2001 CHRYSLER VOYAGER torque

(5) Rotate crankshaft so that the connecting rod
journal is on the center of the cylinder bore. Insert
rod and piston assembly into cylinder bore and guide
rod over the crankshaft journal.
(6) Tap the piston down in cylinder bore, using a
hammer handle. At the same time, guide connecting
rod into position on connecting rod journal.
NOTE: The connecting rod cap bolts should not be
reused.
(7) Before installing theNEWbolts the threads
should be coated with clean engine oil.
(8) Install each bolt finger tight than alternately
torque each bolt to assemble the cap properly.
CAUTION: Do not use a torque wrench for second
part of last step.
(9) Tighten the bolts to 27 N´m PLUS 1/4 turn (20
ft. lbs. PLUS 1/4 turn).
(10) Using a feeler gauge, check connecting rod
side clearance (Fig. 70).
PISTON RINGS
PISTON RINGÐFITTING
(1) Wipe cylinder bore clean. Insert ring and push
down with piston to ensure it is square in bore. The
ring gap measurement must be made with the ring
positioning at least 12 mm (0.50 inch) from bottom of
cylinder bore. Check gap with feeler gauge (Fig. 71).
Refer to Engine Specifications.
(2) Check piston ring to groove side clearance (Fig.
72). Refer to Engine Specifications.
Fig. 69 PistonÐInstallation
Fig. 70 Checking Connecting Rod Side Clearance
Fig. 71 Piston Ring Gap
1 - FEELER GAUGE
Fig. 72 Piston Ring Side Clearance
1 - FEELER GAUGE
9 - 44 ENGINE 2.4LRS
PISTON & CONNECTING ROD (Continued)

VIBRATION DAMPER
REMOVAL
(1) Remove accesory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)
(2) Remove crankshaft damper bolt.
(3) Remove damper using Special Tool 3-Jaw
Puller 1026 and Insert 6827±A (Fig. 76).
INSTALLATION
(1) Install crankshaft vibration damper using M12
1.75 x 150 mm bolt, washer, thrust bearing and nut
from Special Tool 6792 (Fig. 77).
(2) Install crankshaft vibration damper bolt and
tighten to 142 N´m (105 ft. lbs.).
(3) Install accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION)
STRUCTURAL COLLAR
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove engine front mount bracket and front
insulator mount. (Refer to 9 - ENGINE/ENGINE
MOUNTING/FRONT MOUNT - REMOVAL)
(3) Remove structural collar attaching bolts (Fig.
78).
(4) Remove collar.
INSTALLATION
CAUTION: Torque procedure for the structural collar
must be followed or damage could occur to oil pan
and collar.(1) Perform the following steps for installing struc-
tural collar. Refer to (Fig. 78):
²Step 1: Position collar between transaxle and oil
pan. Install collar to transaxle bolt,hand start
only.
²Step 2: Install collar to oil pan bolts,hand snug
only.
Fig. 76 Crankshaft Vibration Damper - Removal
1 - SPECIAL TOOL 1026 3-JAW PULLER
2 - SPECIAL TOOL 6827±A INSERT
Fig. 77 Crankshaft Vibration Damper - Installation
1 - M12±1.753150 MM BOLT, WASHER AND THRUST
BEARING FROM SPECIAL TOOL 6792
Fig. 78 Structural Collar
1 - BOLT - COLLAR TO OIL PAN
2 - BOLT - COLLAR TO TRANSAXLE
3 - STRUCTURAL COLLAR
4 - OIL PAN
9 - 46 ENGINE 2.4LRS

