1996 CHRYSLER VOYAGER servo

2.4L ENGINE
INDEX
page page
DESCRIPTION AND OPERATION
ENGINE COMPONENTS.................. 15
ENGINE IDENTIFICATION................. 14
ENGINE LUBRICATION SYSTEM............ 14
DIAGNOSIS AND TESTING
CHECKING ENGINE OIL PRESSURE......... 16
SERVICE PROCEDURES
CRANKSHAFT END PLAY................. 20
FITTING CONNECTING ROD BEARINGS..... 18
FITTING MAIN BEARINGS................. 19
FITTING PISTON RINGS.................. 16
FITTING PISTONS....................... 16
VALVE SERVICE RECONDITION............ 21
REMOVAL AND INSTALLATION
BALANCE SHAFTS CARRIER ASSEMBLY..... 30
CAMSHAFT FOLLOWER.................. 30
CAMSHAFT OIL SEALÐFRONT............. 41
CAMSHAFT............................ 28
CRANKSHAFT OIL SEALÐFRONT........... 42
CRANKSHAFT OIL SEALÐREAR............ 43
CRANKSHAFT.......................... 46
CYLINDER HEAD COVER................. 28
CYLINDER HEAD........................ 34
ENGINE ASSEMBLY...................... 26
ENGINE MOUNTÐFRONT................. 23
ENGINE MOUNTÐLEFT.................. 24
ENGINE MOUNTÐREAR.................. 25
ENGINE MOUNTÐRIGHT................. 24HYDRAULIC LASH ADJUSTER.............. 33
OILFILTER ............................ 47
OILPAN ............................... 45
OIL PUMP............................. 47
PISTON AND CONNECTING ROD........... 49
STRUCTURAL COLLAR................... 25
TIMING BELT COVER.................... 37
TIMING BELT TENSIONER ASSEMBLY....... 40
TIMING BELT........................... 37
VALVE SPRINGS AND
VALVE SEALS IN VEHICLE............... 33
VALVES AND VALVE SPRINGS............. 35
VIBRATION DAMPER.................... 36
DISASSEMBLY AND ASSEMBLY
OIL PUMP............................. 50
CLEANING AND INSPECTION
OIL PUMP............................. 52
CRANKSHAFT.......................... 52
CYLINDER BLOCK....................... 54
CYLINDER HEAD........................ 51
VALVE AND VALVE SPRING................ 51
ADJUSTMENTS
ENGINE MOUNTS....................... 54
SPECIFICATIONS
2.4L ENGINE........................... 55
TORQUE CHART 2.4L.................... 57
SPECIAL TOOLS
2.4L ENGINE........................... 58
DESCRIPTION AND OPERATION
ENGINE IDENTIFICATION
The engine identification number is located on the
rear of the cylinder block (Fig. 1).
ENGINE LUBRICATION SYSTEM
OIL PAN
A structural die cast aluminum oil pan provides
lower engine protection as well as serving as the
engine oil reservoir. Oil pan is attached to block and
sealed with a gasket. The oil pickup tube has a
strainer and cover.
PRESSURE LUBRICATION
Oil drawn up through the pickup tube is pressur-
ized by the pump and routed through the full flow fil-
ter to the main oil gallery running the length of thecylinder block. Oil pickup, pump and check valve pro-
vide oil flow to the main oil gallery.
MAIN/ROD BEARINGS
A diagonal hole in each bulkhead feeds oil to each
main bearing. Drilled passages within the crankshaft
route oil from main bearing journals to connecting
rod journals.
CAMSHAFT/HYDRAULIC LASH ADJUSTERS
A vertical hole at the number five bulkhead routes
pressurized oil through a restrictor up past a cylin-
der head bolt to an oil gallery running the length of
the cylinder head. The camshaft journals are par-
tially slotted to allow a predetermined amount of
pressurized oil to pass into the bearing cap cavities
with small holes directed to spray lubricate the cam-
shaft lobes.
9 - 14 2.4L ENGINENS

(2) Tighten mount to transmission bolts to 55 N´m
(40 ft. lbs.) (Fig. 22).
Tighten through bolt to 75 N´m (55 ft. lbs.)
(3) Engine mount adjustment, Refer to Engine
Mount Insulator Adjustment of this section.
REAR MOUNT
(1) Raise vehicle on hoist.
