1996 CHRYSLER VOYAGER Service Manual

(3) Remove balance shaft gear and chain sprocket
retaining screws and crankshaft chain sprocket.
Remove chain and sprocket assembly (Fig. 39). Using
two wide pry bars, work the sprocket back and forth
until it is off the shaft.
(4) Remove carrier gear cover and balance shafts
(Fig. 40).
(5) Remove four carrier to crankcase attaching
bolts to separate carrier from engine bedplate.BALANCE SHAFT CARRIER
REMOVAL
The following components will remain intact dur-
ing carrier removal. Gear cover, gears, balance shafts
and the rear cover (Fig. 41).
(1) Remove chain cover and driven balance shaft
chain sprocket screw.
(2) Loosen tensioner pivot and adjusting screws,
move driven balance shaft inboard through driven
chain sprocket. Sprocket will hang in lower chain
loop.
(3) Remove carrier to crankcase attaching bolts to
remove carrier.
BALANCE SHAFT INSTALLATION
Balance shaft and carrier assembly installation is
the reverse of the removal procedure.During instal-
lation crankshaft to balance shaft timing must
be established. Refer to Timing procedure out-
lined in this section.
BALANCE SHAFT TIMING
(1) With balance shafts installed in carrier (Fig.
42) position carrier on crankcase and install four
attaching bolts and tighten to 54 N´m (40 ft. lbs.).
(2) Turn balance shafts until both shaft key ways
are up Parallel to vertical centerline of engine.
Install short hub drive gear on sprocket driven shaft
and long hub gear on gear driven shaft. After instal-
lation gear and balance shaft keyways must be up
with gear timing marks meshed as shown in (Fig.
43).
Fig. 39 Drive Chain and Sprockets
Fig. 40 Gear Cover and Gears
Fig. 41 Balance Shaft(s)ÐRemoval/Installation
NS2.4L ENGINE 9 - 31
REMOVAL AND INSTALLATION (Continued)

(3) Install gear cover and tighten double ended
stud/washer fastener to 12 N´m (105 in. lbs.).
(4) Install crankshaft sprocket using Special Tool
6052 (Fig. 44).
(5) Turn crankshaft until number one cylinder is
at Top Dead Center (TDC). The timing marks on the
chain sprocket should line up with the parting line
on the left side of number one main bearing cap.
(Fig. 45).
(6) Place chain over crankshaft sprocket so that
the nickel plated link of the chain is over the number
1 cylinder timing mark on the crankshaft sprocket
(Fig. 45).
(7) Place balance shaft sprocket into the timing
chain (Fig. 45) so that the timing mark on the
sprocket (yellow dot) mates with the (lower) nickel
plated link on the chain
(8) With balance shaft keyways pointing up (12
o'clock) slide the balance shaft sprocket onto the noseof the balance shaft. The balance shaft may have to
be pushed in slightly to allow for clearance.
Fig. 42 Balance Shaft(s)ÐRemoval/Installation
Fig. 43 Gear Timing
Fig. 44 Crankshaft SprocketÐInstallation
Fig. 45 Balance Shaft Timing
9 - 32 2.4L ENGINENS
REMOVAL AND INSTALLATION (Continued)

