Chrysler Voyager 1996-2000 3.8L Engine Bolt Torque Specifications & Fastener Values
Chrysler Voyager 1996-2000

Chrysler Voyager 1996-2000 3.8L Engine Bolt Torque Specifications

Comprehensive list of torque specifications for bolts on the 3.8L V6 engine found in the 1996-2000 Chrysler Voyager, including cylinder head, intake manifold, exhaust manifold, and other critical components.

Updated

Important Information

Safety guidelines and reference information for proper torque application

Quick Reference Guide
ft-lbs → Nm
× 1.356
ft-lbs → kg-m
× 0.138
Nm → ft-lbs
× 0.738
in-lbs → ft-lbs
× 0.083

Common Torque Patterns

Star Pattern

Used for wheels and other circular bolt patterns

Star Pattern torque pattern diagram showing proper bolt tightening sequence
Cross Pattern

Used for gaskets and cover plates

Cross Pattern torque pattern diagram showing proper bolt tightening sequence
Sequential Pattern

Used for head bolts and other critical components

Sequential Pattern torque pattern diagram showing proper bolt tightening sequence

Common Mistakes to Avoid

Over-tightening

Exceeding the specified torque value can stretch or break fasteners, damage threads, or crack components.

Prevention:

Always use a calibrated torque wrench and follow specifications exactly.

Incorrect Torque Sequence

Tightening bolts in the wrong order can cause uneven pressure distribution and potential leaks or damage.

Prevention:

Follow the manufacturer's specified torque sequence pattern.

Dirty Threads

Dirt, rust, or old thread locker can affect torque readings and proper fastener tension.

Prevention:

Clean and inspect all threads before assembly. Use new thread locker if specified.

Reusing TTY Bolts

Torque-to-yield bolts are designed to stretch and must not be reused.

Prevention:

Always replace TTY bolts with new ones. They are single-use only.

Dry vs. Lubricated

Not accounting for whether torque specs are for dry or lubricated fasteners can lead to incorrect tension.

Prevention:

Check if specs are for dry or lubricated threads. Use specified lubricant when required.

Recommended Tools

Torque Wrench (1/4" Drive)

Range: 2-25 ft-lbs
Small fasteners, delicate components

Torque Wrench (3/8" Drive)

Range: 10-100 ft-lbs
Most common automotive fasteners

Torque Wrench (1/2" Drive)

Range: 30-250 ft-lbs
Large fasteners, wheels

Angle Gauge

Torque-to-yield (TTY) bolts

Torque Wrench Care

  • Calibrate annually or after 5,000 clicks
  • Store at lowest setting
  • Keep clean and lubricated

Search Specifications

Search by component name, bolt size, or description

Torque Calculator

Convert between different torque units

Cylinder Head

Components related to the cylinder head, including bolts for securing it to the engine block and related parts.

1

Cylinder Head Bolts

M12 x 1.75
Important Notes
Torque in sequence using a three step process. Torque all bolts to 20ft-lbs, then rotate an additional 90 degrees, and then rotate another 90 degrees. Always follow the specific torque sequence for your vehicle.
2

Valve Cover Bolts

M6 x 1.0
Torque Value
8.75 ft-lbs (12 N·m)
Important Notes
Torque bolts evenly to avoid leaks
3

Rocker Arms/Shafts Bolts

M6 x 1.0
Torque Value
8.75 ft-lbs (12 N·m)
Important Notes
Torque evenly and in sequence to avoid binding.
4

Exhaust Manifold/Headers Bolts

M8 x 1.25
Torque Value
20 ft-lbs (27 N·m)
Important Notes
Use a proper tightening sequence to avoid warpage, torque values may vary based on material.
5

Spark Plugs

M14 x 1.25
Torque Value
20 ft-lbs (27 N·m)
Important Notes
Do not over-tighten, use a torque wrench to ensure proper sealing and heat transfer.

Engine Block

Specifications for components directly related to the engine block, such as main bearings, connecting rods, and the oil system.

1

Main Bearing Bolts

M12 x 1.75
Important Notes
Torque in sequence, follow manufacturer's tightening sequence. Use new bolts if specified.
2

Connecting Rod Nuts

M9 x 1.25
Torque Value
45 ft-lbs (61 N·m)
Important Notes
Ensure proper rod cap orientation, torque in sequence.
3

Oil Pan Bolts

M6 x 1.0
Torque Value
8.75 ft-lbs (12 N·m)
Important Notes
Torque in a crisscross pattern to prevent leaks.
4

Oil Drain Plug Bolt

M14 x 1.5
Torque Value
25 ft-lbs (34 N·m)
Important Notes
Use a new crush washer. Do not over-tighten
5

Timing Cover Bolts

M6 x 1.0
Torque Value
8.75 ft-lbs (12 N·m)
Important Notes
Use a new gasket. Torque in a criss-cross pattern to ensure even sealing.
6

Water Pump Bolts

M6 x 1.0
Torque Value
8.75 ft-lbs (12 N·m)
Important Notes
Use a new gasket. Tighten in a criss-cross pattern.