(2) Support the transmission with a transmission
jack so it will not rotate.
(3) Remove the insulator through bolt from the
mount and rear suspension crossmember.
(4) Remove the four transmission mount fasteners
and remove the mount.
(5) Reverse the removal procedure for installation.
Refer to (Fig. 23).
ENGINE MOUNT RUBBER INSULATORS
Insulator location on (right side) is adjustable to
allow right/left drive train adjustment in relation to
driveshaft assembly length. See Engine Mount
Adjustments in this section.
Check and reposition right engine mount insulator.
Adjust drive train position, if required, for the follow-
ing conditions:
²Driveshaft distress: See Group 2, Suspension
and Driveshafts.
²Any front end structural damage (after repair).
²Insulator replacement.
ENGINE ASSEMBLY
REMOVAL
(1) Perform fuel pressure release procedure. Refer
to Group 14, Fuel System for procedure. Remove fuel
line to fuel rail.
(2) Disconnect battery.
(3) Remove Air cleaner and hoses.
(4) Remove battery cover, battery and battery tray,
with integral vacuum reservoir, from vehicle.
(5) Block off heater hoses to rear heater assembly,
if equipped.
(6) Drain cooling system. Refer to Group 7, Cooling
System for procedure.
(7) Disconnect heater hoses.
(8) Remove fan module and radiator. Refer to
Group 7, Cooling System for procedure.
(9) Disconnect transmission shift linkage.
(10) Disconnect throttle body linkage and vacuum
hoses from throttle body.
(11) Remove accessory drive belts. Refer to Acces-
sory Drive System located in Group 7, Cooling Sys-
tem for procedure.
(12) Remove air conditioning compressor from
engine and set it aside.
(13) Disconnect generator wiring harness and
remove generator.
(14) Hoist vehicle and remove axle shafts. Refer to
Group 2, Driveshaft for procedure.
(15) Remove right and left inner splash shields.
(16) Disconnect exhaust pipe from manifold.
(17) Remove front engine mount and bracket as an
assembly.
(18) Remove rear transmission mount and bracket.
(19) Remove power steering pump and bracket
assembly.
(20) Remove wiring harness and connectors from
front of engine.
(21) Remove bending braces and install tool num-
ber 6910 on engine.
(22) Remove trans inspection cover and mark flex-
plate to torque converter.
(23) Remove driveplate to torque converter bolts.
(24) Lower the vehicle.
Fig. 22 Engine MountÐLeft
Fig. 23 Engine MountÐRear
NS3.0L ENGINE 9 - 69
REMOVAL AND INSTALLATION (Continued)

ENGINE MOUNT RUBBER INSULATORS
Insulator location on (right side) is adjustable to
allow right/left drive train adjustment in relation to
drive shaft assembly length.
Check and reposition right engine mount insulator.
See Adjustments in this section. Adjust drive train
position, if required, for the following conditions:
a. Drive shaft distress. See Group 2, Suspension
and Driveshafts.
b. Any front end structural damage (after repair).
c. Insulator replacement.
ENGINE ASSEMBLY
REMOVAL
(1) Perform fuel pressure release procedure. Refer
to group 14 fuel system for procedure. Remove fuel
line to fuel rail.
(2) Disconnect battery.
(3) Remove air cleaner and hoses.
(4) Remove battery cover, battery and battery tray,
with integral vacuum reservoir, from vehicle.
(5) Block off heater hoses to rear heater assembly,
if equipped.
(6) Drain cooling system. Refer to Group 7, Cooling
System for procedure.
(7) Disconnect heater hoses.
(8) Remove fan module and radiator. Refer to
Group 7 Cooling System for procedure.
(9) Disconnect transmission shift linkage.
(10) Disconnect throttle body linkage and vacuum
hoses from throttle body.
(11) Remove accessory drive belts. Refer to Group
7, Accessory Drive Belts located in Cooling System
for procedure.
(12) Remove air conditioning compressor from
engine and set it aside.
(13) Disconnect generator wiring harness and
remove generator.
(14) Hoist vehicle and remove right and left inner
splash shields.
(15) Remove crossmember cradle plate (Fig. 27).
(16) Remove axle shafts. Refer to Group 3, Differ-
ential and Driveline for procedure.
