Chrysler RG Voyager. Manual — part 929

AIR CLEANER ELEMENT

REMOVAL

(1) Unsnap 2 clips.
(2) Lift cover and pull toward the engine and

remove cover tabs from air box.

(3) Lift cover and remove the element (Fig. 11).

INSTALLATION

(1) Install the air filter element into air box (Fig.

11).

(2) Move cover so that the tabs insert into the air

box.

(3) Push cover down and snap the 2 clips.

AIR CLEANER HOUSING

REMOVAL

(1) Disconnect the negative battery cable.
(2) Disconnect the inlet air temperature sensor

(Fig. 12).

(3) Remove the inlet hose to throttle body (Fig. 11).
(4) Remove the bolt for air box at upper radiator

cross member.

(5) Pull air box up and off over the single locating

pin.

(6) Remove air box from vehicle

INSTALLATION

(1) Install air box into vehicle and onto the locat-

ing pin.

(2) Install bolt to hold air box to the upper radia-

tor cross member.

(3) Install the inlet hose to the throttle body.
(4) Connect the inlet air temperature sensor (Fig.

12).

(5) Connect the negative battery cable.

CYLINDER HEAD

DESCRIPTION

The cross flow designed, aluminum cylinder head

contains dual over-head camshafts with four valves
per cylinder (Fig. 13). The valves are arranged in two
in-line banks. The intake valves face toward the
front of the vehicle. The exhaust valves face the dash
panel. The cylinder head incorporates powdered
metal valve guides and seats. The cylinder head is
sealed to the block using a multi-layer steel head
gasket and retaining bolts.

Integral oil galleries provide lubrication passages

to the hydraulic lash adjusters, camshafts, and valve
mechanisms.

DIAGNOSIS AND TESTING

CYLINDER HEAD GASKET

A cylinder head gasket leak can be located between

adjacent cylinders or between a cylinder and the
adjacent water jacket.

Possible indications of the cylinder head gasket

leaking between adjacent cylinders are:

• Loss of engine power

• Engine misfiring

• Poor fuel economy
Possible indications of the cylinder head gasket

leaking between a cylinder and an adjacent water
jacket are:

Fig. 11 Air Box Cover

Fig. 12 IAT Sensor 2.4L

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ENGINE 2.4L

9 - 25

• Engine overheating

• Loss of coolant

• Excessive steam (white smoke) emitting from

exhaust

• Coolant foaming

CYLINDER-TO-CYLINDER LEAKAGE TEST

To determine if an engine cylinder head gasket is

leaking between adjacent cylinders, follow the proce-
dures in Cylinder Compression Pressure Test (Refer
to 9 - ENGINE - DIAGNOSIS AND TESTING). An
engine cylinder head gasket leaking between adja-
cent cylinders will result in approximately a 50–70%
reduction in compression pressure.

CYLINDER-TO-WATER JACKET LEAKAGE TEST

WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING WITH COOLANT PRES-
SURE CAP REMOVED.

VISUAL TEST METHOD

With the engine cool, remove the coolant pressure

cap. Start the engine and allow it to warm up until
thermostat opens.

If a large combustion/compression pressure leak

exists, bubbles will be visible in the coolant.

COOLING SYSTEM TESTER METHOD

WARNING: WITH COOLING SYSTEM TESTER IN
PLACE, PRESSURE WILL BUILD UP FAST. EXCES-
SIVE

PRESSURE

BUILT

UP,

BY

CONTINUOUS

ENGINE OPERATION, MUST BE RELEASED TO A
SAFE PRESSURE POINT. NEVER PERMIT PRES-
SURE TO EXCEED 138 kPa (20 psi).

Install Cooling System Tester 7700 or equivalent to

pressure cap neck. Start the engine and observe the
tester’s pressure gauge. If gauge pulsates with every
power stroke of a cylinder a combustion pressure
leak is evident.

CHEMICAL TEST METHOD

Combustion leaks into the cooling system can also

be checked by using Bloc-Chek Kit C-3685-A or
equivalent. Perform test following the procedures
supplied with the tool kit.

