2001 CHRYSLER VOYAGER engine

Fig. 5 ENGINE HARNESS SPLICES - 3.3L/3.8L
RG8W-95 SPLICE LOCATIONS BUX8Wa-95-9
SPLICE LOCATIONS BUX (Continued)

Fig. 6 LEFT FRONT ENGINE COMPARTMENT SPLICES
Fig. 7 LEFT FRONT ENGINE COMPARTMENT DIESEL
8Wa - 95 - 10 8W-95 SPLICE LOCATIONS BUXRG
SPLICE LOCATIONS BUX (Continued)

Fig. 8 RIGHT FRONT ENGINE COMPARTMENT SPLICES
RG8W-95 SPLICE LOCATIONS BUX8Wa-95-11
SPLICE LOCATIONS BUX (Continued)

ENGINE 2.4L
TABLE OF CONTENTS
page page
ENGINE 2.4L.............................. 1ENGINE 3.3/3.8L......................... 71
ENGINE 2.4L
TABLE OF CONTENTS
page page
ENGINE 2.4L
DESCRIPTION............................3
DIAGNOSIS AND TESTING..................3
CYLINDER COMBUSTION PRESSURE
LEAKAGE TEST.........................3
CYLINDER COMPRESSION PRESSURE
TEST.................................3
ENGINE OIL LEAK INSPECTION............4
ENGINE...............................5
ENGINE DIAGNOSIS - PERFORMANCE......5
ENGINE DIAGNOSIS - MECHANICAL.........7
STANDARD PROCEDURE...................9
ENGINE CORE AND OIL GALLERY PLUGS....9
REPAIR OF DAMAGED OR WORN
THREADS..............................9
HYDROSTATIC LOCKED ENGINE...........9
FORM-IN-PLACE GASKETS AND SEALERS. . . 10
ENGINE GASKET SURFACE PREPARATION . . 11
MEASURING WITH PLASTIGAGE..........11
REMOVAL..............................12
INSTALLATION...........................13
SPECIFICATIONS........................16
SPECIAL TOOLS.........................19
AIR CLEANER ELEMENT
REMOVAL..............................22
INSTALLATION...........................22
AIR CLEANER HOUSING
REMOVAL..............................22
INSTALLATION...........................22
CYLINDER HEAD
DESCRIPTION...........................22
OPERATION.............................23
DIAGNOSIS AND TESTING.................23
CYLINDER HEAD GASKET...............23
REMOVAL..............................23
CLEANING..............................24
INSPECTION............................24
INSTALLATION...........................24CAMSHAFT OIL SEAL(S)
REMOVAL..............................26
INSTALLATION...........................26
CAMSHAFT(S)
DESCRIPTION...........................26
OPERATION.............................27
STANDARD PROCEDURE..................27
CAMSHAFT END-PLAY..................27
REMOVAL..............................27
CLEANING..............................28
INSPECTION............................28
INSTALLATION...........................28
CYLINDER HEAD COVER
REMOVAL..............................29
CLEANING..............................29
INSPECTION............................29
INSTALLATION...........................29
INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION...........................30
CLEANING..............................30
VALVE SPRINGS
REMOVAL..............................30
INSPECTION............................31
INSTALLATION...........................31
HYDRAULIC LIFTERS
DIAGNOSIS AND TESTING.................32
LASH ADJUSTER (TAPPET) NOISE
DIAGNOSIS...........................32
REMOVAL..............................32
INSTALLATION...........................32
ROCKER ARMS
REMOVAL..............................33
INSPECTION............................33
INSTALLATION...........................33
ENGINE BLOCK
DESCRIPTION...........................33
STANDARD PROCEDURE..................33
CYLINDER BORE AND PISTON - FITTING....33
CYLINDER BORE HONING...............34
RSENGINE 2.4L9-1

