2001 CHRYSLER VOYAGER Service Manual

Page 2649 of 4284

CHRYSLER VOYAGER 2001 Service Manual 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 s

Page 2650 of 4284

CHRYSLER VOYAGER 2001 Service Manual (13) Raise vehicle and install the exhaust pipe to
the manifold.
(14) Install accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION)
(15) Install heater tube support

(13) Raise vehicle and install the exhaust pipe to
the manifold.
(14) Install accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION)
(15) Install heater tube support bracket to cylinder
head.
(16) Connect radiator upper and heater hoses to
intake manifold water outlet connections.
(17) Install upper intake manifold. (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSTALLATION)
(18) Using new gaskets, install EGR tube and
tighten fasteners to 11 N´m (95 in. lbs.).
(19) Install air inlet tube and housing.
(20) Connect all vacuum lines, electrical wiring,
ground straps and fuel line.
(21) Fill cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(22) Connect battery negative cable.
CAMSHAFT OIL SEAL(S)
REMOVAL
(1) Remove timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL)
(2) Hold each camshaft sprocket with Special Tool
6847 while removing center bolt (Fig. 20).
(3) Remove camshaft sprockets.
(4) Remove rear timing belt cover. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL)
(5) Remove camshaft seal using Special Tool
C-4679-A (Fig. 21).
CAUTION: Do not nick shaft seal surface or seal
bore.
INSTALLATION
(1) Shaft seal surface must be free of varnish, dirt
or nicks. Polish with 400 grit paper if necessary.
(2) Install camshaft seals into cylinder head using
Special Tool MD-998306 until flush with head (Fig.
22).
(3) Install timing belt rear cover. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION)
(4) Install camshaft sprockets. Hold each sprocket
with Special Tool 6847 and tighten center bolt to 101
N´m (75 ft. lbs.) (Fig. 20).
(5) Install timing belt and front covers. (Refer to 9
- ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - INSTALLATION) (Refer to 9 -ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION)
CAMSHAFT(S)
DESCRIPTION
Both nodular iron camshafts have six bearing jour-
nal surfaces and two cam lobes per cylinder (Fig. 23).
Flanges at the rear journals control camshaft end
play. Provision for a cam position sensor is located on
the intake camshaft on the rear of the cylinder head.
A hydrodynamic oil seal is used for oil control at the
front of the camshaft.
Fig. 20 Camshaft Sprocket - Removal/Installation
1 - SPECIAL TOOL 6847
Fig. 21 Camshaft Oil Seal - Removal With C-4679-A
1 - SPECIAL TOOL C-4679
9 - 26 ENGINE 2.4LRS
CYLINDER HEAD (Continued)

Page 2651 of 4284

CHRYSLER VOYAGER 2001 Service Manual OPERATION
The camshaft is driven by the crankshaft via drive
sprockets and belt. The camshaft has precisely
machined lobes to provide accurate valve timing and
duration.
STANDARD PROCEDURES - CAMSHAFT

Page 2652 of 4284

CHRYSLER VOYAGER 2001 Service Manual (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 i

Page 2653 of 4284

CHRYSLER VOYAGER 2001 Service Manual NOTE: Bearing end caps must be installed before
seals can be installed.
(5) Install camshaft oil seals. (Refer to 9 -
ENGINE/CYLINDER HEAD/CAMSHAFT OIL
SEAL(S) - INSTALLATION)
(6) Install camshaft tar

Page 2654 of 4284

CHRYSLER VOYAGER 2001 Service Manual (3) Apply MopartEngine RTV GEN II at the
camshaft cap corners and at the top edges of the 1/2
round seal (Fig. 32).
(4) Install cylinder head cover assembly to cylin-
der head. Install all bolts, ensu

