2001 CHRYSLER VOYAGER check engine

(7) Identify the camshafts before removing from
the head. The camshafts are not interchangeable.
(8) Remove camshafts from cylinder head.
NOTE: If removing rocker arms, identify for reinstal-
lation in the original position.
CLEANING
Clean camshaft with a suitable solvent.
INSPECTION
(1) Inspect camshaft bearing journals for damage
and binding (Fig. 27). If journals are binding, check
the cylinder head for damage. Also check cylinder
head oil holes for clogging.
(2) Check the cam lobe and bearing surfaces for
abnormal wear and damage. Replace camshaft if
defective.
NOTE: If camshaft is replaced due to lobe wear or
damage, always replace the rocker arms.(3) Measure the lobe actual wear (unworn area -
wear zone = actual wear) (Fig. 27) and replace cam-
shaft if out of limit. Standard value is 0.0254 mm
(0.001 in.), wearlimitis 0.254 mm (0.010 in.).
INSTALLATION
CAUTION: Ensure that NONE of the pistons are at
top dead center when installing the camshafts.
(1) Lubricate all camshaft bearing journals, rocker
arms and camshaft lobes.
(2) Install all rocker arms in original positions, if
reused.
(3) Position camshafts on cylinder head bearing
journals. Install right and left camshaft bearing caps
No.2±5andright No. 6. Tighten M6 fasteners to 12
N´m (105 in. lbs.) in sequence shown in (Fig. 28).
(4) Apply MopartGasket Maker to No. 1 and No.
6 bearing caps (Fig. 29). Install bearing caps and
tighten M8 fasteners to 28 N´m (250 in. lbs.).
Fig. 25 Camshaft Bearing Cap Identification
Fig. 26 Camshaft Bearing Cap - Removal
1 - REMOVE OUTSIDE BEARING CAPS FIRST
Fig. 27 Checking Camshaft(s) for Wear
1 - UNWORN AREA
2 - ACTUAL WEAR
3 - BEARING JOURNAL
4 - LOBE
5 - WEAR ZONE
Fig. 28 Camshaft Bearing Cap Tightening Sequence
9 - 28 ENGINE 2.4LRS
CAMSHAFT(S) (Continued)

CAUTION: When depressing the valve spring retain-
ers with valve spring compressor the locks can
become dislocated. Ensure both locks are in the
correct location after removing tool.
(4) Check the valve spring installed height B after
refacing the valve and seat (Fig. 37). Make sure mea-
surements are taken from top of spring seat to the
bottom surface of spring retainer. If height is greater
than 38.75 mm (1.525 in.), install a 0.762 mm (0.030
in.) spacer under the valve spring seat to bring
spring height back within specification.
HYDRAULIC LIFTERS
DIAGNOSIS AND TESTING - LASH ADJUSTER
(TAPPET) NOISE
A tappet-like noise may be produced from several
items. Check the following items.
(1) Engine oil level too high or too low. This may
cause aerated oil to enter the adjusters and cause
them to be spongy.
(2) Insufficient running time after rebuilding cylin-
der head. Low speed running up to 1 hour may be
required.
(3) During this time, turn engine off and let set for
a few minutes before restarting. Repeat this several
times after engine has reached normal operating
temperature.
(4) Low oil pressure.
(5) The oil restrictor (integral to the head gasket)
in the vertical oil passage to the cylinder head is
plugged with debris.
(6) Air ingested into oil due to broken or cracked
oil pump pick up.
(7) Worn valve guides.
(8) Rocker arm ears contacting valve spring
retainer.(9) Rocker arm loose, adjuster stuck or at maxi-
mum extension and still leaves lash in the system.
(10) Faulty lash adjuster.
²Check lash adjusters for sponginess while
installed in cylinder head. Depress part of rocker
arm over adjuster. Normal adjusters should feel very
firm. Spongy adjusters can be bottomed out easily.
²Remove suspected lash adjusters, and replace as
necessary.
REMOVAL
NOTE: This procedure is for in-vehicle service with
camshafts installed.
