2001 CHRYSLER VOYAGER Service Manual

oil dipstick trunk release brake fluid brake rotor wipers oil pressure

Page 2665 of 4284

CHRYSLER VOYAGER 2001 Service Manual CRANKSHAFT OIL SEAL -
REAR
REMOVAL
(1) Remove transaxle. Refer to Group 21, Tran-
saxle for procedure.
(2) Remove flex plate.
(3) Insert a 3/16 flat bladed screwdriver between
the dust lip and the met

Page 2666 of 4284

CHRYSLER VOYAGER 2001 Service Manual NOTE: When installing seal, no lube on seal is
needed.
(1) Place Special Tool 6926-1 Seal Guide on crank-
shaft (Fig. 63).
(2) Position seal over guide tool (Fig. 63). Guide
tool should remain on cran

NOTE: When installing seal, no lube on seal is
needed.
(1) Place Special Tool 6926-1 Seal Guide on crank-
shaft (Fig. 63).
(2) Position seal over guide tool (Fig. 63). Guide
tool should remain on crankshaft during installation
of seal. Ensure that the lip of the seal is facing
towards the crankcase during installation.
CAUTION: If the seal is driven into the block past
flush, this may cause an oil leak.
(3) Drive the seal into the block using Special Tool
6926-2 and handle C-4171 (Fig. 64) until the tool bot-
toms out against the block (Fig. 65).
(4) Install flex plate. Apply MopartLock & Seal
Adhesive to bolt threads and tighten bolts to 95 N´m
(70 ft. lbs.).
(5) Install transaxle. Refer to Group 21, Transaxle
for procedure.
PISTON & CONNECTING ROD
DESCRIPTION
The pistons are made of a cast aluminum alloy.
The pistons have pressed-in pins attached to forged
powdered metal connecting rods. The pistons pin isoffset 1 mm (0.0394 in.) towards the thrust side of
the piston. The connecting rods are a cracked cap
design and are not repairable. Hex head cap screws
are used to provide alignment and durability in the
assembly. The pistons and connecting rods are ser-
viced as an assembly.
OPERATION
The piston and connecting rod is the link between
the combustion force to the crankshaft.
REMOVAL
NOTE: Cylinder Head must be removed before Pis-
tons and Rods. Refer to Cylinder Head Removal in
this section.
(1) Remove top ridge of cylinder bores with a reli-
able ridge reamer before removing pistons from cyl-
inder block.Be sure to keep tops of pistons
covered during this operation. Mark piston with
matching cylinder number (Fig. 66).
(2) Remove oil pan. Scribe the cylinder number on
the side of the rod and cap (Fig. 67) for identification.
(3) Pistons have a directional stamping in the
front half of the piston facing towards thefrontof
engine.
Fig. 63 Rear Crankshaft Seal and Special Tool
6926-1
1 - SPECIAL TOOL 6926±1 PILOT
2 - SEAL
Fig. 64 Crankshaft Seal and Special Tools 6926-2 &
C-4171
1 - SPECIAL TOOL 6926±1 PILOT
2 - SEAL
3 - SPECIAL TOOL 6926±2 INSTALLER
4 - SPECIAL TOOL C-4171
9 - 42 ENGINE 2.4LRS
CRANKSHAFT OIL SEAL - REAR (Continued)

Page 2667 of 4284

CHRYSLER VOYAGER 2001 Service Manual (4) Pistons and connecting rods must be removed
from top of cylinder block. Rotate crankshaft so that
each connecting rod is centered in cylinder bore.
(5) Remove Balance Shaft Assembly. Refer to Bal-

Page 2668 of 4284

CHRYSLER VOYAGER 2001 Service Manual (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

Page 2669 of 4284

CHRYSLER VOYAGER 2001 Service Manual PISTON RINGSÐINSTALLATION
(1) Install rings with manufacturers I.D. mark fac-
ing up, to the top of the piston (Fig. 73).
CAUTION: Install piston rings in the following
order:
²Oil ring expander.
²

Page 2670 of 4284

CHRYSLER VOYAGER 2001 Service Manual 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
Pul

Page 2671 of 4284

CHRYSLER VOYAGER 2001 Service Manual 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-
t

Page 2672 of 4284

CHRYSLER VOYAGER 2001 Service Manual (8) Remove the horizontal bolts from the mount to
the transaxle (Fig. 82) or (Fig. 83).
NOTE: To remove mount, additional lowering of
transaxle may be required.
(9) Remove left mount.
INSTALLATION
(1)

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