²Step 3: Final torque collar to transaxle bolts to
101 N´m (75 ft. lbs.)
²Step 4: Final torque collar to oil pan bolts to 54
N´m (40 ft. lbs.).
(2) Install engine front mount bracket and insula-
tor. (Refer to 9 - ENGINE/ENGINE MOUNTING/
FRONT MOUNT - INSTALLATION)
(3) Lower vehicle.
ENGINE MOUNTING
DESCRIPTION
The engine mounting system consist of four
mounts; right and a left side support the powertrain,
and a front and a rear mount control powertrain
torque. The right side mount is a hydro-type (Fig.
79), all others are of molded rubber material.
FRONT MOUNT
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove the front engine mount through bolt
from the insulator (Fig. 80).
(3) Remove the engine front mount bolts and
remove the insulator assembly (Fig. 80).(4) Remove the front mounting bracket from
engine, if necessary (Fig. 80).
INSTALLATION
(1) Install the front mount bracket to engine, if
removed (Fig. 80).
(2) Install the insulator mount assembly (Fig. 80).
(3) Install the front engine mount through bolt to
the insulator (Fig. 80).
(4) Lower the vehicle.
LEFT MOUNT
REMOVAL
(1) Raise the vehicle on hoist.
(2) Remove the left front wheel.
(3) Remove the left mount through bolt access
cover.
(4) Support the transaxle with a suitable jack.
(5) Remove the engine front mount through bolt to
allow left mount removal clearance (Fig. 90).
(6) Remove the left mount through frame rail bolt
(Fig. 81).
(7) Lower transaxle for access to horizontal bolts.
Fig. 79 Engine Hydro-type Mount - Right Side
1 - BOLT
2 - BOLT
3 - FRAME RAIL
4 - RIGHT MOUNT - 2.4L ENGINE
5 - RIGHT MOUNT - 3.3/3.8L ENGINE
Fig. 80 Front Mount and Bracket
1 - BRACKET - FRONT MOUNT
2 - NUT - 68 N´m (50 ft. lbs.)
3 - BOLT - 54 N´m (40 ft. lbs.)
4 - MOUNT - FRONT INSULATOR
5 - BOLT - 68 N´m (50 ft. lbs.)
6 - BOLT - 68 N´m (50 ft. lbs.)
7 - FRONT CROSSMEMBER
RSENGINE 2.4L9-47
STRUCTURAL COLLAR (Continued)

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
OPERATION
The intake manifold delivers air to the combustion
chambers. This air allows the fuel delivered by the
fuel injectors to ignite when the spark plug fire.
DIAGNOSIS AND TESTING - INTAKE
MANIFOLD LEAKS
An intake manifold air leak is characterized by
lower than normal manifold vacuum. Also, one or
more cylinders may not be functioning.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
(1) Start the engine.
(2) Spray a small stream of water (Spray Bottle) at
the suspected leak area.
(3) If engine RPM'S change, the area of the sus-
pected leak has been found.
(4) Repair as required.
INTAKE MANIFOLD - UPPER
REMOVAL
(1) Disconnect negative cable from battery.
(2) Disconnect connector from inlet air tempera-
ture sensor (Fig. 104).
(3) Disconnect air intake tube at throttle body and
remove upper air cleaner housing.
(4) Disconnect connector from throttle position
sensor (TPS) (Fig. 106).
(5) Disconnect connector from idle air control (IAC)
motor (Fig. 106).
(6) Disconnect connector from MAP sensor (Fig.
105).
(7) Remove vacuum lines for purge solenoid and
PCV valve at intake manifold.
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
Fig. 104 INLET AIR TEMPERATURE SENSOR - 2.4L
9 - 56 ENGINE 2.4LRS
OIL PUMP (Continued)

(8) Remove vacuum lines for power brake booster,
LDP, EGR transducer, and speed control vacuum res-
ervoir (if equipped) at upper intake manifold fittings.
(9) Disconnect throttle, speed control (if equipped),
and transaxle control (31TH equipped only) cables
from throttle lever and bracket. (Refer to 14 - FUEL
SYSTEM/FUEL INJECTION/THROTTLE CONTROL
CABLE - REMOVAL)
(10) Remove the EGR tube. (Refer to 25 - EMIS-
SIONS CONTROL/EXHAUST GAS RECIRCULA-
TION/TUBE - REMOVAL)
(11) Remove the upper manifold support bracket
bolt to manifold (Fig. 107).
(12) Remove engine oil dipstick from tube.(13) Remove upper intake manifold bolts (Fig.
108). Remove upper intake manifold.
CAUTION: Cover intake manifold to prevent foreign
material from entering engine.
INSPECTION
(1) Check manifold surfaces for flatness with
straight edge. Surface must be flat within 0.15 mm
per 300 mm (0.006 in. per foot) of manifold length.
(2) Inspect manifold for cracks or distortion.
Replace manifold if necessary.
INSTALLATION
(1) Clean manifold sealing surfaces.
(2) Apply a 1.5 mm (0.060 in.) bead MopartGas-
ket Maker to the perimeter of the lower intake man-
ifold runner openings.
(3) Install upper intake manifold and tighten fas-
teners to 28 N´m (250 in. lbs.) in sequence shown in
(Fig. 108). Repeat this procedures until all fasteners
are at specified torque.
(4) Install engine oil dipstick.
(5) Install upper bolt in intake manifold to front
support bracket (Fig. 107). Torque to 28 N´m (250 in.
lbs.).
(6) Install EGR tube. (Refer to 25 - EMISSIONS
CONTROL/EXHAUST GAS RECIRCULATION/
TUBE - INSTALLATION)
(7) Install throttle cables in bracket.
(8) Connect throttle, speed control, (if equipped),
transaxle control (31TH equipped only) cables to
throttle lever.
Fig. 105 MAP SENSOR - 2.4L
1 - MAP SENSOR
Fig. 106 Throttle Body Electrical Connectors -
Typical
1 - IDLE AIR CONTROL MOTOR CONNECTOR
2 - TPS CONNECTOR
Fig. 107 Upper Intake Manifold Support Bracket
1 - NUT - BRACKET TO CYLINDER HEAD COVER
2 - BOLT - BRACKET TO UPPER INTAKE MANIFOLD
3 - UPPER INTAKE MANIFOLD SUPPORT BRACKET
RSENGINE 2.4L9-57
INTAKE MANIFOLD - UPPER (Continued)