(1) Remove cylinder head cover. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL)
(2) Remove rocker arm. (Refer to 9 - ENGINE/
CYLINDER HEAD/ROCKER ARMS - REMOVAL)
(3) Remove hydraulic lifter (Fig. 38).
(4) Repeat removal procedure for each hydraulic
lifter.
(5) If reusing, mark each hydraulic lifter for reas-
sembly in original position. Lifters are serviced as an
assembly.
INSTALLATION
(1) Install hydraulic lifter (Fig. 38). Ensure the
lifters are at least partially full of engine oil. This is
indicated by little or no plunger travel when the
lifter is depressed.
(2) Install rocker arm. (Refer to 9 - ENGINE/CYL-
INDER HEAD/ROCKER ARMS - INSTALLATION)
(3) Repeat installation procedure for each hydrau-
lic lifter.
(4) Install cylinder head cover. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION)
Fig. 37 Checking Spring Installed Height and Valve
Tip Height Dimensions
1 - GARTER SPRING
2 - VALVE SPRING SEAT
3 - CYLINDER HEAD SURFACE
Fig. 38 Hydraulic Lifter
9 - 32 ENGINE 2.4LRS
VALVE SPRINGS (Continued)

should be measured halfway down the cylinder bore
and transverse to the engine crankshaft center line
shown in (Fig. 42). Refer to for Engine Specifications
(Refer to 9 - ENGINE - SPECIFICATIONS). Correct
piston to bore clearance must be established in order
to assure quiet and economical operation.
NOTE: Pistons and cylinder bores should be mea-
sured at normal room temperature, 21ÉC (70ÉF).
STANDARD PROCEDURES - CYLINDER BORE
HONING
(1) Used carefully, the cylinder bore resizing hone,
recommended tool C-823 or equivalent, equipped
with 220 grit stones, is the best tool for this honing
procedure. In addition to deglazing, it will reducetaper and out-of-round as well as removing light
scuffing, scoring or scratches. Usually a few strokes
will clean up a bore and maintain the required lim-
its.
(2) Deglazing of the cylinder walls may be done
using a cylinder surfacing hone, recommended tool
C-3501 or equivalent, equipped with 280 grit stones,
if the cylinder bore is straight and round. 20±60
strokes depending on the bore condition, will be suf-
ficient to provide a satisfactory surface. Use a light
honing oil.Do not use engine or transmission oil,
mineral spirits or kerosene.Inspect cylinder walls
after each 20 strokes.
(3) Honing should be done by moving the hone up
and down fast enough to get a cross-hatch pattern.
When hone marksintersectat 40-60 degrees, the
cross hatch angle is most satisfactory for proper seat-
ing of rings (Fig. 44).
Fig. 41 Cylinder Block and Bedplate
1 - CYLINDER BLOCK
2 - BEDPLATE
Fig. 42 Checking Cylinder Bore
Fig. 43 Piston Measurement
Fig. 44 Cylinder Bore Cross-Hatch Pattern
1 - CROSS-HATCH PATTERN
2 - 40ɱ60É
9 - 34 ENGINE 2.4LRS
ENGINE BLOCK (Continued)

(4) A controlled hone motor speed between
200±300 RPM is necessary to obtain the proper cross-
hatch angle. The number of up and down strokes per
minute can be regulated to get the desired 40±60
degree angle. Faster up and down strokes increase
the cross-hatch angle.
(5) After honing, it is necessary that the block be
cleaned again to remove all traces of abrasive.
CAUTION: Ensure all abrasives are removed from
engine parts after honing. It is recommended that a
solution of soap and hot water be used with a
brush and the parts then thoroughly dried. The bore
can be considered clean when it can be wiped
clean with a white cloth and cloth remains clean.
Oil the bores after cleaning to prevent rusting.
CLEANING
Clean cylinder block thoroughly using a suitable
cleaning solvent.
INSPECTION
ENGINE BLOCK
(1) Clean cylinder block thoroughly and check all
core hole plugs for evidence of leaking.
(2) If new core plugs are to be installed, refer to
Engine Core Plugs for procedures (Refer to 9 -
ENGINE - STANDARD PROCEDURE).
(3) Examine block and cylinder bores for cracks or
fractures.
