Chrysler RG Voyager. Manual — part 923
ENGINE
TABLE OF CONTENTS
page
page
ENGINE 2.4L. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
ENGINE 3.3/3.8L . . . . . . . . . . . . . . . . . . . . . . . . . 77
ENGINE 2.4L
TABLE OF CONTENTS
page
page
ENGINE 2.4L
. . . . . . . . . . . . . . . . . . . . . . . . . . 3
ENGINE DIAGNOSIS - INTRODUCTION
ENGINE DIAGNOSIS - PERFORMANCE
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - MECHANICAL . . . . . . . . . . . . . . 6
DIAGNOSIS AND TESTING - ENGINE OIL
LEAK INSPECTION . . . . . . . . . . . . . . . . . . . . . 8
TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . 9
ENGINE CORE AND OIL GALLERY PLUGS
THREADS . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
FORM-IN-PLACE GASKETS AND SEALERS
ENGINE GASKET SURFACE PREPARATION
STANDARD PROCEDURE - MEASURING
BEARING CLEARANCE USING
PLASTIGAGE . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION - ENGINE ASSEMBLY
. . . . . . . . . . . . . . . . . . . . . . . . . 17
. . . . . . . . . . . . . . . . . . . . . . . . . 21
AIR CLEANER ELEMENT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
. . . . . . . . . . . . . . . . . . . . . . . . . 25
AIR CLEANER HOUSING
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
. . . . . . . . . . . . . . . . . . . . . . . . . 25
CYLINDER HEAD
. . . . . . . . . . . . . . . . . . . . . . . . . 25
. . . . . . . . . . . . . . 25
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
. . . . . . . . . . . . . . . . . . . . . . . . . . 27
CAMSHAFT OIL SEAL(S)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
. . . . . . . . . . . . . . . . . . . . . . . . . 29
CAMSHAFT(S)
. . . . . . . . . . . . . . . . . . . . . . . . . 29
. . . . . . . . . . . . . . . . . . . . . . . . . . . 29
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
. . . . . . . . . . . . . . . . . . . . . . . . . . 31
. . . . . . . . . . . . . . . . . . . . . . . . . 31
CYLINDER HEAD COVER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
. . . . . . . . . . . . . . . . . . . . . . . . . . 32
. . . . . . . . . . . . . . . . . . . . . . . . . 32
INTAKE/EXHAUST VALVES & SEATS
. . . . . . . . . . . . . . . . . . . . . . . . . 33
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
VALVE SPRINGS & SEALS
. . . . . . . . . . . . . . . . . 33
. . . . . . . . . . . . . . . . . . . . . . . . . . 33
INSTALLATION - CYLINDER HEAD ON
. . . . . . . . . . . . . . . . . 34
RS
ENGINE
9 - 1
HYDRAULIC LASH ADJUSTERS
DIAGNOSIS AND TESTING - HYDRAULIC
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
. . . . . . . . . . . . . . . . . . . . . . . . . 35
ROCKER ARMS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
. . . . . . . . . . . . . . . . . . . . . . . . . . 36
. . . . . . . . . . . . . . . . . . . . . . . . . 36
ENGINE BLOCK
. . . . . . . . . . . . . . . . . . . . . . . . . 36
. . . . . . . . . . . . . . 36
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
. . . . . . . . . . . . . . . . . . . . . . . . . . 37
CRANKSHAFT
STANDARD PROCEDURE - CRANKSHAFT
. . . . . . . . . . . . . . . . . . . . . . . . . . . 37
. . . . . . . . . . . . . . . . 38
. . . . . . . . . . . . . . . . . . . . . . . . . . 39
CRANKSHAFT OIL SEAL - FRONT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
. . . . . . . . . . . . . . . . . . . . . . . . . 42
CRANKSHAFT OIL SEAL - REAR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
. . . . . . . . . . . . . . . . . . . . . . . . . 43
PISTON & CONNECTING ROD
. . . . . . . . . . . . . . . . . . . . . . . . . 44
STANDARD PROCEDURE - PISTON TO
. . . . . . . . . . . . . . 44
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
. . . . . . . . . . . . . . . . . . . . . . . . . 45
CONNECTING ROD BEARINGS
PISTON RINGS
. . . . . . . . . . . . . . . . 47
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
. . . . . . . . . . . . . . . . . . . . . . . . . 48
VIBRATION DAMPER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
. . . . . . . . . . . . . . . . . . . . . . . . . 49
STRUCTURAL COLLAR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
. . . . . . . . . . . . . . . . . . . . . . . . . 50
ENGINE MOUNTING
. . . . . . . . . . . . . . . . . . . . . . . . . 50
FRONT MOUNT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
. . . . . . . . . . . . . . . . . . . . . . . . . 51
LEFT MOUNT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
. . . . . . . . . . . . . . . . . . . . . . . . . 52
REAR MOUNT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
. . . . . . . . . . . . . . . . . . . . . . . . . 53
RIGHT MOUNT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
. . . . . . . . . . . . . . . . . . . . . . . . . 54
LUBRICATION
. . . . . . . . . . . . . . . . . . . . . . . . . 54
. . . . . . . . . . . . . . . . . . . . . . . . . . . 54
OIL
STANDARD PROCEDURE - ENGINE OIL
AND FILTER CHANGE . . . . . . . . . . . . . . . . . . 55
OIL FILTER
. . . . . . . . . . . . . . . . . . . . . . . . . 55
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
. . . . . . . . . . . . . . . . . . . . . . . . . 56
OIL PAN
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