CLEANING..............................35
INSPECTION............................35
CONNECTING ROD BEARINGS
STANDARD PROCEDURE..................35
CONNECTING ROD - FITTING.............35
CRANKSHAFT
DESCRIPTION...........................36
OPERATION.............................36
STANDARD PROCEDURE..................36
CRANKSHAFT END-PLAY................36
REMOVAL..............................36
INSPECTION............................37
INSTALLATION...........................37
CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDURE..................38
MAIN BEARING - FITTING................38
CRANKSHAFT OIL SEAL - FRONT
REMOVAL..............................40
INSTALLATION...........................40
CRANKSHAFT OIL SEAL - REAR
REMOVAL..............................41
INSTALLATION...........................41
PISTON & CONNECTING ROD
DESCRIPTION...........................42
OPERATION.............................42
REMOVAL..............................42
INSTALLATION...........................43
PISTON RINGS
STANDARD PROCEDURE..................44
PISTON RING - FITTING.................44
VIBRATION DAMPER
REMOVAL..............................46
INSTALLATION...........................46
STRUCTURAL COLLAR
REMOVAL..............................46
INSTALLATION...........................46
ENGINE MOUNTING
DESCRIPTION...........................47
FRONT MOUNT
REMOVAL..............................47
INSTALLATION...........................47
LEFT MOUNT
REMOVAL..............................47
INSTALLATION...........................48
REAR MOUNT
REMOVAL..............................48
INSTALLATION...........................48
RIGHT MOUNT
REMOVAL..............................50
INSTALLATION...........................50
LUBRICATION
DESCRIPTION...........................50
OPERATION.............................50
DIAGNOSIS AND TESTING.................50
ENGINE OIL PRESSURE CHECKING........50
OIL
STANDARD PROCEDURE..................51ENGINE OIL LEVEL CHECK...............51
ENGINE OIL CHANGE...................51
OIL FILTER
DESCRIPTION...........................51
REMOVAL..............................51
INSTALLATION...........................52
OIL PAN
REMOVAL..............................52
INSTALLATION...........................52
OIL PUMP
REMOVAL..............................52
DISASSEMBLY...........................53
CLEANING..............................53
INSPECTION............................53
ASSEMBLY.............................55
INSTALLATION...........................55
INTAKE MANIFOLD
DESCRIPTION...........................56
OPERATION.............................56
DIAGNOSIS AND TESTING.................56
INTAKE MANIFOLD LEAKS...............56
INTAKE MANIFOLD - UPPER
REMOVAL..............................56
INSPECTION............................57
INSTALLATION...........................57
INTAKE MANIFOLD - LOWER
REMOVAL..............................58
INSPECTION............................58
INSTALLATION...........................58
EXHAUST MANIFOLD
DESCRIPTION...........................59
OPERATION.............................59
REMOVAL..............................59
CLEANING..............................59
INSPECTION............................59
INSTALLATION...........................59
TIMING BELT COVER(S)
REMOVAL..............................60
INSTALLATION...........................61
TIMING BELT AND SPROCKET(S)
REMOVAL..............................61
CLEANING..............................62
INSTALLATION...........................62
TIMING BELT TENSIONER & PULLEY
REMOVAL..............................64
INSTALLATION...........................65
BALANCE SHAFT
DESCRIPTION...........................66
OPERATION.............................66
REMOVAL..............................66
INSTALLATION...........................67
BALANCE SHAFT CARRIER
REMOVAL..............................70
INSTALLATION...........................70
BALANCE SHAFT CHAIN
REMOVAL..............................70
INSTALLATION...........................70
9 - 2 ENGINE 2.4LRS