(17)(AWD equipped)Mark orientation and sepa-
rate propeller shaft from power transfer unit. Refer
to Group 3, Differential and Driveline for procedure.
(18) Disconnect exhaust pipe from manifold.
(19) Remove front engine mount and bracket as an
assembly.
Fig. 25 Engine MountingÐLeft
Fig. 26 Engine MountingÐRear
Fig. 27 Crossmember Cradle Plate
9 - 104 3.3/3.8L ENGINENS
REMOVAL AND INSTALLATION (Continued)

ENGINE ASSEMBLY
REMOVAL
(1) Disconnect the battery.
(2) Remove the air cleaner assembly and inlet
hose.
(3) Remove both hoses at intercooler and engine.
(4) Disconnect EGR vacuum hose.
(5) Disconnect brake booster vacuum hose.
(6) Disconnect oil pressure switch connector (Fig.
19).
(7) Disconnect Wiring harness bracket at transaxle
shift tower.
(8) Disconnect transaxle wiring at speed sensor,
crank sensor, and backup light switch.
(9) Remove both transmission shift cables at trans-
mission.
(10) Remove negative battery cable at cylinder
block (Fig. 19).
(11) Remove oil separator.
(12) Remove connectors at coolant temperature
sensor and A/C compressor.
(13) Disconnect fuel injection pump wiring connec-
tors (Fig. 19).
(14) Disconnect glow plug connectors.
(15) Disconnect electrical connector at number 1
fuel injector.
(16) Raise vehicle on hoist.
(17) Remove right side splash shield (Fig. 20).
WARNING: THE COOLANT IN A RECENTLY OPER-
ATED ENGINE IS HOT AND PRESSURIZED. USE
CARE TO PREVENT SCALDING BY HOT COOLANT.CAREFULLY RELEASE THE PRESSURE BEFORE
REMOVING THE RADIATOR DRAIN COCK AND CAP.
(18) Drain the cooling system (refer to Group 7,
Cooling).
(19) Lower vehicle.
(20) Remove Coolant pressure bottle and discon-
nect low coolant level sensor.
(21) Disconnect both heater hoses.
(22) Remove the lower radiator hose.
(23) Remove the upper radiator hose.
(24) Remove fuel line at injector pump and cap.
(25) Remove power steering reservoir and reposi-
tion.
(26) Remove upper radiator crossmember.
(27) Disconnect cooling fan module connector.
Fig. 18 Shift Cables at Rear MountFig. 19 Component Locations
Fig. 20 Right Side Splash Shield
NS/GSENGINE 9 - 53
REMOVAL AND INSTALLATION (Continued)

(6) Remove vacuum lines for purge solenoid and
PCV valve at intake manifold (Fig. 7).
(7) Remove vacuum lines for power brake booster
and speed control vacuum reservoir at upper intake
manifold fittings (Fig. 8).
(8) Remove throttle cable and speed control cable
(if equipped) from throttle lever (Fig. 9).
(9) Remove throttle cables from bracket by com-
pressing retaining tabs.
(10) Remove two top bolts from intake manifold to
rear support bracket and spacer (Fig. 10).
(11) Remove upper bolt from intake manifold to
front support bracket (Fig. 11).
(12) Remove dipstick.
(13) Remove dipstick tube.
CAUTION: Moving the dipstick tube will cause dam-
age to the sealer, causing an oil leak. Dipstick tube
must be sealed at cylinder block.
(14) Remove upper intake manifold bolts. Remove
upper intake manifold.CAUTION: Cover intake manifold to prevent foreign
material from entering engine.
Fig. 6 Throttle Body Electrical Connectors
Fig. 7 Vacuum Line Connections
Fig. 8 Vacuum Fitting at Rear of Upper Intake
Manifold
Fig. 9 Throttle Cable Attachment to Throttle Body
Fig. 10 Intake Manifold Rear Support Bracket
NSEXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 5
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Install new upper intake manifold gasket.
NOTE: Center outboard fastener is a double stud.
(2) Tighten upper intake manifold fasteners start-
ing at center and progressing outward in both direc-
tions. Tighten bolts to 28 N´m (250 in. lbs.). Repeat
this procedures until all fasteners are at specified
torque.
(3) Install dipstick tube. Seal tube to cylinder
block using MopartStud N' Bearing Mount Adhe-
sive. Tighten dipstick tube fastener to 12 N´m (105
in. lbs.)