(4) Check block deck surfaces for flatness. Deck
surface must be within service limit of 0.1 mm (0.004
in.).
CYLINDER BORE
NOTE: The cylinder bores should be measured at
normal room temperature, 21ÉC (70ÉF).
The cylinder walls should be checked for out-of-
round and taper with Tool C119 or equivalent (Fig.
45). (Refer to 9 - ENGINE - SPECIFICATIONS) If
the cylinder walls are badly scuffed or scored, the
cylinder block should be replaced, and new pistons
and rings fitted.
Measure the cylinder bore at three levels in direc-
tions A and B (Fig. 45). Top measurement should be
10 mm (3/8 in.) down and bottom measurement
should be 10 mm (3/8 in.) up from bottom of bore.
Refer to Engine Specifications (Refer to 9 - ENGINE
- SPECIFICATIONS).
CONNECTING ROD BEARINGS
CONNECTING RODÐFITTING
(1) For measuring connecting rod bearing clear-
ance procedure and use of Plastigage(Refer to 9 -
ENGINE - STANDARD PROCEDURE). For bearing
clearance refer to Engine Specifications. (Refer to 9 -
ENGINE - SPECIFICATIONS)
NOTE: The rod bearing bolts should not be reused.
(2) Before installing theNEWbolts the threads
should be oiled with clean engine oil.
(3) Install each bolt finger tight than alternately
torque each bolt to assemble the cap properly.
(4) Tighten the bolts to 27 N´m PLUS 1/4 turn (20
ft. lbs. PLUS 1/4 turn)Do not use a torque
wrench for last step.
(5) Using a feeler gauge, check connecting rod side
clearance (Fig. 46). Refer to clearance specifications
(Refer to 9 - ENGINE - SPECIFICATIONS).
Fig. 45 Checking Cylinder Bore Size
RSENGINE 2.4L9-35
ENGINE BLOCK (Continued)

CRANKSHAFT
DESCRIPTION
The crankshaft is made of nodular cast iron and
includes five main bearing journals and four connect-
ing rod journals (Fig. 47). The number three journal
is the location for the thrust bearing. The mains and
connecting rod journals have undercut fillet radiuses
that are rolled for added strength. To optimize bear-
ing loading, eight counterweights are used.
OPERATION
The crankshaft transfers force generated by com-
bustion within the cylinder to the flywheel or flex-
plate.
STANDARD PROCEDURE - CRANKSHAFT END
PLAY
(1) Using Dial Indicator C-3339 and Mounting
Post L-4438, attach to front of engine, locating probe
perpendicular on nose of crankshaft (Fig. 48).
(2) Move crankshaft all the way to the rear of its
travel.
(3) Zero the dial indicator.
(4) Move crankshaft all the way to the front and
read the dial indicator. Refer to Engine Specifica-
tions.
REMOVAL
NOTE: Crankshaft can not be removed when engine
is in vehicle.
(1) Remove engine assembly from vehicle. (Refer to
9 - ENGINE - REMOVAL)
(2) Separate engine from transaxle.
(3) Remove flex plate and crankshaft rear oil seal.
(4) Mount engine on a repair stand.
(5) Drain engine oil and remove oil filter.
(6) Remove the oil pan. (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL)
(7) Remove the timing belt covers. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL)
(8) Remove the timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL)
(9) Remove the oil pump. (Refer to 9 - ENGINE/
LUBRICATION/OIL PUMP - REMOVAL)
Fig. 46 Connecting Rod Side Clearance
Fig. 47 CRANKSHAFT - TYPICAL
1 - MAIN BEARING JOURNALS
2 - COUNTER BALANCE WEIGHTS
Fig. 48 CHECKING CRANKSHAFT END PLAY
9 - 36 ENGINE 2.4LRS
CONNECTING ROD BEARINGS (Continued)

(10) Remove balance shafts and housing assembly.
(Refer to 9 - ENGINE/VALVE TIMING/BALANCE
SHAFT - REMOVAL)
(11) Remove all bedplate bolts from the engine
block (Fig. 49).
(12) Using a mallet gently tap the bedplate loose
from the engine block dowel pins.
