1996 CHRYSLER VOYAGER cooling

(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)

OIL PUMP
REMOVAL
1. Remove accessory drive belts. Refer to Accessory
Drive Belts Group 7, Cooling System.
2. Remove Timing Belt. Refer to procedure in this
section.
3. Remove 5 bolts that attach oil pump to block
(Fig. 66).
INSTALLATION
(1) Clean block and pump surfaces.
(2) Install new gasket (Fig. 67) make sure correct
length bolts are used (Fig. 66).
(3) Torque bolts to 13 N´m (120 in. lbs.).
OIL FILTER AND ADAPTOR
(1) Check the oil filter mounting surface. The sur-
face must be smooth, flat and free of debris or old
pieces of rubber (Fig. 68).
(2) Check adaptor for cracks and oil leaks.
CAUTION: When servicing the oil filter avoid
deforming the filter. Install the remove/install tool
band strap against the can-to-base lock seam. The
lock seam joining the can-to-base is reinforced by
the base plate.
(3) Using Tool C-4065, turn filter counterclockwise
to remove from base. Properly discard filter.
(4) Wipe base clean, then inspect gasket contact
surface.
(5) Lubricate gasket of new filter with clean
engine oil.
Fig. 64 Oil Pump
Fig. 65 Front Crankshaft Oil SealÐInstallation
Fig. 66 Oil Pump Assembly
Fig. 67 Oil Pump Components
9 - 84 3.0L ENGINENS
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)

(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)

CRANKSHAFT DAMPER
REMOVAL
(1) Disconnect negative cable from battery.
(2) Raise vehicle on hoist.
(3) Remove right wheel and inner splash shield.
(4) Remove drive belt. Refer to Group 7, Cooling
System for procedure.
(5) Remove crankshaft pulley (Fig. 29).
INSTALLATION
(1) Install crankshaft pulley (Fig. 30).
(2) Install drive belt. Refer to Cooling System
Group 7 for installation procedure.
(3) Install inner splash shield and wheel.
(4) Connect negative cable to battery.
ROCKER ARMS AND SHAFT ASSEMBLY
REMOVAL
(1) Remove upper intake manifold assembly. Refer
to Group 11, Intake and Exhaust Manifolds.(2) Disconnect spark plug wires by pulling on the
boot straight out in line with plug.
(3) Disconnect closed ventilation system.
(4) Remove cylinder head cover and gasket.
(5) Remove four rocker shaft bolts and retainers.
(6) Remove rocker arms and shaft assembly.
(7) If rocker arm assemblies are disassembled for
cleaning or replacement. Assemble rocker arms in
their original position. Refer to (Fig. 31) for rocker
arm for positioning on the shaft.
INSTALLATION
(1) Install rocker arm and shaft assemblies with
the stamped steel retainers in the four positions,
tighten to 28 N´m (250 in. lbs.) (Fig. 31).
CAUTION: THE ROCKER ARM SHAFT SHOULD BE
TORQUED DOWN SLOWLY, STARTING WITH THE
CENTER BOLTS. ALLOW 20 MINUTES TAPPET
BLEED DOWN TIME AFTER INSTALLATION OF THE
ROCKER SHAFTS BEFORE ENGINE OPERATION.
(2) Clean cylinder head cover gasket surface.
Inspect cover for distortion and straighten if neces-
sary.
(3) Clean head rail if necessary. Install a new gas-
ket and tighten cylinder head cover fasteners to 12
N´m (105 in. lbs.).
(4) Install closed crankcase ventilation system.
(5) Install spark plug wires.
(6) Install upper intake manifold assembly. Refer
to Group 11, Exhaust Systems and Intake Manifolds.
VALVE STEM SEALS OR SPRINGS, CYLINDER
HEAD NOT REMOVED
(1) Perform fuel system pressure release procedure
before attempting any repairs.
(2) Disconnect negative cable from battery.
(3) Remove air cleaner cover and hose assembly.
Fig. 29 Crankshaft DamperÐRemoval
Fig. 30 Crankshaft DamperÐInstallation
Fig. 31 Rocker Arm Location Left Bank
9 - 106 3.3/3.8L ENGINENS
REMOVAL AND INSTALLATION (Continued)

²Non±isolatedcylinder head cover to 12 N´m
(105 in. lbs.).
²Isolatedcylinder head cover to 10 N´m (90 in.
lbs.) (Fig. 32).
(4) Connect PCV hose from cylinder head cover.
(5) Install intake manifold upper plenum. Refer to
Group 11, Exhaust System and Intake Manifold for
procedure.
(6) Install Wiper Unit. Refer to Group 8K, Wind-
shield Wipers and Washers for procedure.
(7) Connect negative cable to battery.
CYLINDER HEAD
REMOVAL
(1) Drain cooling system. Refer to Group 7, Cooling
System for procedure and disconnect negative cable
from battery.
(2) Remove upper and lower intake manifolds.
Refer to Group 11, Exhaust System and Intake Man-
ifold.
WARNING: INTAKE MANIFOLD GASKET IS MADE
OF VERY THIN METAL AND MAY CAUSE PER-
SONAL INJURY, HANDLE WITH CARE.
(3) Disconnect coil wires, sending unit wire, heater
hoses and bypass hose.
(4) Remove PCV system hoses, evaporation control
system hose and cylinder head covers.
(5) Remove exhaust manifolds.
(6) Remove rocker arm and shaft assemblies.
Remove push rods andmark positions to ensure
installation in original locations.
(7) Remove the 9 head bolts from each cylinder
head and remove cylinder heads (Fig. 33).
INSTALLATION
(1) Clean all sealing surfaces of cylinder block and
cylinder heads.
(2) Install new gaskets on cylinder block (Fig. 34).
(3)The cylinder head bolts are torqued using
the torque yield method, they should be exam-
ined BEFORE reuse. If the threads are necked
down, the bolts should be replaced(Fig. 35).
(4) Necking can be checked by holding a scale or
straight edge against the threads. If all the threads
do not contact the scale the bolt should be replaced.
(5) Tighten the cylinder head bolts1-8inthe
sequence shown in (Fig. 33). Using the 4 step torque
turn method, tighten according to the following val-
ues:
²Step 1: Bolts1±8to61N´m(45ft.lbs.)
²Step 2: Bolts1±8to88N´m(65ft.lbs.)
²Step 3: Bolts1±8(again) to 88 N´m (65 ft. lbs.)
²Step 4: Bolts1±8turn an additional 1/4 Turn.
(Do not use a torque wrench for this step.)
NOTE: Bolt torque after 1/4 turn should be over 122
N´m (90 ft. lbs.). If not, replace the bolt.
(6) Tighten head bolt number 9 (Fig. 33) to 33 N´m
(25 ft. lbs.) after head bolts1±8have been tighten
to specifications.
Fig. 33 Cylinder Head Bolts Location and
Tightening Sequence
Fig. 34 Head Gasket Installation
Fig. 35 Checking Bolts for Stretching (Necking)
9 - 108 3.3/3.8L ENGINENS
REMOVAL AND INSTALLATION (Continued)