Flywheel And Crankshaft

Specifications for components directly related to the crankshaft, including the flywheel/flexplate and harmonic balancer.

1

Flywheel Bolts

M10 x 1.5
Torque Value
80 ft-lbs (108 N·m)
Important Notes
Use new bolts. Torque in a star pattern.
2

Crankshaft Pulley/Harmonic Balancer Bolt

M16 x 1.5
Torque Value
105 ft-lbs (142 N·m)
Important Notes
Use a new bolt, lubricate bolt threads with engine oil. Hold the crankshaft from turning.

Timing System

Specifications for components related to the engine's timing system, including timing belt/chain tensioner and camshaft sprockets.

1

Timing Belt/Chain Tensioner Bolt

M8 x 1.25
Torque Value
20.8 ft-lbs (28 N·m)
Important Notes
Ensure the tensioner is properly aligned, use torque wrench
2

Camshaft Sprocket Bolt

M10 x 1.5
Torque Value
40 ft-lbs (54 N·m)
Important Notes
Ensure camshaft is correctly timed before tightening.

Intake And Fuel

Specifications for components related to the intake and fuel delivery systems.

1

Throttle Body Bolts

M6 x 1.0
Torque Value
10 ft-lbs (14 N·m)
Important Notes
Tighten evenly to avoid vacuum leaks.
2

Intake Manifold Bolts

M6 x 1.0
Torque Value
8.75 ft-lbs (12 N·m)
Important Notes
Tighten in sequence, start from the center out to avoid leaks.
3

Intake Plenum/Upper Intake Manifold Bolts

M6 x 1.0
Torque Value
8.75 ft-lbs (12 N·m)
Important Notes
Torque in a crisscross pattern to avoid leaks.
4

EGR Valve Bolts

M6 x 1.0
Torque Value
8.75 ft-lbs (12 N·m)
Important Notes
Tighten evenly to avoid vacuum leaks.
5

Fuel Rail Bolts

M6 x 1.0
Torque Value
8.75 ft-lbs (12 N·m)
Important Notes
Do not over-tighten, use a torque wrench to avoid fuel leaks
6

Fuel Injector Bolts

M6 x 1.0
Torque Value
8.75 ft-lbs (12 N·m)
Important Notes
Torque evenly to avoid leaks.

Cooling System

Specifications for components related to the engine's cooling system.

1

Water Pump Pulley Bolts

M6 x 1.0
Torque Value
8.75 ft-lbs (12 N·m)
Important Notes
Tighten evenly to avoid wobble or damage
2

Thermostat Housing Bolts

M6 x 1.0
Torque Value
8.75 ft-lbs (12 N·m)
Important Notes
Use a new gasket. Tighten evenly.

Accessory Drive

Specifications for components related to the accessory drive system.

1

Serpentine/Accessory Drive Belt Tensioner Bolt

M10 x 1.5
Torque Value
40 ft-lbs (54 N·m)
Important Notes
Ensure the tensioner is properly aligned before tightening.
2

Drive Belt Idler Pulley Bolt

M8 x 1.25
Torque Value
8.75 ft-lbs (12 N·m)
Important Notes
Ensure pulley is aligned and properly seated.

Ignition System

Specifications for components related to the ignition system.

1

Ignition Coil Bolt

M6 x 1.0
Torque Value
8.75 ft-lbs (12 N·m)
Important Notes
Do not over-tighten.
2

Distributor Hold Down Bolt

M8 x 1.25
Torque Value
18 ft-lbs (24 N·m)
Important Notes
Ensure proper distributor orientation.