CAUTION: Do not pry up on one side of the bed-
plate. Damage may occur to cylinder block to bed-
plate alignment and thrust bearing.
(13) Bedplate should be removed evenly from the
cylinder block dowel pins to prevent damage to the
dowel pins and thrust bearing.
(14) Lift out crankshaft from cylinder block. Do
not damage the main bearings or journals when
removing the crankshaft.
INSPECTION
The crankshaft journals should be checked for
excessive wear, taper and scoring (Fig. 50). Limits of
taper or out of round on any crankshaft journals
should within specitifications. (Refer to 9 - ENGINE -
SPECIFICATIONS) Journal grinding should not
exceed 0.305 mm (0.012 in.) under the standard jour-
nal diameter. DO NOT grind thrust faces of No. 3
main bearing. DO NOT nick crank pin or bearing fil-
lets. After grinding, remove rough edges from crank-
shaft oil holes and clean out all passages.
CAUTION: With the nodular cast iron crankshafts, it
is important that the final paper or cloth polish be
in the same direction as normal rotation in the
engine.
INSTALLATION
(1) Install the main bearing shells with the lubri-
cation groove in the cylinder block (Fig. 51).(2) Make certain oil holes in block line up with oil
hole in bearings and bearing tabs seat in the block
tab slots.
CAUTION: Do not get oil on the bedplate mating
surface. It will affect the sealer ability to seal the
bedplate to cylinder block.
(3) Oil the bearings and journals. Install crank-
shaft.
CAUTION: Use only the specified anaerobic sealer
on the bedplate or damage may occur to the
engine.
Fig. 49 Bedplate Bolt Tightenening Sequence
Fig. 50 Crankshaft Journal Measurements
Fig. 51 Installing Main Bearing Upper Shell
1 - LUBRICATION GROOVES
2 - OIL HOLES
RSENGINE 2.4L9-37
CRANKSHAFT (Continued)

(4) Apply 1.5 to 2.0 mm (0.059 to 0.078 in.) bead of
MopartBed Plate Sealant to cylinder block as shown
in (Fig. 52).
(5) Install lower main bearings into main bearing
cap/bedplate. Make certain the bearing tabs are
seated into the bedplate slots. Install the main bear-
ing/bedplate into engine block.
(6) Before installing the bolts the threads should
be oiled with clean engine oil, wipe off any excess oil.
(7) Install main bearing bedplate to engine block
bolts 11, 17, and 20 finger tight. Tighten these bolts
down together until the bedplate contacts the cylin-
der block.
(8) To ensure correct thrust bearing alignment,
perform the following steps:
²Step 1: Rotate crankshaft until number 4 piston
is at TDC.
²Step 2: Move crankshaft rearward to limits of
travel.
²Step 3: Then, move crankshaft forward to limits
of travel.
²Step 4: Wedge an appropriate tool between the
rear of the cylinder block(NOT BED PLATE)andthe rear crankshaft counterweight. This will hold the
crankshaft in it's furthest forward position.
²Step 5: Install and tighten bolts (1±10) in
sequence shown in (Fig. 53) to 41 N´m (30 ft. lbs.).
²Step 6: Remove wedge tool used to hold crank-
shaft.
(9) Tighten bolts (1±10) again to 41 N´m (30 ft.
lbs.) +1/4 turn in sequence shown in (Fig. 53).
(10) Install main bearing bedplate to engine block
bolts (11±20), and torque each bolt to 28 N´m (20 ft.
lbs.) in sequence shown in (Fig. 53).
(11) After the main bearing bedplate is installed,
check the crankshaft turning torque. The turning
torque should not exceed 5.6 N´m (50 in. lbs.).
(12) Install balance shafts and housing assembly.
(Refer to 9 - ENGINE/VALVE TIMING/BALANCE
SHAFT - INSTALLATION)
(13) Install the oil pump. (Refer to 9 - ENGINE/
LUBRICATION/OIL PUMP - INSTALLATION)
(14) Install the timing belt rear cover. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION)
(15) Install the timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION)
(16) Install the timing belt front covers. (Refer to 9
- ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION)
(17) Install engine support bracket.