(6) Start and operate engine. Warm up to normal
operating temperature.
CAUTION: To prevent damage to valve mechanism,
engine must not be run above fast idle until all
hydraulic tappets have filled with oil and have
become quiet.
TIMING CHAIN COVER
REMOVAL
(1) Disconnect negative cable from battery.
(2) Drain cooling system. Refer to Cooling System
Group 7 for procedure.
(3) Support engine and remove right engine
mount.
(4) Raise vehicle on hoist. Drain engine oil.
(5) Remove oil pan and oil pump pick-up. It may
necessary to remove transaxle inspection cover.
(6) Remove right wheel and inner splash shield.
(7) Remove drive belt. Refer to Cooling System
Group 7 for procedure.
(8) Remove A/C compressor and set aside.
(9) Remove A/C compressor mounting bracket.
(10) Remove crankshaft damper (Fig. 44).
(11) Remove idler pulley from engine bracket.
(12) Remove engine bracket (Fig. 45).
(13) Remove cam sensor from chain case cover
(Fig. 46).
(14) Remove chain case cover (Fig. 46).
INSTALLATION
(1) Be sure mating surfaces of chain case cover
and cylinder block are clean and free from burrs.
Crankshaft oil seal must be removed to insure cor-
rect oil pump engagement.
NOTE: DO NOT USE SEALER ON COVER GASKET
(2) Use a new cover gasket, and O-rings (Fig. 47).
Adhere new gasket to chain case cover, making surethat the lower edge of the gasket is flush to 0.5 mm
(0.020 in.) passed the lower edge of the cover. Refer
to Oil Pan sealing outlined in this section.
Fig. 43 Roller Tappets Aligning Yoke and Retainer
Fig. 44 Crankshaft DamperÐRemoval
Fig. 45 Engine Bracket
Fig. 46 Timing Chain Case Cover
NS3.3/3.8L ENGINE 9 - 111
REMOVAL AND INSTALLATION (Continued)

(3) Rotate crankshaft so that the oil pump drive
flats are vertical.
(4) Position oil pump inner rotor so the mating
flats are in the same position as the crankshaft drive
flats (Fig. 47).
(5) Install cover onto crankshaft. Make sure the oil
pump is engaged on the crankshaft correctly or
severe damage may result.
(6) Install chain case cover screws and torque to
27 N´m (20 ft. lbs.).
(7) Install crankshaft oil seal (Fig. 48).
(8) Install crankshaft pulley (Fig. 49).
(9) Install engine bracket (Fig. 45) and torque fas-
teners to 54 N´m (40 ft. lbs.).(10) Install idler pulley on engine bracket.
(11) Install cam sensor. Refer to Group 8D, Igni-
tion System for installation procedure.
(12) Install A/C compressor mounting bracket.
(13) Install A/C compressor.
(14) Install drive belt Refer to Group 7, Cooling
System for installation procedure.
(15) Install inner splash shield and wheel.
(16) Install oil pump pick-up and oil pan and tran-
saxle inspection cover if removed.
(17) Install engine mount.
(18) Fill crankcase with oil to proper level.
(19) Fill cooling system. Refer to Group 7, Cooling
System for procedure.
(20) Connect negative cable to battery.
TIMING CHAIN
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove timing chain cover. Refer to procedure
outlined in this section.
(3) Remove camshaft sprocket attaching bolt, and
timing chain with camshaft sprocket.
(4) Using a suitable puller remove the crankshaft
sprocket. Be careful not to damage the crankshaft
surface.
INSTALLATION
(1) Position a new crankshaft sprocket on the
shaft, install sprocket with suitable tool and mallet.
Be sure sprocket is seated into position.
(2) Rotate crankshaft so the timing arrow is to the
12 o'clock position.
(3) Place timing chain around camshaft sprocket
and place the timing mark to the 6 o'clock position.
(4) Align the dark colored links with the dot on the
camshaft sprocket, place timing chain around crank-
shaft sprocket with the dark colored link lined up
Fig. 47 Timing Chain Case Cover Gaskets and
O-Rings
Fig. 48 Crankshaft Oil SealÐInstallation
Fig. 49 Crankshaft DamperÐInstallation
9 - 112 3.3/3.8L ENGINENS
REMOVAL AND INSTALLATION (Continued)