Troubleshooting Guide

Common issues, diagnostic steps, and prevention guidelines

Common Issues

Bolt stretching, stripped threads, uneven torque patterns

Loose Components

Symptoms:
  • Rattling or vibration noises
  • Visible movement in components
  • Uneven panel gaps
Solutions:
  • Clean threads and mounting surfaces
  • Replace damaged fasteners
  • Apply proper torque in sequence
  • Use thread locker if specified

Stripped Fasteners

Symptoms:
  • Unable to achieve proper torque
  • Fastener spins freely
  • Visible thread damage
Solutions:
  • Use thread repair kit if appropriate
  • Install thread insert (HeliCoil)
  • Replace component if threaded hole is damaged
  • Upgrade to higher grade fastener if recommended

Overtightened Components

Symptoms:
  • Cracked or deformed parts
  • Broken fasteners
  • Compressed gaskets or seals
Solutions:
  • Replace damaged components
  • Use new fasteners
  • Follow proper torque sequence
  • Verify correct torque specifications

Diagnostic Steps

Visual inspection, torque verification, thread assessment

1

Visual Inspection

Inspect the affected area for any visible signs of damage or wear

  • Check for cracks or deformation
  • Look for signs of excessive wear
  • Verify proper fastener installation
2

Torque Verification

Verify the torque applied to the fasteners

  • Check the torque wrench calibration
  • Verify the torque specification
  • Compare the applied torque to the specification
3

Thread Assessment

Assess the condition of the threads

  • Check for signs of thread damage
  • Verify the thread type and size
  • Check for proper thread engagement

Prevention Guidelines

Best practices, maintenance tips, tool care

Best Practices

  • Always follow the recommended torque specification
  • Use the correct type and size of fasteners
  • Verify the torque wrench calibration regularly

Maintenance Tips

  • Regularly inspect the affected area for signs of wear or damage
  • Replace damaged or worn-out components promptly
  • Keep the work area clean and organized

Tool Care

  • Regularly clean and maintain the torque wrench
  • Store the torque wrench in a dry and secure location
  • Verify the torque wrench calibration before each use

Frequently Asked Questions

Find answers to common questions about torque specifications

Q1

Why is using the correct torque specification important?

Using the correct torque specification ensures bolts are tightened sufficiently to prevent loosening from vibration and thermal expansion while also avoiding over-tightening, which can damage threads, gaskets, and the components being joined. For example, over-tightening a cylinder head bolt can distort the head, causing leaks and engine damage. Under-tightening can lead to coolant or oil leaks and potential engine failure.

Q2

Can I use the same torque specs for all bolts on the 3.8L engine?

No. Torque specifications vary depending on the bolt size, material, and the component it's securing. For example, intake manifold bolts have a different torque specification than cylinder head bolts or exhaust manifold bolts on the 3.8L Chrysler engine. Always refer to the specific torque specification chart for each component.

Q3

What if I don't have a torque wrench?

While it's highly recommended to use a torque wrench, you can estimate torque by feel, but it is much less accurate. Improper torque can cause leaks or damage and it may lead to needing to redo the repair. For this reason, purchasing or renting a torque wrench is strongly suggested when working on your engine. If borrowing one, always check to make sure it was calibrated recently.

Q4

Do I need to use a specific tightening sequence?

Yes, for certain components like the cylinder head, intake manifold, and exhaust manifold, a specific tightening sequence is crucial to ensure even clamping pressure and proper sealing. The manufacturer recommends particular procedures to prevent warping or leaks. For example, cylinder head bolts typically use a multi-step, spiral pattern from the center bolts outward.

Q5

Should I use thread locker on these bolts?

Generally, thread locker (like Loctite) is not required for most engine bolts when using the correct torque specification. However, some applications, like bolts on the crankshaft pulley, flywheel, or timing components, may benefit from thread locker to prevent them from backing out due to vibration. Always refer to the service manual or a trusted resource for specific recommendations.

Environmental Considerations

Temperature, humidity, and seasonal effects on torque specifications

Temperature Effects

Includes: High Heat, Cold Weather, Thermal Cycling

Temperature can significantly impact torque values and fastener behavior

Cold Weather

Effects:
  • Increased material brittleness
  • Higher torque required due to thread contraction
  • Reduced thread lubricant effectiveness
Recommendations:
  • Allow components to warm to room temperature when possible
  • Consider using winter-grade thread lubricants
  • Check torque values more frequently during winter months

Hot Weather

Effects:
  • Thermal expansion of components
  • Decreased friction in threads
  • Accelerated lubricant breakdown
Recommendations:
  • Check torque when components are at normal operating temperature
  • Use temperature-resistant thread lockers
  • Consider re-torquing after heat cycles

Humidity and Corrosion

Covers: Rust Prevention, Salt Exposure, Moisture Control

Moisture and corrosion can affect fastener integrity and torque values

High Humidity

Effects:
  • Accelerated corrosion formation
  • Reduced friction coefficient
  • Potential thread seizing
Prevention:
  • Use corrosion-resistant fasteners
  • Apply appropriate anti-seize compounds
  • Maintain proper protective coatings