(9) Connect vacuum lines for power brake booster,
LDP, EGR transducer, and speed control vacuum res-
ervoir (if equipped) at upper intake manifold fittings.
(10) Connect vacuum lines for purge solenoid and
PCV valve.
(11) Connect electrical connectors for MAP sensor,
throttle position sensor (TPS), and idle air control
(IAC) motor.
(12) Install air cleaner upper housing and air
intake tube to throttle body.
(13) Connect inlet air temperature sensor connec-
tor (Fig. 104).
(14) Connect negative cable to battery.
INTAKE MANIFOLD - LOWER
REMOVAL
(1) Perform fuel system pressure release proce-
durebefore attempting any repairs.(Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY - STANDARD
PROCEDURE)
(2) Remove upper intake manifold. (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
REMOVAL)
CAUTION: Cover intake manifold openings to pre-
vent foreign material from entering engine.
(3) Disconnect fuel line. (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/QUICK CONNECT FIT-
TING - STANDARD PROCEDURE)
(4) Drain the cooling system. (Refer to 7 - COOL-
ING - STANDARD PROCEDURE)
(5) Remove heater supply and radiator upper
hoses at intake manifold.
(6) Disconnect coolant temperature sensor/fuel
injector wire harness connector.
(7) Remove lower intake manifold support bracket
bolts (Fig. 109).(8) Loosen the lower intake manfold support
bracket lower bolt (Fig. 109).
(9) Disconnect fuel injector harness.
(10) Remove the bolts attaching the power steering
reservoir to manifold. Set reservoir aside. Do not dis-
connect line
(11) Remove lower intake manifold fasteners (Fig.
110). Remove the manifold from engine.
(12) Inspect the manifold. (Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD - INSPECTION)
INSPECTION
(1) Check manifold surfaces for flatness with
straight edge. Surface must be flat within 0.15 mm
per 300 mm (0.006 in. per foot) of manifold length.
(2) Inspect manifold for cracks or distortion.
Replace manifold if necessary.
INSTALLATION
If the following items were removed, install and
torque to specifications:
²Fuel rail bolts - 22 N´m (200 in. lbs.)
²Coolant outlet connector bolts - 28 N´m (250 in.
lbs.)
²Coolant temperature sensor - 7 N´m (60 in. lbs.)
(1) Position a new gasket on cylinder head and
install lower manifold.
(2) Install and tighten intake manifold fasteners to
28 N´m (250 in. lbs.) in the sequence shown in (Fig.
110). Repeat procedure until all bolts are at specified
torque.
(3) Install lower intake manifold support bracket
bolts (Fig. 109) and tighten to:
Fig. 108 Upper Intake Manifold Tightening Sequence
- 2.4L
Fig. 109 Lower Intake Manifold Support Bracket
1 - SUPPORT BRACKET
2 - BOLTS - UPPER TO MANIFOLD
3 - BOLT - LOWER TO ENGINE BLOCK
9 - 58 ENGINE 2.4LRS
INTAKE MANIFOLD - UPPER (Continued)