REMOVAL - CYLINDER HEAD

(1) Perform fuel system pressure release procedure

before attempting any repairs. (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY - SPECIFICA-
TIONS)

(2) Disconnect battery negative cable.
(3) Drain cooling system. (Refer to 7 - COOLING -

STANDARD PROCEDURE)

(4) Remove air filter housing and inlet tube.
(5) Remove upper intake manifold. (Refer to 9 -

ENGINE/MANIFOLDS/INTAKE

MANIFOLD

-

REMOVAL)

(6) Remove heater tube support bracket from cyl-

inder head.

(7) Disconnect radiator upper and heater supply

hoses from intake manifold water outlet connections.

(8) Remove accessory drive belts. (Refer to 7 -

COOLING/ACCESSORY

DRIVE/DRIVE

BELTS

-

REMOVAL)

(9) Raise vehicle and remove exhaust pipe from

manifold.

(10) Remove power steering pump reservoir and

line support bracket from lower intake manifold and
set aside. Do not disconnect lines.

(11) Remove ignition coil and wires from engine.
(12) Disconnect cam sensor and fuel injector wir-

ing connectors.

(13) Remove timing belt and camshaft sprockets.

(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT/CHAIN AND SPROCKETS - REMOVAL)

(14) Remove timing belt idler pulley and rear tim-

ing belt cover. (Refer to 9 - ENGINE/VALVE TIM-
ING/TIMING

BELT

/

CHAIN

COVER(S)

-

REMOVAL)

Fig. 13 Cylinder Head and Camshafts

1 - CAMSHAFT BEARING CAPS
2 - PLUG
3 - CAMSHAFT
4 - CYLINDER HEAD
5 - CAMSHAFT OIL SEAL

9 - 26

ENGINE 2.4L

RS

CYLINDER HEAD (Continued)

(15) Remove cylinder head cover. (Refer to 9 -

ENGINE/CYLINDER

HEAD/CYLINDER

HEAD

COVER(S) - REMOVAL)

(16) Remove camshafts (Refer to 9 - ENGINE/

CYLINDER HEAD/CAMSHAFT(S) - REMOVAL).

NOTE: Identify rocker arm position to ensure cor-
rect re-installation in original position, if reused.

(17) Remove rocker arms. (Refer to 9 - ENGINE/

CYLINDER HEAD/ROCKER ARMS - REMOVAL)

(18) Remove cylinder head bolts in REVERSE

sequence of tightening (Fig. 19).

(19) Remove cylinder head from engine block.
(20) Inspect and clean cylinder head. (Refer to 9 -

ENGINE/CYLINDER HEAD - INSPECTION) (Refer
to 9 - ENGINE/CYLINDER HEAD - CLEANING)

CLEANING

To ensure engine gasket sealing, proper surface

preparation must be performed, especially with the
use of aluminum engine components and multi-layer
steel cylinder head gaskets.

NOTE: Multi-Layer Steel (MLS) head gaskets require
a scratch free sealing surface.

Remove all gasket material from cylinder head and

block (Refer to 9 - ENGINE - STANDARD PROCE-
DURE). Be careful not to gouge or scratch the alumi-
num head sealing surface.

Clean all engine oil passages.

INSPECTION

(1)

Cylinder head must be flat within 0.1 mm

(0.004 in.) (Fig. 14).

(2)

Inspect camshaft bearing journals for scoring.

(3) Remove carbon and varnish deposits from

inside of valve guides with a reliable guide cleaner.

(4) Using a small hole gauge and a micrometer,

measure valve guides in 3 places top, middle and bot-
tom (Fig. 15). (Refer to 9 - ENGINE - SPECIFICA-
TIONS) Replace guides if they are not within
specification.

(5) Check valve guide height (Fig. 16).

INSTALLATION - CYLINDER HEAD

NOTE: The Cylinder head bolts should be examined
BEFORE reuse. If the threads are necked down, the
bolts must be replaced (Fig. 17).

