Chrysler RG Voyager. Manual — part 937
OIL PRESSURE SWITCH
REMOVAL
(1) Raise vehicle.
(2) Position oil collecting container under pressure
switch location.
(3) Disconnect oil pressure switch electrical con-
nector and remove switch (Fig. 91).
INSTALLATION
(1) Install oil pressure switch. Torque switch to 21
N·m (190 in. lbs.) (Fig. 91).
(2) Connect electrical connector
(3) Lower vehicle.
(4) Start engine and allow to run a minimum of 2
minutes.
(5) Shut engine off and check engine oil level.
Adjust level as necessary.
OIL PUMP
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
REMOVAL).
(3) Remove timing belt rear cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT COVER(S)
- REMOVAL).
(4) Remove oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - REMOVAL).
(5) Remove
crankshaft
sprocket
using
Special
Tools 6793 and C-4685-C2 (Fig. 92).
(6) Remove crankshaft key (Fig. 93).
(7) Remove oil pick-up tube.
(8) Remove oil pump (Fig. 94) and front crankshaft
seal.
Fig. 91 Engine Oil Pressure Switch
Fig. 92 Crankshaft Sprocket - Removal
1 - SPECIAL TOOL 6793
2 - SPECIAL TOOL C-4685–C2
3 - CRANKSHAFT SPROCKET
Fig. 93 Crankshaft Key
1 - CRANKSHAFT KEY
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ENGINE 2.4L
9 - 57
DISASSEMBLY
(1)
To remove the relief valve, proceed as follows:
(a) Remove the threaded plug and gasket from
the oil pump (Fig. 95).
(b) Remove spring and relief valve (Fig. 95).
(2)
Remove oil pump cover fasteners, and lift off
cover (Fig. 96).
(3)
Remove pump rotors (Fig. 96).
(4)
Wash all parts in a suitable solvent and
inspect carefully for damage or wear.
CLEANING
(1) Clean all parts thoroughly in a suitable sol-
vent.
INSPECTION
(1) Inspect the mating surfaces of the oil pump
cover. Surface should be smooth. Replace pump cover
if scratched or grooved.
(2) Lay a straightedge across the pump cover sur-
face (Fig. 97). If a 0.025 mm (0.001 in.) feeler gauge
can be inserted between cover and straight edge,
cover should be replaced.
(3) Measure thickness and diameter of outer rotor.
If outer rotor thickness measures 9.40 mm (0.370 in.)
or less (Fig. 98), or if the diameter is 79.95 mm
(3.148 in.) or less, replace outer rotor.
(4) If inner rotor measures 9.40 mm (0.370 in.) or
less replace inner rotor (Fig. 99).
Fig. 94 Oil Pump
1 - BOLTS
2 - BOLTS
3 - OIL PUMP
Fig. 95 Oil Pressure Relief Valve
1 - PLUG
2 - OIL PUMP BODY
3 - RELIEF VALVE
4 - SPRING
5 - SEAL
Fig. 96 Oil Pump
1 - O-RING
2 - SEAL
3 - INNER ROTOR
4 - OIL PUMP COVER
5 - FASTENER
6 - OUTER ROTOR
7 - OIL PUMP BODY
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ENGINE 2.4L
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OIL PUMP (Continued)
ASSEMBLY
(1) Assemble pump, using new parts as required.
Install the inner rotor with chamfer facing the
cast iron oil pump cover.
(2)
Prime oil pump before installation by filling
rotor cavity with engine oil.
(3)
Install cover and tighten fasteners to 12 N·m
(105 in. lbs.) (Fig. 96).
CAUTION: Oil pump pressure relief valve must be
installed as shown in (Fig. 95) or serious engine
damage may occur.
(4)
Install relief valve, spring, gasket and cap as
shown in (Fig. 95). Tighten cap to 41 N·m (30 ft.
lbs.).
INSTALLATION
(1) Make sure all surfaces are clean and free of oil
and dirt.
(2) Apply Mopar
t Gasket Maker to oil pump as
shown in (Fig. 100). Install O-ring into oil pump body
discharge passage.
(3) Prime oil pump with engine oil before installa-
tion.
(4) Align oil pump rotor flats with flats on crank-
shaft. Install the oil pump to the block (Fig. 94).
CAUTION: To align, the front crankshaft seal MUST
be out of pump, or damage may result.
(5) Install new front crankshaft seal using Special
Tool 6780 (Fig. 101).
(6) Install crankshaft key (Fig. 93).
Fig. 97 Checking Oil Pump Cover Flatness
1 - STRAIGHT EDGE
2 - FEELER GAUGE
3 - OIL PUMP COVER
Fig. 98 Measuring Outer Rotor Thickness
Fig. 99 Measuring Inner Rotor Thickness
Fig. 100 Oil Pump Sealing
1 - O-RING
2 - SEALER LOCATION
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ENGINE 2.4L
9 - 59
OIL PUMP (Continued)
CAUTION: The crankshaft sprocket is set to a pre-
determined depth from the factory for correct tim-
ing belt tracking. If removed, use of Special Tool
6792 is required to set the sprocket to original
installation depth. An incorrectly installed sprocket
will result in timing belt and engine damage.
(7) Install crankshaft sprocket using Special Tool
6792 (Fig. 102).
(8) Install oil pump pick-up tube.
(9) Install oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION).
(10) Install timing belt rear cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT COVER(S)
- INSTALLATION).
(11) Install timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
INSTALLATION).
INTAKE MANIFOLD
DESCRIPTION
The intake manifold is a two piece aluminum cast-
ing (Fig. 103) that attaches to the cylinder head with
fasteners. The manifold is a long branch design to
enhance low and mid-range torque
Fig. 101 Front Crankshaft Seal - Installation
1 - PROTECTOR
2 - SEAL
3 - SPECIAL TOOL 6780
Fig. 102 Crankshaft Sprocket - Installation
1 - SPECIAL TOOL 6792
2 - TIGHTEN NUT TO INSTALL
Fig. 103 Intake Manifold - Upper and Lower
1 - UPPER INTAKE MANIFOLD
2 - LOWER INTAKE MANIFOLD
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ENGINE 2.4L
RS
OIL PUMP (Continued)
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