Salt Exposure

Effects:
  • Rapid corrosion development
  • Thread damage
  • Seized fasteners
Prevention:
  • Regular underbody washing
  • Use of sacrificial anodes where appropriate
  • Application of protective coatings

Seasonal Maintenance

Spring, Summer, Fall, and Winter maintenance schedules

Spring

  • Inspect for winter damage
  • Clean and protect exposed fasteners
  • Check torque on critical components

Summer

  • Monitor heat-affected components
  • Check expansion-related loosening
  • Inspect cooling system mounts

Fall

  • Prepare for winter conditions
  • Apply corrosion protection
  • Verify all fasteners are properly torqued

Winter

  • More frequent inspection of critical fasteners
  • Check for salt damage
  • Monitor suspension component torque

Related Resources

Tools, service procedures, and technical bulletins

Recommended Tools

Torque Wrench (1/2-inch drive)

A calibrated torque wrench capable of measuring torque in foot-pounds (ft-lbs) or inch-pounds (in-lbs) as required.

  • Accurate torque readings
  • Wide torque range
  • Durable construction
Learn more

Torque Wrench (3/8-inch drive)

A smaller calibrated torque wrench for lower torque applications and tighter spaces.

  • Accurate torque readings
  • Lower torque range
  • Smaller profile
Learn more

Socket Set (Metric)

A comprehensive set of metric sockets including standard and deep sockets.

  • Various sizes for different bolts
  • 6-point and 12-point options
  • Durable material
Learn more

Socket Extensions

Extensions of various lengths to reach difficult to access bolts.

  • Multiple lengths
  • Durable material
  • Secure fit
Learn more

Universal Joint

A universal joint to allow socket to reach bolts at an angle.

  • Smooth rotation
  • Durable Material
  • Secure fit
Learn more
Service Procedures

Intake Manifold Bolt Torque Procedure

Procedure for torquing the intake manifold bolts to specifications on the 3.8L engine.

  • 1. Clean all bolt threads and mating surfaces.
  • 2. Install the intake manifold gasket.
  • 3. Install the intake manifold and all bolts by hand.
  • 4. Torque all bolts in sequence to 5 ft-lbs.
  • 5. Torque all bolts in sequence to 12 ft-lbs.
  • 6. Check for correct tightness.
View full procedure

Cylinder Head Bolt Torque Procedure

Procedure for torquing the cylinder head bolts to specifications on the 3.8L engine. This procedure is critical and requires multiple steps.

  • 1. Clean all bolt threads and mating surfaces.
  • 2. Install the cylinder head gasket.
  • 3. Install the cylinder head and all bolts by hand.
  • 4. Torque all bolts in sequence to 30 ft-lbs.
  • 5. Torque all bolts in sequence to 65 ft-lbs.
  • 6. Turn all bolts in sequence an additional 1/4 turn (90 degrees).
  • 7. Check for correct tightness.
View full procedure

Rocker Arm Cover Bolt Torque Procedure

Procedure for torquing the rocker arm cover bolts to specifications on the 3.8L engine.

  • 1. Clean all bolt threads and mating surfaces.
  • 2. Install the rocker arm cover gasket.
  • 3. Install the rocker arm cover and all bolts by hand.
  • 4. Torque all bolts in sequence to 105 in-lbs.
  • 5. Check for correct tightness.
View full procedure

Oil Pan Bolt Torque Procedure

Procedure for torquing the oil pan bolts to specifications on the 3.8L engine.

  • 1. Clean all bolt threads and mating surfaces.
  • 2. Install the oil pan gasket.
  • 3. Install the oil pan and all bolts by hand.
  • 4. Torque all bolts in sequence to 12 ft-lbs.
  • 5. Check for correct tightness.
View full procedure
Technical Service Bulletins

Intake Manifold Gasket Leakage

1998-05-15

Report of intermittent intake manifold gasket leakage due to improper torque application during assembly.

1996-1999

Resolution: Verify torque spec is 12 ft-lbs in sequence. Inspect gasket before installation and re-torque after warm-up if necessary.

Cylinder Head Bolt Retorque Recommendation

2000-01-10

Technical service bulletin recommending checking cylinder head bolt torque after initial warm-up due to gasket compression.

1996-2000

Resolution: Check cylinder head bolt torque to 65 ft-lbs + 1/4 turn after engine has reached operating temperature, and after cooling down to ensure proper seal and avoid premature failure.

About the Author

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Alan Montanye - Automotive Technical Specialist
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Alan Montanye

Automotive Technical Specialist

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