ENGINE 2.4L
DESCRIPTION
The 2.4 Liter (148 cu. in.) in-line four cylinder
engine is a double over head camshaft with hydraulic
lifters and four valve per cylinder design. The engine
is free-wheeling; meaning it has provisions for piston-
to-valve clearance. However valve-to-valve interfer-
ence can occur, if camshafts are rotated
independently.
The cylinders are numbered from front of the
engine to the rear. The firing order is 1±3±4±2.
The engine identification number is located on the
rear of the cylinder block (Fig. 1).
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE
The combustion pressure leakage test provides an
accurate means for determining engine condition.
Combustion pressure leakage testing will detect:
²Exhaust and intake valve leaks (improper seat-
ing).
²Leaks between adjacent cylinders or into water
jacket.
²Any causes for combustion/compression pressure
loss.
WARNING: DO NOT REMOVE THE RADIATOR CAP
WITH THE SYSTEM HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM COOLANT CAN
OCCUR.
Check the coolant level and fill as required. DO
NOT install the radiator cap.
Start and operate the engine until it attains nor-
mal operating temperature, then turn the engine
OFF.
Clean spark plug recesses with compressed air.
Remove the spark plugs.
Remove the oil filler cap.Remove the air cleaner.
Calibrate the tester according to the manufactur-
er's instructions. The shop air source for testing
should maintain 483 kPa (70 psi) minimum, 1,379
kPa (200 psi) maximum, with 552 kPa (80 psi) rec-
ommended.
Perform the test procedures on each cylinder
according to the tester manufacturer's instructions.
While testing, listen for pressurized air escaping
through the throttle body, tailpipe and oil filler cap
opening. Check for bubbles in the radiator coolant.
All gauge pressure indications should be equal,
with no more than 25% leakage per cylinder.
FOR EXAMPLE:At 552 kPa (80 psi) input pres-
sure, a minimum of 414 kPa (60 psi) should be main-
tained in the cylinder.
DIAGNOSIS AND TESTING - CYLINDER
COMPRESSION PRESSURE
The results of a cylinder compression pressure test
can be utilized to diagnose several engine malfunc-
tions.
Ensure the battery is completely charged and the
engine starter motor is in good operating condition.
Otherwise the indicated compression pressures may
not be valid for diagnosis purposes.
(1) Check engine oil level and add oil if necessary.
(2) Drive the vehicle until engine reaches normal
operating temperature. Select a route free from traf-
fic and other forms of congestion, observe all traffic
laws, and accelerate through the gears several times
briskly.
(3) Remove all spark plugs from engine. As spark
plugs are being removed, check electrodes for abnor-
mal firing indicators fouled, hot, oily, etc. Record cyl-
inder number of spark plug for future reference.
(4) Disconnect the ignition coil electrical connector.
(5) Be sure throttle blade is fully open during the
compression check.
(6) Insert compression gage adaptor Special Tool
8116 or the equivalent, into the #1 spark plug hole in
cylinder head. Connect the 0±500 psi (Blue) pressure
transducer with cable adaptors to the DRBIIIt.
(7) Crank engine until maximum pressure is
reached on gage. Record this pressure as #1 cylinder
pressure.
(8) Repeat the previous step for all remaining cyl-
inders.
(9) Compression should not be less than 689 kPa
(100 psi) and not vary more than 25 percent from cyl-
inder to cylinder.
(10) If one or more cylinders have abnormally low
compression pressures, repeat the compression test.
(11) If the same cylinder or cylinders repeat an
abnormally low reading on the second compression
test, it could indicate the existence of a problem in
Fig. 1 Engine Identification
1 - ENGINE IDENTIFICATION LOCATION
RSENGINE 2.4L9-3

the cylinder in question.The recommended com-
pression pressures are to be used only as a
guide to diagnosing engine problems. An engine
should not be disassembled to determine the
cause of low compression unless some malfunc-
tion is present.
DIAGNOSIS AND TESTING - ENGINE OIL LEAK
Begin with a thorough visual inspection of the
engine, particularly at the area of the suspected leak.
If an oil leak source is not readily identifiable, the
following steps should be followed:
(1) Do not clean or degrease the engine at this
time because some solvents may cause rubber to
swell, temporarily stopping the leak.
(2) Add an oil soluble dye (use as recommended by
manufacturer). Start the engine and let idle for
approximately 15 minutes. Check the oil dipstick to
make sure the dye is thoroughly mixed as indicated
with a bright yellow color under a black light.
(3) Using a black light, inspect the entire engine
for fluorescent dye, particularly at the suspected area
of oil leak. If the oil leak is found and identified,
repair as necessary.
(4) If dye is not observed, drive the vehicle at var-
ious speeds for approximately 24 km (15 miles), and
repeat inspection.
(5)If the oil leak source is not positively
identified at this time, proceed with the air leak
detection test method as follows:
²Disconnect the fresh air hose (make-up air) at
the cylinder head cover and plug or cap the nipple on
the cover.
²Remove the PCV valve hose from the cylinder
head cover. Cap or plug the PCV valve nipple on the
cover.
²Attach an air hose with pressure gauge and reg-
ulator to the dipstick tube.
CAUTION: Do not subject the engine assembly to
more than 20.6 kpa (3 PSI) of test pressure.
²Gradually apply air pressure from 1 psi to 2.5
psi maximum while applying soapy water at the sus-
pected source. Adjust the regulator to the suitable
test pressure that provides the best bubbles which
will pinpoint the leak source. If the oil leak is
detected and identified, repair per service manual
procedures.
²If the leakage occurs at the crankshaft rear oil
seal area, refer to the section, Inspection for Rear
Seal Area Leak.
(6) If no leaks are detected, turn off the air supply.
Remove the air hose, all plugs, and caps. Install the
PCV valve and fresh air hose (make-up air). Proceed
to next step.(7) Clean the oil off the suspect oil leak area using
a suitable solvent. Drive the vehicle at various
speeds approximately 24 km (15 miles). Inspect the
engine for signs of an oil leak by using a black light.
NOTE: If oil leakage is observed at the dipstick tube
to block location; remove the tube, clean and reseal
using MoparTStud & Bearing Mount (press fit tube
applications only), and for O-ring style tubes,
remove tube and replace the O-ring seal.
INSPECTION FOR REAR SEAL AREA LEAKS
Since it is sometimes difficult to determine the
source of an oil leak in the rear seal area of the
engine, a more involved inspection is necessary. The
following steps should be followed to help pinpoint
the source of the leak.
If the leakage occurs at the crankshaft rear oil seal
area:
(1) Disconnect the battery.
(2) Raise the vehicle.
(3) Remove torque converter or clutch housing
cover and inspect rear of block for evidence of oil.
Use a black light to check for the oil leak. If a leak is
present in this area, remove transmission for further
inspection.
(a) Circular spray pattern generally indicates
seal leakage or crankshaft damage.
(b) Where leakage tends to run straight down,
possible causes are a porous block, oil gallery cup
plug, bedplate to cylinder block mating surfaces
and seal bore. See proper repair procedures for
these items.
(4) If no leaks are detected, pressurize the crank-
case as previously described.
CAUTION: Do not exceed 20.6 kPa (3 psi).
(5) If the leak is not detected, very slowly turn the
crankshaft and watch for leakage. If a leak is
detected between the crankshaft and seal while
slowly turning the crankshaft, it is possible the
crankshaft seal surface is damaged. The seal area on
the crankshaft could have minor nicks or scratches
that can be polished out with emery cloth.
CAUTION: Use extreme caution when crankshaft
polishing is necessary to remove minor nicks and
scratches. The crankshaft seal flange is especially
machined to complement the function of the rear oil
seal.
(6) For bubbles that remain steady with shaft
rotation, no further inspection can be done until dis-
assembled.
9 - 4 ENGINE 2.4LRS
ENGINE 2.4L (Continued)