(4) Install dipstick.
(5) Install upper bolt in intake manifold to front
support bracket (Fig. 11). Torque to 28 N´m (250 in.
lbs.).
(6) Install two top bolts at intake manifold to rear
support bracket making sure bracket to manifold
spacer is in place (Fig. 10). Tighten bolts to 28 N´m
(250 in. lbs.)
(7) Install throttle cables in bracket.
(8) Install throttle cable and speed control cable (if
equipped) to throttle lever.
(9) Install vacuum lines for power brake booster
and speed control vacuum reservoir at upper intake
manifold fittings.
(10) Install vacuum lines for purge solenoid and
PCV valve.
(11) Install electrical connectors for MAP sensor,
throttle position sensor, and idle air control motor.(12) Install air intake tube and resonator box to
throttle body.
(13) Connect negative cable to battery.
INTAKE MANIFOLD LOWERÐ2.4L ENGINE
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL SYSTEM COMPONENTS.
SERVICE VEHICLES IN WELL VENTILATED AREAS
AND AVOID IGNITION SOURCES. NEVER SMOKE
WHILE SERVICING THE VEHICLE
To release fuel pressure, refer to the Fuel Delivery
System Pressure Release section of Group 14 Fuel
System for procedure.
REMOVAL
(1) Perform fuel system pressure release proce-
durebefore attempting any repairs.
(2) Remove upper intake manifold. Refer to proce-
dure in this section.
CAUTION: Cover intake manifold to prevent foreign
material from entering engine.
(3) Disconnect electrical connector from intake air
temperature sensor (Fig. 12).
(4) Remove fuel hose quick connect fitting from
the chassis tube (Fig. 13).Refer to Fuel Hoses,
Clamps and Quick Connect Fittings in the Fuel
Delivery Section of this Group.
WARNING: WRAP A SHOP TOWEL AROUND
HOSES TO CATCH ANY GASOLINE SPILLAGE.
Fig. 11 Intake Manifold Front Support Bracket and
Map Sensor
Fig. 12 Intake Air Temperature Sensor
11 - 6 EXHAUST SYSTEM AND INTAKE MANIFOLDNS
REMOVAL AND INSTALLATION (Continued)

FUEL DELIVERY SYSTEM
INDEX
page page
DESCRIPTION AND OPERATION
FUEL DELIVERY SYSTEM.................. 4
FUEL INJECTORS........................ 5
FUEL LEVEL SENSOR..................... 5
FUEL PRESSURE REGULATOR.............. 5
FUEL PUMP MODULE..................... 4
FUEL TANK............................. 5
PRESSURE-VACUUM FILLER CAP........... 6
QUICK-CONNECT FITTINGS................ 6
DIAGNOSIS AND TESTING
FUEL INJECTORS........................ 9
FUEL LEVEL SENSOR..................... 9
FUEL PUMP PRESSURE TEST 2.4/3.3/3.8L..... 6
SERVICE PROCEDURES
FUEL SYSTEM PRESSURE RELEASE
PROCEDUREÐ2.4/3.3/3.8L............... 11
FUEL SYSTEM PRESSURE RELEASE
PROCEDUREÐ3.0L ENGINE............. 11
HOSES AND CLAMPS.................... 12QUICK-CONNECT FITTINGS............... 12
REMOVAL AND INSTALLATION
ACCELERATOR PEDAL................... 26
FUEL FILTER........................... 12
FUEL INJECTOR RAILÐ2.4L............... 18
FUEL INJECTOR RAILÐ3.0L............... 19
FUEL INJECTOR RAILÐ3.3/3.8L............ 21
FUEL INJECTORSÐ3.0L.................. 25
FUEL INJECTORÐ2.4L................... 24
FUEL INJECTORÐ3.3/3.8L................. 26
FUEL LEVEL SENSOR.................... 15
FUEL PRESSURE REGULATOR............. 14
FUEL PUMP INLET STRAINER............. 15
FUEL PUMP MODULE.................... 13
FUEL TANK............................ 17
THROTTLE CABLE...................... 27
SPECIFICATIONS
FUEL TANK CAPACITY................... 28
TORQUE.............................. 28
DESCRIPTION AND OPERATION
FUEL DELIVERY SYSTEM
The front wheel drive van uses a plastic fuel tank
located on the left side of the vehicle.