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.

(1) Before installing the bolts, the threads should

be coated with engine oil.

Fig. 14 Checking Cylinder Head Flatness

1 - FEELER GAUGE
2 - STRAIGHT EDGE

Fig. 15 Checking Wear on Valve Guide—Typical

1 - TOP
2 - MIDDLE
3 - BOTTOM
4 - CUT AWAY VIEW OF VALVE GUIDE MEASUREMENT
LOCATIONS

Fig. 16 Valve Guide Height

1 - VALVE GUIDE
2 - 13.25 - 13.75 MM (0.521 - 0.541 IN.)
3 - SPRING SEAT

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ENGINE 2.4L

9 - 27

CYLINDER HEAD (Continued)

(2) Position cylinder head gasket on engine block

(Fig. 18).

(3) Install cylinder head on engine block.
(4) Tighten the cylinder head bolts in the sequence

shown in (Fig. 19). Using the 4 step torque turn
method, tighten according to the following values:

• First All to 34 N·m (25 ft. lbs.)

• Second All to 68 N·m (50 ft. lbs.)

• Third All to 68 N·m (50 ft. lbs.)

CAUTION: Do not use a torque wrench for the fol-
lowing step.

• Fourth Turn an additional 1/4 Turn,
(5) Install rocker arms. (Refer to 9 - ENGINE/

CYLINDER HEAD/ROCKER ARMS - INSTALLA-
TION)

(6) Install camshafts. (Refer to 9 - ENGINE/CYL-

INDER HEAD/CAMSHAFT(S) - INSTALLATION).

(7) Install cylinder head cover. (Refer to 9 -

ENGINE/CYLINDER

HEAD/CYLINDER

HEAD

COVER(S) - INSTALLATION)

(8) Install timing belt rear cover and timing belt

idler pulley. (Refer to 9 - ENGINE/VALVE TIMING/
TIMING BELT / CHAIN COVER(S) - INSTALLA-
TION)

(9)

Install timing belt and camshaft sprockets.

(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT/CHAIN AND SPROCKETS - INSTALLATION)

(10) Connect cam sensor and fuel injectors wiring

connectors.

(11) Install ignition coil and wires. Connect igni-

tion coil wiring connector.

(12) Install power steering pump reservoir and

line support bracket to cylinder head.

(13) Raise vehicle and install the exhaust pipe to

the manifold.

(14) Install accessory drive belts. (Refer to 7 -

COOLING/ACCESSORY

DRIVE/DRIVE

BELTS

-

INSTALLATION)

(15) Install heater tube support bracket to cylinder

head.

(16) Connect radiator upper and heater hoses to

intake manifold water outlet connections.

(17) Install upper intake manifold. (Refer to 9 -

ENGINE/MANIFOLDS/INTAKE

MANIFOLD

-

INSTALLATION)

(18) Using new gaskets, install EGR tube and

tighten fasteners to 11 N·m (95 in. lbs.).

(19) Install air inlet tube and housing.
(20) Connect all vacuum lines, electrical wiring,

ground straps and fuel line.

(21) Fill cooling system. (Refer to 7 - COOLING -

STANDARD PROCEDURE)

(22) Connect battery negative cable.

CAMSHAFT OIL SEAL(S)

REMOVAL

(1) Remove timing belt (Refer to 9 - ENGINE/

VALVE TIMING/TIMING BELT AND SPROCKETS -
REMOVAL).

Fig. 17 Checking Bolts for Stretching (Necking)

1 - STRETCHED BOLT
2 - THREADS ARE NOT STRAIGHT ON LINE
3 - THREADS ARE STRAIGHT ON LINE
4 - UNSTRETCHED BOLT

Fig. 18 Cylinder Head Gasket Positioning

1 - PART NUMBER FACES UP
2 - NO. 1 CYLINDER

Fig. 19 Cylinder Head Tightening Sequence

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ENGINE 2.4L

RS

CYLINDER HEAD (Continued)