 grams
(15.450160.1764 oz.)
Pistons for Service..............Standard Only
Piston Pins
Type .......................Press Fit in Rod
(Serviced as an Assembly)
Diameter.........................22.88 mm
(0.9009 - 0.9007 in.)
Length±3.3L................67.25 - 67.75 mm
(2.648 - 2.667 in.)
Lenth±3.8L.................71.25 - 71.75 mm
(2.805 - 2.824 in.)
Clearance in Piston @ 70É......0.006 - 0.019 mm
(0.0002 - 0.0007 in.)
Clearance in Rod................(Interference)
CYLINDER BORE AND PISTON
SPECIFICATION CHART
EngineStandard
BoreMaximum
Out-Of-
RoundMaximum
Taper
3.3L 92.993 -
93.007 mm0.076 mm 0.51 mm
(3.661 -
3.6617 in.)(0.003 in.) (0.002 in.)
3.8L 95.993 -
96.007 mmSame Same
3.7792 -
3.780 in.
Standard Piston Size
3.3L 92.950 - 92.968 mm
(3.6594 - 3.6602 in.)
3.8L 95.950 - 95.968 mm
(3.7776 - 3.7783 in.)
Piston to Bore Clearance: 0.025 - 0.057 mm
(0.0009 - 0.0022 in.)
Measurements taken at Piston Size Location.
NS3.3/3.8L ENGINE 9 - 123
CLEANING AND INSPECTION (Continued)

SPLASH LUBRICATION
Oil returning to the pan from pressurized compo-
nents supplies lubrication to the valve stems. Cylin-
der bores and wrist pins are splash lubricated from
directed slots on the connecting rod thrust collars.
ENGINE COMPONENTS
CYLINDER BLOCK AND BEDPLATE ASSEM-
B LY:A partial open deck is used for cooling and
weight reduction with water pump molded into the
block. Nominal wall thickness is 4 mm. The bedplate
incorporates main bearing caps. Rear seal retainer is
integral with the block.
CRANKSHAFT:A nodular cast iron crankshaft is
used. The engine has 5 main bearings, with number
3 flanged to control thrust. The 52 mm diameter
main and 48 mm diameter crank pin journals (all)
have undercut fillet radiuses that are deep rolled for
added strength. To optimize bearing loading 8 coun-
terweights are used. Hydrodynamic seals provide end
sealing, where the crankshaft exits the block.
Anaerobic gasket material is used for parting line
sealing. A sintered iron timing belt sprocket is
mounted on the crankshaft nose. This sprocket trans-
mits crankshaft movement, via timing belt to the
camshaft sprocket providing timed valve actuation.
PISTONS:The SOHC EngineDOES NOThave
provision for a free wheeling valve train. Non free
wheeling valve train means, in the event of a broken
timing belt Pistons will contact the Valves. All
engines use pressed-in piston pins to attach forged
powdered metal connecting rods. The connecting rods
are a cracked cap design and are not repairable. Hexhead cap screw are used to provide alignment and
durability in the assembly. Pistons And Connecting
rods are serviced as an assembly.
PISTON RINGS:The piston rings include a
molybdenum faced top ring for reliable compression
sealing and a taper faced intermediate ring for addi-
tional cylinder pressure control. Oil Control Ring
Package consist of 2 steel rails and a expander
spacer.
CYLINDER HEADÐSOHC:It features a Single
Over Head Camshaft, four-valves per cylinder cross
flow design. The valves are arranged in two inline
banks, with the two intake per cylinder facing
toward the radiator. The exhaust valves facing
toward the dash panel. Rocker arm shafts mount
directly to the cylinder head. It incorporates powder
metal valve guides and seats. The hollow rocker arm
shafts supplies oil to the hydraulic lash adjusters,
camshaft and valve mechanisms.
CAMSHAFTÐSOHC:The nodular iron camshaft
has five bearing journals and 3 cam lobes per cylin-
der. Provision for cam position sensor on the cam at
the rear of cylinder head which also acts as thrust
plate. A hydrodynamic oil seal is used for oil control
at the front of the camshaft.
VALVESÐSOHC:Four valves per cylinder are
actuated by roller rocker arms/hydraulic lash adjust-
ers assemblies which pivot on rocker arm shafts. All
valves have 6 mm diameter chrome plated valve
stems. The valve train has 33 mm (1.299 inch) diam-
eter intake valves and 28 mm (1.10 inch) diameter
exhaust valves. Viton rubber valve stem seals are
integral with spring seats. Valve springs, spring
retainers, and locks are conventional design.
INTAKE MANIFOLD:The intake manifold is a
molded plastic composition, attached to the cylinder
head with ten fasteners. This long branch design
enhances low and mid-range torque.
EXHAUST MANIFOLD:The exhaust manifold is
made of nodular cast iron for strength and high tem-
peratures. Exhaust gasses exit through a machined,
articulated joint connection to the exhaust pipe.
DIAGNOSIS AND TESTING
CHECKING ENGINE OIL PRESSURE
(1) Remove oil pressure switch and install gauge
assembly C-3292 with adaptor.
(2) Run engine until thermostat opens.
CAUTION: If oil pressure is 0 at idle, Do Not per-
form the 3000 RPM test in the next step.
(3) Oil Pressure:Curb Idle25 kPa (4 psi) mini-
mum3000 RPM170-550 kPa (25-80 psi).
Fig. 2 Engine Lubrication SystemÐ SOHC
NS/GSENGINE 9 - 3
DESCRIPTION AND OPERATION (Continued)

