Chrysler RG Voyager. Manual — part 927
(26) Connect the fuel line. (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY/QUICK CONNECT FIT-
TING - STANDARD PROCEDURE)
(27) Connect radiator lower and upper hoses.
(28) Install radiator fans. (Refer to 7 - COOLING/
ENGINE/RADIATOR FAN - INSTALLATION)
(29) Fill cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(30) Connect battery cables.
(31) Install air cleaner and inlet hose.
(32) Fill engine crankcase with proper oil to cor-
rect level.
(33) Start engine and run until operating temper-
ature is reached.
(34) Adjust transmission linkage, if necessary.
SPECIFICATIONS
2.4L ENGINE
GENERAL SPECIFICATIONS
DESCRIPTION
SPECIFICATION
Metric
Standard
Type
In-Line OHV, DOHC
Number of
Cylinders
4
Firing Order
1-3-4-2
Compression
Ratio
9.5:1
Max. Variation
Between
Cylinders
25%
Displacement
2.4 Liters
148 cu. in.
Bore
87.5 mm
3.445 in.
Stroke
101.0 mm
3.976 in.
Compression
Pressure
1172-1551 kPa
170-225 psi
CYLINDER BLOCK
DESCRIPTION
SPECIFICATION
Metric
Standard
Cylinder Bore
Diameter
87.4924-
87.5076 mm
3.4446-3.4452
in.
Out-of-Round
(Max.)
0.051 mm
0.002 in.
Taper (Max.)
0.051 mm
0.002 in.
PISTONS
DESCRIPTION
SPECIFICATION
Metric
Standard
Piston Diameter
87.456-87.474
mm
3.4431-3.4439
in.
Clearance @
24.6 mm (0.551
in.) from bottom
of skirt
0.018-0.0516
mm
0.0007-0.0020
in.
Weight
345-355 grams
12.17-12.52 oz.
Land Clearance
(Diametrical)
0.563-0.621
mm
0.022-0.024 in.
Piston Length
66.25 mm
2.608 in.
Piston Ring
Groove Depth
No. 1
3.946-4.045
mm
0.155-0.159 in.
Piston Ring
Groove Depth
No. 2
4.555-4.680
mm
0.179-0.184 in.
Piston Ring
Groove Depth
No. 3
4.108-4.220
mm
0.162-0.166 in.
PISTON PINS
DESCRIPTION
SPECIFICATION
Metric
Standard
Clearance in
Piston
0.005-0.018
mm
0.0002-0.0008
in.
Clearance in
Connecting Rod
Interference
Diameter
21.99822.003
mm
0.8660-0.8662
in.
End Play
None
Length
72.75-73.25
mm
2.864-2.883 in.
RS
ENGINE 2.4L
9 - 17
ENGINE 2.4L (Continued)
PISTON RINGS
DESCRIPTION
SPECIFICATION
Metric
Standard
Ring Gap-Top
Compression
Ring
0.25-0.51 mm
0.0098-0.020 in.
Wear Limit
0.8 mm
0.031 in.
Ring Gap-2nd
Compression
Ring
0.23-0.48 mm
0.009-0.018 in.
Wear Limit
0.8 mm
0.031 in.
Ring Gap-Oil
Control Steel
Rails
0.25-0.64 mm
0.009-0.025 in.
Wear Limit
1.0 mm
0.039 in.
Ring Side
Clearance-
Compression
Rings
0.030-0.080
mm
0.0011-0.0031
in.
Wear Limit
0.10 mm
0.004 in.
Ring Side
Clearance-Oil
Ring Pack
0.012-0.178
mm
0.0004-0.0070
in.
Ring Width-
Compression
Rings
1.47-1.50 mm
0.057-0.059 in.
Ring Width-Oil
Ring Pack
2.72–2.88 mm
0.107–0.1133
in.
CONNECTING ROD
DESCRIPTION
SPECIFICATION
Metric
Standard
Bearing
Clearance
0.025–0.071
mm
0.0009–0.0027
in.
Wear Limit
0.075 mm
0.003 in.
Bore Diameter-
Piston Pin
20.96–20.98
mm
0.8664-0.8667
in.
Bore Diameter-
Crankshaft End
52.993-53.007
mm
2.0863-2.0868
in.
Side Clearance
0.13–0.38 mm
0.005–0.015 in.
Wear Limit
0.40 mm
0.016 in.
Weight-Total
(Less Bearing)
565.8 grams
19.96 oz.
CRANKSHAFT
DESCRIPTION
SPECIFICATION
Metric
Standard
Connecting Rod
Journal
Diameter
49.984 - 50.000
mm
1.968 - 1.9685
in.
Main Bearing
Journal
Diameter
59.992 - 60.008
mm
2.362 - 2.3625
in.
Journal
Out-of-Round
(Max.)
0.0035 mm
0.0003 in.
Journal Taper
(Max.)
0.007 mm
0.0001 in.
End Play
0.09 - 0.24 mm
0.0035 - 0.0094
in.
Wear Limit
0.38 mm
0.015 in.
Main Bearing
Diametrical
Clearance
0.018 - 0.062
mm
0.0007 - 0.0024
in.
HYDRAULIC LASH ADJUSTER
DESCRIPTION
SPECIFICATION
Metric
Standard
Body Diameter
15.901 - 15.913
mm
0.626 - 0.6264
in.
Plunger Travel
Minimum (Dry)
3.0 mm
0.118 in.
CYLINDER HEAD CAMSHAFT BEARING BORE
DIAMETER
DSECRIPTION
SPECIFICATION
Metric
Standard
Journals No.1 -
6
26.020 - 26.041
mm
1.024 - 1.025 in.