. . . . . . . . . . . . . . . . . . . . . . . . . 56
OIL PRESSURE SWITCH
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
. . . . . . . . . . . . . . . . . . . . . . . . . 57
OIL PUMP
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
. . . . . . . . . . . . . . . . . . . . . . . . . 58
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
. . . . . . . . . . . . . . . . . . . . . . . . . . 58
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
. . . . . . . . . . . . . . . . . . . . . . . . . 59
INTAKE MANIFOLD
. . . . . . . . . . . . . . . . . . . . . . . . . 60
. . . . . . . . . . . . . . 61
INTAKE MANIFOLD - UPPER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
. . . . . . . . . . . . . . . . . . . . . . . . . . 62
. . . . . . . . . . . . . . . . . . . . . . . . . 62
INTAKE MANIFOLD - LOWER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
. . . . . . . . . . . . . . . . . . . . . . . . . . 63
. . . . . . . . . . . . . . . . . . . . . . . . . 63
EXHAUST MANIFOLD
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
. . . . . . . . . . . . . . . . . . . . . . . . . . 64
. . . . . . . . . . . . . . . . . . . . . . . . . 64
TIMING BELT COVER(S)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
. . . . . . . . . . . . . . . . . . . . . . . . . 66
TIMING BELT AND SPROCKET(S)
. . . . . . . . . . . . . . . 66
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
9 - 2
ENGINE 2.4L
RS
INSTALLATION - CRANKSHAFT SPROCKET
INSTALLATION - CAMSHAFT SPROCKETS
TIMING BELT TENSIONER & PULLEY
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
. . . . . . . . . . . . . . . . . . . . . . . . . 71
BALANCE SHAFTS AND CARRIER ASSEMBLY
. . . . . . . . . . . . . . . . . . . . . . . . . 72
. . . . . . . . . . . . . . . . . . . . . . . . . . . 72
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
. . . . . . . . . . . . . . . . . . . . . . . . . 74
ENGINE 2.4L
DESCRIPTION
The 2.4 Liter (148 cu. in.) in-line four cylinder
engine is a double over head camshaft with hydraulic
lash adjusters and four valve per cylinder design.
The engine is free-wheeling; meaning it has provi-
sions for piston-to-valve clearance. However valve-to-
valve interference can occur, if camshafts are rotated
independently.
The cylinders are numbered from front of the
engine to the rear. The firing order is 1–3–4–2.
The engine identification number is located on the
rear of the cylinder block (Fig. 1).
DIAGNOSIS AND TESTING
ENGINE DIAGNOSIS - INTRODUCTION
Engine diagnosis is helpful in determining the
causes of malfunctions not detected and remedied by
routine maintenance.
These malfunctions may be classified as either
mechanical (e.g., a strange noise), or performance
(e.g., engine idles rough and stalls).
Refer to the Engine Mechanical and the Engine
Performance diagnostic charts, for possible causes
and corrections of malfunctions (Refer to 9 - ENGINE
- DIAGNOSIS AND TESTING - MECHANICAL)
(Refer to 9 - ENGINE - DIAGNOSIS AND TESTING
- PERFORMANCE).
For fuel system diagnosis, (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY
-
DIAGNOSIS AND
TESTING).
Additional tests and diagnostic procedures may be
necessary for specific engine malfunctions that can-
not be isolated with the Service Diagnosis charts.
Information concerning additional tests and diagno-
sis is provided within the following:
• Cylinder Compression Pressure Test
• Cylinder Combustion Pressure Leakage Test
• Engine Cylinder Head Gasket Failure Diagnosis
• Intake Manifold Leakage Diagnosis
• Hydraulic Lash Adjuster Noise Diagnosis
• Engine Oil Leak Inspection
Fig. 1 Engine Identification
1 - ENGINE IDENTIFICATION LOCATION
RS
ENGINE 2.4L
9 - 3
ENGINE DIAGNOSIS - PERFORMANCE
CONDITION
POSSIBLE CAUSE
CORRECTION
ENGINE WILL NOT START
1. Weak battery.
1. Test battery. Charge or replace
as necessary. (Refer to 8 -
ELECTRICAL/BATTERY SYSTEM -
DIAGNOSIS AND TESTING)
2. Corroded or loose battery
connections.
2. Clean and tighten battery
connections. Apply a coat of light
mineral grease to terminals.
3. Faulty starter.
3. Test starting system. (Refer to 8 -
ELECTRICAL/STARTING -
DIAGNOSIS AND TESTING)
4. Faulty coil(s) or control unit.
4. Test and replace as needed.
(Refer to Appropriate Diagnostic
Information)
5. Incorrect spark plug gap.
5. Set gap. (Refer to 8 -
ELECTRICAL/IGNITION CONTROL
- SPECIFICATIONS)
6. Contamination in fuel system.
6. Clean system and replace fuel
filter.
7. Faulty fuel pump.
7. Test fuel pump and replace as
needed. (Refer to Appropriate
Diagnostic Information)
8. Incorrect engine timing.
8. Check for a skipped timing
belt/chain.
ENGINE STALLS OR IDLES
ROUGH
1. Idle speed too low.
1. Test minimum air flow. (Refer to
Appropriate Diagnostic Information)
2. Incorrect fuel mixture.
2. (Refer to Appropriate Diagnostic
Information)
3. Intake manifold leakage.
3. Inspect intake manifold, manifold
gasket, and vacuum hoses.
4. Faulty ignition coil(s).
4. Test and replace as necessary.
(Refer to Appropriate Diagnostic
Information)
9 - 4
ENGINE 2.4L
RS
ENGINE 2.4L (Continued)
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