filter on until gasket contacts base. Tighten to 21
N´m (15 ft. lbs.).
OIL PUMP
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove Timing Belt. Refer to Timing Belt Sys-
tem, in this section.
(3) Remove Oil Pan. Refer to Oil Pan Removal in
this section.
(4) Remove Crankshaft Sprocket using Special Tool
6793 and insert C-4685-C2 (Fig. 70).
(5) Remove oil pick-up tube.
(6) Remove oil pump (Fig. 71) and front crankshaft
seal.
INSTALLATION
(1) Make sure all surfaces are clean and free of oil
and dirt.(2) Apply MopartGasket Maker to oil pump as
shown in (Fig. 72). Install o±ring into oil pump body
discharge passage.
(3) Prime oil pump before installation.
(4) Align oil pump rotor flats with flats on crank-
shaft as you install the oil pump to the block.
NOTE: Front crankshaft seal MUST be out of pump
to align, or damage may result.
(5) Torque all oil pump attaching bolts to 28 N´m
(250 in. lbs.)
(6) Install new front crankshaft seal using Special
Tool 6780 (Fig. 73).
(7) Install crankshaft sprocket, using Special Tool
6792 (Fig. 74).
(8) Install oil pump pick-up tube and oil pan.
(9) Install Timing Belt. Refer to procedure outlined
in this section.
(10) Connect negative cable to battery.
PISTON AND CONNECTING ROD
REMOVAL
(1) Remove top ridge of cylinder bores with a reli-
able ridge reamer before removing pistons from cyl-
inder block.Be sure to keep tops of pistons
covered during this operation. Mark piston with
matching cylinder number (Fig. 75).
(2) Remove oil pan. Scribe the cylinder number on
the side of the rod and cap (Fig. 76) for identification.
(3) Pistons will have a stamping in the approxi-
mate location shown in (Fig. 75). These stamps will
be either a directional arrow or a weight identifica-
tion for the assembly. L is for light and H is for
heavy. These assemblies should all be the same
weight class. Service piston assemblies are marked
with a S and can be used with either L or H produc-
tion assemblies. The weight designation stamps
should face toward the timing belt side of the engine.
(4) Pistons and connecting rods must be removed
from top of cylinder block. Rotate crankshaft so that
each connecting rod is centered in cylinder bore.
(5) Remove connecting rod cap boltsDo not use
old bolts if reinstalling connecting rod.Push
each piston and rod assembly out of cylinder bore.
NOTE: Be careful not to nick crankshaft journals.
(6) After removal, install bearing cap on the mat-
ing rod.
(7) Piston and Rods are serviced as an assembly.
PISTON RINGÐREMOVAL
(1) ID mark on face of upper and intermediate pis-
ton rings must point toward piston crown.
Fig. 69 Engine Oil Filter
Fig. 70 Crankshaft SprocketÐRemoval
NS/GSENGINE 9 - 25
REMOVAL AND INSTALLATION (Continued)

on the thrust direction. Staggering ring gap is impor-
tant for oil control.
PISTON AND ROD ÐINSTALLATION
(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.
(2) Before installing the ring compressor, make
sure the oil ring expander ends are butted and the
rail gaps located as shown in (Fig. 80).
(3) Immerse the piston head and rings in clean
engine oil, slide the ring compressor, over the piston
(Fig. 81).Be sure position of rings does not
change during this operation.
(4) The weight stamp designation L or H will be in
the front half of the piston should face toward the
front of the engine for SOHC engine. The arrow
should face toward the front of the engine for DOHC
engine (Fig. 75).
(5) Rotate crankshaft so that the connecting rod
journal is on the center of the cylinder bore. Insertrod and piston assembly into cylinder bore and guide
rod over the crankshaft journal.
(6) Tap the piston down in cylinder bore, using a
hammer handle. At the same time, guide connecting
rod into position on connecting rod journal.
(7) Install rod caps. InstallNewbolts and tighten
to 27 N´m (20 ft.lb.) Plus 1/4 turn.
VIBRATION DAMPER
NOTE: If a gap is found in the crankshaft damper,
in the area where the Poly-V Generator belt rides
this is normal and is acceptable (Fig. 82).
REMOVAL
(1) Remove accessory drive belts. Refer to Group 7,
Cooling System for procedure outlined in that sec-
tion.
(2) Remove crankshaft damper bolt. Remove
damper using the large side of Special Tool 1026 and
insert 6827±A (Fig. 83).
Fig. 80 Piston Ring End Gap Position
Fig. 81 Installing Piston
Fig. 82 Weld Gap
Fig. 83 Crankshaft DamperÐRemoval
9 - 28 ENGINENS/GS
REMOVAL AND INSTALLATION (Continued)