(7) After the oil leak root cause and appropriate
corrective action have been identified, replace compo-
nent(s) as necessary.
DIAGNOSIS AND TESTING - ENGINE
Engine diagnosis is helpful in determining the
causes of malfunctions not detected and remedied by
routine maintenance.
These malfunctions may be classified as either
mechanical (e.g., a strange noise), or performance
(e.g., engine idles rough and stalls).
Refer to the Engine Mechanical and the Engine
Performance diagnostic charts, for possible causes
and corrections of malfunctions (Refer to 9 - ENGINE
- DIAGNOSIS AND TESTING - MECHANICAL)
(Refer to 9 - ENGINE - DIAGNOSIS AND TESTING
- PERFORMANCE).For fuel system diagnosis, (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY - DIAGNOSIS AND
TESTING).
Additional tests and diagnostic procedures may be
necessary for specific engine malfunctions that can-
not be isolated with the Service Diagnosis charts.
Information concerning additional tests and diagno-
sis is provided within the following:
²Cylinder Compression Pressure Test
²Cylinder Combustion Pressure Leakage Test
²Engine Cylinder Head Gasket Failure Diagnosis
²Intake Manifold Leakage Diagnosis
²Lash Adjuster (Tappet) Noise Diagnosis
²Engine Oil Leak Inspection
DIAGNOSIS AND TESTING - ENGINE PERFORMANCE
CONDITION POSSIBLE CAUSE CORRECTION
ENGINE WILL NOT START 1. Weak battery. 1. Test battery. Charge or replace
as necessary. (Refer to 8 -
ELECTRICAL/BATTERY SYSTEM -
DIAGNOSIS AND TESTING)
2. Corroded or loose battery
connections.2. Clean and tighten battery
connections. Apply a coat of light
mineral grease to terminals.
3. Faulty starter. 3. Test starting system. (Refer to 8 -
ELECTRICAL/STARTING -
DIAGNOSIS AND TESTING)
4. Faulty coil(s) or control unit. 4. Test and replace as needed.
(Refer to Appropriate Diagnostic
Information)
5. Incorrect spark plug gap. 5. Set gap. (Refer to 8 -
ELECTRICAL/IGNITION CONTROL
- SPECIFICATIONS)
6. Contamination in fuel system. 6. Clean system and replace fuel
filter.
7. Faulty fuel pump. 7. Test fuel pump and replace as
needed. (Refer to Appropriate
Diagnostic Information)
8. Incorrect engine timing. 8. Check for a skipped timing
belt/chain.
RSENGINE 2.4L9-5
ENGINE 2.4L (Continued)