(18) Install the oil pan. (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - INSTALLATION)
(19) Install the oil filter.
(20) Install crankshaft rear oil seal. (Refer to 9 -
ENGINE/ENGINE BLOCK/CRANKSHAFT OIL
SEAL - REAR - INSTALLATION)
(21) Install flex plate. Apply MopartLock & Seal
Adhesive to bolt threads and tighten to 95 N´m (70
ft. lbs.).
(22) Attach transaxle to engine. Tighten attaching
bolts to 101 N´m (75 ft. lbs.).
(23) Install the engine assembly. (Refer to 9 -
ENGINE - INSTALLATION)
CRANKSHAFT MAIN
BEARINGS
STANDARD PROCEDURE - MAIN BEARING
FITTING
For crankshaft specifications (Refer to 9 - ENGINE
- SPECIFICATIONS).
CRANKSHAFT MAIN BEARINGS
The crankshaft is supported in five main bearings.
All upper and lower bearing shells in the crankcase
have oil grooves. Crankshaft end play is controlled by
Fig. 52 Bedplate Sealing
Fig. 53 Bedplate Bolt Torque Sequence
9 - 38 ENGINE 2.4LRS
CRANKSHAFT (Continued)

(5) Install lower main bearings into main bearing
cap/bedplate. Make certain the bearing tabs are
seated into the bedplate slots.
(6) Position the main bearing/bedplate onto the
engine block.
(7) Before installing bolts, lubricate the threads
with clean engine oil, wipe off any excess oil.
(8) Install main bearing bedplate to engine block
bolts 11, 17 and 20 finger tight. Tighten these bolts
down together until the bedplate contacts the cylin-
der block.
(9) To ensure correct thrust bearing alignment,
perform the following steps:
²Step 1: Rotate crankshaft until number 4 piston
is at TDC.
²Step 2: Move crankshaft rearward to limits of
travel.
²Step 3: Then, move crankshaft forward to limits
of travel.
²Step 4: Wedge an appropriate tool between the
rear of the cylinder block(NOT BED PLATE)and
the rear crankshaft counterweight. This will hold the
crankshaft in it's furthest forward position.
²Step 5: Install and tighten bolts (1±10) in
sequence shown in (Fig. 57) to 41 N´m (30 ft. lbs.).
²Step 6: Remove wedge tool used to hold crank-
shaft.
(10) Tighten bolts (1±10) again to 41 N´m (30 ft.
lbs.)PLUS1/4 turn in sequence shown in (Fig. 57).
(11) Install main bearing bedplate to engine block
bolts (11±20), and torque each bolt to 28 N´m (20 ft.
lbs.) in sequence shown in (Fig. 57).
(12) After the main bearing bedplate is installed,
check the crankshaft turning torque. The turning
torque should not exceed 5.6 N´m (50 in. lbs.).
CRANKSHAFT OIL SEAL -
FRONT
REMOVAL
(1) Remove the crankshaft vibration damper.
(Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL)
(2) Remove timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL)
(3) Remove crankshaft sprocket using Special Tool
6793 and insert C-4685-C2 (Fig. 58).
CAUTION: Do not nick shaft seal surface or seal
bore.
(4) Using Tool 6771 to remove front crankshaft oil
seal (Fig. 59). Be careful not to damage the seal sur-
face of cover.INSTALLATION
(1) Install new seal by using Special Tool 6780
(Fig. 60).
(2) Place seal into opening with seal spring
towards the inside of engine. Install seal until flush
with cover.
(3) Install crankshaft sprocket using Special Tool
6792 (Fig. 61).
(4) Install timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION)
(5) Install crankshaft vibration damper. (Refer to 9
- ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
INSTALLATION)
Fig. 58 Crankshaft Sprocket - Removal
1 - SPECIAL TOOL 6793
2 - CRANKSHAFT SPROCKET
Fig. 59 Front Crankshaft Oil Seal - Removal
1 - SPECIAL TOOL 6771
2 - REAR TIMING BELT COVER
9 - 40 ENGINE 2.4LRS
CRANKSHAFT MAIN BEARINGS (Continued)