9 - 18
ENGINE 2.4L
RS
ENGINE 2.4L (Continued)
CAMSHAFT
DESCRIPTION
SPECIFICATION
Metric
Standard
Journal
Diameter No.
1–6
25.976 - 25.995
mm
1.022 - 1.023 in.
Bearing
Clearance -
Diametrical
0.025 - 0.065
mm
0.0009 - 0.0025
in.
End Play
0.05 - 0.17 mm
0.0019 - 0.0066
in.
Lift (Zero Lash)
Intake
8.25 mm
(0.324 in.)
Exhaust
6.60 mm
(0.259 mm)
Intake Valve
Timing*
Closes (ABDC)
44.3°
Opens (ATDC)
6.2°
Duration
218°
Exhaust Valve
Timing*
Closes (ATDC)
0.8°
Opens (BBDC)
39.9°
Duration
220.7°
Valve Overlap
5.4°
*
All reading in crankshaft degrees at 0.5 mm (0.019
in.) valve lift.
CYLINDER HEAD
DESCRIPTION
SPECIFICATION
Metric
Standard
Material
Cast Aluminum
Gasket
Thickness
(Compressed)
0.71 mm
0.028 in.
VALVE SEAT
DESCRIPTION
SPECIFICATION
Metric
Standard
Angle
44.5 - 45°
Seat Diameter -
Intake
34.37 - 34.63
mm
1.353 - 1.363 in.
Seat Diameter -
Exhaust
27.06 - 27.32
mm
1.065 - 1.075 in.
Runout (Max.)
0.05 mm
0.002 in.
Valve Seat
Width - Intake
and Exhaust
0.9 - 1.3 mm
0.035 - 0.051 in.
Service Limit -
Intake
2.0 mm
0.079 in.
Service Limit -
Exhaust
2.5 mm
0.098 in.
VALVE GUIDE
DESCRIPTION
SPECIFICATION
Metric
Standard
Diameter I.D.
5.975 - 6.000
mm
0.235 - 0.236 in.
Guide Bore
Diameter
11.0 - 11.02
mm
0.4330 - 0.4338
in.
Guide Height
(spring seat to
guide tip)
13.25 - 13.75
mm
0.521 - 0.541 in.
VALVES
DESCRIPTION
SPECIFICATION
Metric
Standard
Face Angle -
Intake and
Exhaust
45 - 45.5°
Head Diameter
- Intake
34.67 - 34.93
mm
1.364 - 1.375
in.)
Head Diameter
- Exhaust
28.32 - 28.58
mm
1.114 - 1.125 in.
Valve Length
(Overall)
Intake
111.49 - 111.99
mm
4.389 - 4.409 in.
Exhaust
109.59 - 110.09
mm
4.314 - 4.334 in.
RS
ENGINE 2.4L
9 - 19
ENGINE 2.4L (Continued)
DESCRIPTION
SPECIFICATION
Metric
Standard
Valve Stem
Diameter
Intake
5.934 - 5.952
mm
0.2337 - 0.2344
in.
Exhaust
5.906 - 5.924
mm
0.2326 - 0.2333
in.
VALVE MARGIN
DESCRIPTION
SPECIFICATION
Metric
Standard
Intake
1.2 - 1.7 mm
0.047 - 0.066 in.
Service Limit
0.95 mm
(.0037 in.)
Exhaust
0.985 - 1.315
mm
0.038 - 0.051 in.
Service Limit
1.05 mm
.039 in.
VALVE STEM TIP HEIGHT
DESCRIPTION
SPECIFICATION
Metric
Standard
Intake
48.04 mm
1.891 in.
Exhaust
47.99 mm
1.889 in.
VALVE STEM TO GUIDE CLEARANCE
DESCRIPTION
SPECIFICATION
Metric
Standard
Intake
0.048 - 0.066
mm
0.0018 - 0.0025
in.
Max. Allowable
0.076 mm
0.003 in.
Service Limit
0.25 mm
0.010 in.
Exhaust
0.0736 - 0.094
mm
0.0029 - 0.0037
in.
Max. Allowable
0.101 mm
0.004 in.
Service Limit
0.25 mm
0.010 in.
VALVE SPRINGS
DESCRIPTION
SPECIFICATION
Metric
Standard
Free Length
(Approx.)
49.34 mm
1.943 in.
Nominal Force
(Valve Closed)
311 N @ 38.0
mm
70 lbs. @ 1.496
in.
Nominal Force
(Valve Open)
596 N ± 30.7
N@ 29.25 mm
134 lbs. @
1.152 in.
Installed Height
38.00 mm
1.496 in.
Number of Coils
7.8
Wire Diameter
3.61 mm
0.142 in
OIL PUMP
DESCRIPTION
SPECIFICATION
Metric
Standard
Clearance Over
Rotors (Max.)
0.10 mm
0.004 in.
Cover
Out-of-Flat
(Max.)
0.025 mm
0.001 in.
Inner Rotor
Thickness (Min.)
10.699 mm
0.421 in.
Outer Rotor
Thickness (Min.)
10.699 mm
0.421 in.
Outer Rotor
Clearance
(Max.)
0.039 mm
0.015 in.
Outer Rotor
Diameter (Min.)
85.924 mm
3.383 in.
Tip Clearance
Between Rotors
(Max.)
0.20 mm
0.008 in.
OIL PRESSURE
DESCRIPTION
SPECIFICATION
Metric
Standard
At Curb Idle
Speed*
25 kPa
4 psi
At 3000 rpm
170 - 550 kPa
25 - 80 psi
CAUTION:
*If pressure is ZERO at curb idle, DO NOT run engine
at 3000 rpm.
9 - 20
ENGINE 2.4L
RS
ENGINE 2.4L (Continued)
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