NOTE: THE TIMING MARK ON THE SPROCKET,
THE (LOWER) NICKEL PLATED LINK, AND THE
ARROW ON THE SIDE OF THE GEAR COVER
SHOULD LINE UP WHEN THE BALANCE SHAFTS
ARE TIMED CORRECTLY.
(9) If the sprockets are timed correctly install the
balance shaft bolts and tighten to 28 N´m (250 in.
lbs.). A wood block placed between crankcase and
crankshaft counterbalance will prevent crankshaft
and gear rotation.
CHAIN TENSIONING
(1) Install chain tensioner loosely assembled.
(2) Position guide on double ended stud making
sure tab on the guide fits into slot on the gear cover.
Install and tighten nut/washer assembly to 12 N´m
(105 in. lbs.).
(3) Place a shim 1 mm (0.039 in.) thick x 70 mm
(2.75 in.) long or between tensioner and chain. Push
tensioner and shim up against the chain.Apply firm
pressure (5.5 to 6.6 lbs.) directly behind the
adjustment slot to take up all slack.Chain must
have shoe radius contact as shown in (Fig. 46).
(4) With the load applied, tighten top tensioner
bolt first, then bottom pivot bolt. Tighten bolts to 12
N´m (105 in. lbs.). Remove shim.
(5) Install carrier covers and tighten screws to 12
N´m (105 in. lbs.).HYDRAULIC LASH ADJUSTER
REMOVAL
(1) Remove cylinder head cover. Refer to procedure
outlined in this section.
(2) Remove cam follower assembly. Refer to cam-
shaft removal procedure outlined in this section to
gain access to cam followers and lash adjusters.
(3) Mark hydraulic lash adjusters for reassembly
in their original position. Lash adjusters are serviced
as an assembly.
INSTALLATION
(1) Install hydraulic lash adjuster assembly mak-
ing sure adjusters are at least partially full of oil.
This is indicated by little or no plunger travel when
the lash adjuster is depressed.
(2) Install cam follower assembly as previously
outlined in this section.
(3) Install camshaft as previously outlined in this
section.
(4) Install cylinder head cover as previously out-
lined in this section.
VALVE SPRINGS AND VALVE SEALS IN VEHICLE
REMOVAL
(1) Remove camshafts as previously outlined in
this section.
(2) Rotate crankshaft until piston is at TDC on
compression.
(3) With air hose attached to adapter tool
installed in spark plug hole, apply 90-120 psi air
pressure.
(4) Using Special Tool MD-998772-A with adapter
6779 (Fig. 47) compress valve springs and remove
valve locks.
(5) Remove valve spring.
(6) Remove valve stem seal by a using valve stem
seal tool.
INSTALLATION
(1) Install valve seal/valve spring seat assembly
(Fig. 48). Push the assembly down to seat it onto the
valve guide.
(2) Install valve spring and retainer, use Special
Tool MD-998772-A with adapter 6779 to compress
valve springs only enough to install locks (Fig. 47).
Correct alignment of tool is necessary to avoid nick-
ing valve stems.
(3) Remove air hose and install spark plugs.
(4) Install camshafts as previously outlined in this
section.
(5) Install cylinder head cover as previously out-
lined in this section.
Fig. 46 Chain Tension Adjustment
NS2.4L ENGINE 9 - 33
REMOVAL AND INSTALLATION (Continued)

CYLINDER HEAD
REMOVAL
(1) Perform fuel system pressure release proce-
durebefore attempting any repairs.Refer to
Group 14, Fuel System for procedure.
(2) Disconnect negative battery cable. Drain cool-
ing system. Refer to Group 7, Cooling System for pro-
cedure.
(3) Remove air cleaner and disconnect all vacuum
lines, electrical wiring and fuel lines from throttle
body.
(4) Remove throttle linkage. Refer to Group 14,
Fuel System for procedures
(5) Remove accessory drive belts. Refer to Group
7, Cooling System for procedure.
(6) Remove power brake vacuum hose from intake
manifold.
(7) Raise vehicle and remove exhaust pipe from
manifold.(8) Remove power steering pump assembly and
set aside.
(9) Disconnect coil pack wiring connector and
remove coil pack and plug wires from engine.
(10) Remove cam sensor and fuel injectors wiring
connectors.
(11) Remove timing belt and camshaft sprocket.
Refer to procedure outlined in this section.
(12) Remove timing belt idler pulley and rear tim-
ing belt cover.
(13) Remove cylinder head cover using procedure
outlined in this section.
(14) Remove camshafts and cam followers. Refer to
procedures outlined in this section for procedures.
(15) Remove cylinder head bolts and remove cyl-
inder head from engine block.
(16) Inspect and clean cylinder head. Refer to
Cleaning and Inspection outlined in this section for
procedures.
INSTALLATION
NOTE: The Cylinder head bolts should be exam-
ined BEFORE reuse. If the threads are necked
down, the bolts should be replaced (Fig. 49).
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.
(2) Tighten the cylinder head bolts in the
sequence shown in (Fig. 50). Using the 4 step torque
turn method, tighten according to the following val-
ues:
²First All to 34 N´m (25 ft. lbs.)
²Second All to 68 N´m (50 ft. lbs.)
²Third All to 68 N´m (50 ft. lbs.)
CAUTION: Do not use a torque wrench for the fol-
lowing step.
²Fourth Turn an additional 1/4 Turn,
(3) Install camshafts and cam followers. Refer to
procedures outlined in this section for procedures.
Fig. 47 Valve SpringÐRemoval/Installation
Fig. 48 Valve Stem Seal/Valve Spring Seat
Fig. 49 Checking Bolts for Stretching (Necking)
9 - 34 2.4L ENGINENS
REMOVAL AND INSTALLATION (Continued)