(3) Apply MopartEngine RTV GEN II at the
camshaft cap corners and at the top edges of the 1/2
round seal (Fig. 32).
(4) Install cylinder head cover assembly to cylin-
der head. Install all bolts, ensuring the two (2) bolts
containing the sealing washer are located in the cen-
ter locations of cover. Tighten bolts in sequence
shown in (Fig. 33). Using a 3 step torque method as
follows:
(a) Tighten all bolts to 4.5 N´m (40 in. lbs.).
(b) Tighten all bolts to 9.0 N´m (80 in. lbs.).
(c) Tighten all bolts to 12 N´m (105 in. lbs.).
(5) Install ignition coil and spark plug wires.
Tighten fasteners to 12 N´m (105 in. lbs.).
(6) If the PCV valve was removed, apply Mopart
Thread Sealant with Teflon to threads and install
valve to cylinder head cover. Tighten PCV valve to 8
N´m (70 in. lbs.).
(7) Connect PCV and make-up air hoses to cylin-
der head cover.(8) Install upper intake manifold. (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSTALLATION)
INTAKE/EXHAUST VALVES &
SEATS
DESCRIPTION
The valves are made of heat resistant steel. They
have chrome plated stems to prevent scuffing. Viton
rubber valve stem seals are integral with the spring
seats. The valves have three-bead lock keepers to
retain springs and to promote valve rotation.
CLEANING
(1) Clean all valves thoroughly and discard
burned, warped and cracked valves.
VALVE SPRINGS
REMOVAL - CYLINDER HEAD ON
(1) Remove camshafts.
(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. 34), compress valve springs and remove
valve locks.
(5) Remove valve spring(s).
(6) Remove valve stem seal(s) by a using valve
stem seal tool (Fig. 36).
REMOVAL - CYLINDER HEAD OFF
(1) With cylinder head removed, compress valve
springs using a universal valve spring compressor.
(2) Remove valve retaining locks, valve spring
retainers, valve stem seals and valve springs.
(3) Before removing valves,remove any burrs
from valve stem lock grooves to prevent dam-
Fig. 32 Sealer Locations
1 ± SEALER LOCATION
Fig. 33 Cylinder Head Cover Tightening Sequence
(Typical Cover Shown)
9 - 30 ENGINE 2.4LRS
CYLINDER HEAD COVER (Continued)

Page 2655 of 4284

CHRYSLER VOYAGER 2001 Service Manual age to the valve guides.Identify valves to insure
installation in original location.
(4) Inspect the valves. (Refer to 9 - ENGINE/CYL-
INDER HEAD/VALVE SPRINGS - INSPECTION)
INSPECTION
(1) Whenever va

age to the valve guides.Identify valves to insure
installation in original location.
(4) Inspect the valves. (Refer to 9 - ENGINE/CYL-
INDER HEAD/VALVE SPRINGS - INSPECTION)
INSPECTION
(1) Whenever valves have been removed for inspec-
tion, reconditioning or replacement, valve springs
should be tested for correct tension. Discard the
springs that do not meet specifications. The following
specifications apply to both intake and exhaust
valves springs:
²Valve Closed Nominal TensionÐ76 lbs. @ 38.0
mm (1.50 in.)
²Valve Open Nominal TensionÐ136 lbs. @ 29.75
mm (1.17 in.)
(2) Inspect each valve spring for squareness with a
steel square and surface plate, test springs from both
ends. If the spring is more than 1.5 mm (1/16 inch)
out of square, install a new spring.
INSTALLATION - CYLINDER HEAD ON
(1) Install valve seal/valve spring seat assembly
(Fig. 35). 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. 34).
Correct alignment of tool is necessary to avoid nick-
ing valve stems.
(3) Remove air hose and install spark plugs.
(4) Install camshafts and cylinder head cover .
INSTALLATION - CYLINDER HEAD OFF
(1) Coat valve stems with clean engine oil and
insert in cylinder head.(2) Install new valve stem seals on all valves
using a valve stem seal tool (Fig. 36). The valve stem
seals should be pushed firmly and squarely over
valve guide.
CAUTION: When oversize valves are used, the cor-
responding oversize valve seal must also be used.
Excessive guide wear may result if oversize seals
are not used with oversize valves.
(3) Install valve springs and retainers. Compress
valve springs only enough to install locks, taking
care not to misalign the direction of compression.
Nicked valve stems may result from misalignment of
the valve spring compressor.
Fig. 34 Valve Spring - Removal/Installation
1 - VALVE SPRING COMPRESSOR MD 998772A
2 - AIR HOSEFig. 35 Valve Stem Seal/Valve Spring Seat
1 - VALVE RETAINING LOCKS
2 - VALVE SPRING
3 - VALVE SEAL AND VALVE SPRING SEAT ASSEMBLY
4 - VALVE SPRING RETAINER
Fig. 36 Valve Stem Oil Seal Tool
1 - VALVE SEAL TOOL
2 - VALVE STEM
RSENGINE 2.4L9-31
VALVE SPRINGS (Continued)

Page 2656 of 4284

CHRYSLER VOYAGER 2001 Service Manual 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 val

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)

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