The Fuel Delivery System consists of: the electric
fuel pump module, fuel filter, tubes/lines/hoses, fuel
rail, and fuel injectors.
The in-tank fuel pump module contains the fuel
pump and pressure regulator. The pump is serviced
as part of the fuel pump module. Refer to Fuel Pump
Module.
The fuel filter is a replaceable in-line filter. The fil-
ter attaches to a bracket mounted on top of the fuel
tank. Refer to the Maintenance Schedules in the
Introduction section of this manual for recommended
fuel filter replacement intervals.
A returnless fuel system is used on all vehicles.
Fuel is returned through the fuel pump module and
back to the fuel tank. A separate fuel return line
from the tank to the engine is no longer used.
FUEL PUMP MODULE
The fuel pump module is installed in the top of the
fuel tank (Fig. 1). The fuel pump module contains the
following:
²Electric fuel pump
²Fuel pump reservoir
²Inlet strainer²Fuel pressure regulator
²Fuel gauge sending unit
²Fuel supply line connection
The inlet strainer, fuel pressure regulator
and fuel level sensor are the only serviceable
items. If the fuel pump or electrical wiring har-
ness requires service, replace the fuel pump
module.
ELECTRIC FUEL PUMP
The electric fuel pump is located in and is part of
the fuel pump module. It is a positive displacement,
gerotor type, immersible pump with a permanent
magnet electric motor. The pump draws fuel through
a strainer and pushes it through the motor to the
outlet. The pump contains one check valve. The
Fig. 1 Fuel Pump Module
14 - 4 FUEL SYSTEMNS

WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE DISCONNECTING QUICK-CONNECT FIT-
TINGS AT FUEL FILTER. REFER TO THE FUEL
PRESSURE RELEASE PROCEDURE.
REMOVAL
(1) Perform fuel system pressure release.
(2) Disconnect quick-connect fittings from fuel
pump module and chassis fuel supply tube. Refer to
Quick-Connect Fittings in this section.
(3) Remove filter retaining screw (Fig. 13) and
remove filter from tank.
INSTALLATION
(1) Install fuel filter to tank.
(2) The fuel supply (to filter) tube, return tube (to
pump module) and fuel supply (to chassis fuel line)
are permanently attached the fuel filter. The ends of
the fuel supply and return tubes have different size
quick-connect fittings.
(3) Apply a light coating of clean 30 weight engine
oil to the fuel filter nipples. Install fuel tubes. Refer
to Fuel Tubes and Quick-Connect Fittings in this sec-
tion.
FUEL PUMP MODULE
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL SYSTEM COMPONENTS.
SERVICE VEHICLES IN WELL VENTILATED AREAS
AND AVOID IGNITION SOURCES. NEVER SMOKE
WHILE SERVICING THE VEHICLE.
WARNING: THE FUEL RESERVOIR OF THE FUEL
PUMP MODULE DOES NOT EMPTY OUT WHEN THE
TANK IS DRAINED. THE FUEL IN THE RESERVOIR
WILL SPILL OUT WHEN THE MODULE IS
REMOVED.
REMOVAL
(1) Remove fuel filler cap and perform Fuel Sys-
tem Pressure Release procedure.
(2) Disconnect negative cable from battery.
(3) Insert fuel siphon hose into fuel filler neck and
push it into the tank.
(4) Drain fuel tank dry into holding tank or a
properly labeledGASOLINEsafety container.
(5) Raise vehicle on hoist.
(6) Use a transmission jack to support the fuel
tank. Remove bolts from fuel tank straps. Lower
tank slightly.
(7) Clean area around fuel tank module and tank
to keep dirt and foreign material out of tank.
(8) Disconnect fuel lines from fuel pump module by
depressing quick connect retainers with thumb and
fore finger (Fig. 14).
(9) Slide fuel pump module electrical connector
lock to unlock.
(10) Push down on connector retainer (Fig. 15) and
pull connector off module.
Fig. 13 Fuel Filter
Fig. 14 Fuel Line Retainers and Pump Connector
Lock
Fig. 15 Pump Module Connector Retainer and Lock
NSFUEL SYSTEM 14 - 13
REMOVAL AND INSTALLATION (Continued)