(4) Remove rear timing belt cover fasteners and
remove cover from engine (Fig. 125).
(5) Remove lower bolt attaching timing belt ten-
sioner assembly to engine and remove tensioneras
an assembly(Fig. 126).
INSTALLATION
(1) Align timing belt tensioner assembly to engine
and install lower mounting boltbut do not tighten
(Fig. 126). To properly align tensioner assemblyÐin-
stall one of the engine bracket mounting bolts (M10)
5 to 7 turns into the tensioner's upper mounting loca-
tion (Fig. 126).
(2) Torque the tensioner's lower mounting bolt to
61 N´m (45 ft. lbs.). Remove the upper bolt used for
tensioner alignment.
(3) Install rear timing belt cover and fasteners.
(4) Install timing belt idler pulley and torque
mounting bolt to 61 N´m (45 ft. lbs.).
(5) Install camshaft sprockets. Use Special Tool
6847 to hold sprockets (Fig. 124), torque bolts to 101
N´m (75 ft. lbs.).
(6) Install the timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION)
Fig. 124 Camshaft Sprocket - Removal/Installation
1 - SPECIAL TOOL 6847
Fig. 125 Rear Timing Belt Cover Fasteners
1 - BOLTS - REAR COVER 7 N´m (60 in. lbs.)
2 - BOLTS - REAR COVER 28 N´m (250 in .lbs.)
3 - TIMING BELT TENSIONER
Fig. 126 Timing Belt Tensioner AssemblyÐRemoval/
Installation
1 - TIMING BELT TENSIONER ASSEMBLY
2 - TENSIONER ASSEMBLY UPPER BOLT
3 - TENSIONER ASSEMBLY LOWER BOLT
RSENGINE 2.4L9-65
TIMING BELT TENSIONER & PULLEY (Continued)

DIAGNOSIS AND TESTING - ENGINE MECHANICAL
CONDITION POSSIBLE CAUSES CORRECTION
NOISY VALVES 1. High or low oil level in crankcase. 1. Check and correct engine oil level.
2. Thin or diluted oil. 2. Change oil to correct viscosity.
3. Thick oil 3. (a) Change engine oil and filter.
(b) Run engine to operating temperature.
(c) Change engine oil and filter again.
4. Low oil pressure. 4. Check and correct engine oil level.
5. Dirt in tappets/lash adjusters. 5. Replace rocker arm/hydraulic lash
adjuster assembly.
6. Worn rocker arms. 6. Inspect oil supply to rocker arms.
7. Worn tappets/lash adjusters. 7. Install new rocker arm/hydraulic lash
adjuster assembly.
8. Worn valve guides. 8. Replace cylinder head assembly.
9. Excessive runout of valve seats on valve
faces.9. Grind valve seats and valves.
10. Missing adjuster pivot. 10. Replace rocker arm/hydraulic lash
adjuster assembly.
CONNECTING
ROD NOISE1. Insufficient oil supply. 1. Check engine oil level.
2. Low oil pressure. 2. Check engine oil level. Inspect oil pump
relief valve and spring.
3. Thin or diluted oil. 3. Change oil to correct viscosity.
4. Thick oil 4. (a) Change engine oil and filter.
(b) Run engine to operating temperature.
(c) Change engine oil and filter again.
5. Excessive bearing clearance. 5. Measure bearings for correct clearance.
Repair as necessary.
6. Connecting rod journal out-of-round. 6. Replace crankshaft or grind surface.
7. Misaligned connecting rods. 7. Replace bent connecting rods.
MAIN BEARING
NOISE1. Insufficient oil supply. 1. Check engine oil level.
2. Low oil pressure. 2. Check engine oil level. Inspect oil pump
relief valve and spring.
3. Thin or diluted oil. 3. Change oil to correct viscosity.
4. Thick oil 4. (a) Change engine oil and filter.
(b) Run engine to operating temperature.
(c) Change engine oil and filter again.
5. Excessive bearing clearance. 5. Measure bearings for correct clearance.
Repair as necessary.
6. Excessive end play. 6. Check thrust bearing for wear on flanges.
7. Crankshaft journal out-of-round or worn. 7. Replace crankshaft or grind journals.
8. Loose flywheel or torque converter. 8. Tighten to correct torque.
9 - 76 ENGINE 3.3/3.8LRS
ENGINE 3.3/3.8L (Continued)