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Page 1309 of 2585

CHRYSLER VOYAGER 2004  Service Manual NOTE: Multi-Layer Steel (MLS) head gaskets require
a scratch free sealing surface.
Only use the following for cleaning gasket surfaces:
²Solvent or a commercially available gasket
remover
²Plastic o

Page 1314 of 2585

CHRYSLER VOYAGER 2004  Service Manual (33) Start engine and run until operating temper-
ature is reached.
(34) Adjust transmission linkage, if necessary.
SPECIFICATIONS
SPECIFICATIONS - 2.4L ENGINE
DESCRIPTION SPECIFICATION
General Specif

Page 1315 of 2585

CHRYSLER VOYAGER 2004  Service Manual DESCRIPTION SPECIFICATION
Bore DiameterÐPiston
Pin20.96±20.98 mm
(0.8252±0.8260 in.)
Bore DiameterÐ
Crankshaft End53.007±52.993 mm
(2.0868±2.0863 in.)
Side Clearance 0.13±0.38 mm
(0.005±0.015

Page 1379 of 2585

CHRYSLER VOYAGER 2004  Service Manual CONDITION POSSIBLE CAUSES CORRECTION
OIL CONSUMPTION OR SPARK
PLUGS FOULED1. PCV system malfunction. 1. Check system and repair as
necessary. (Refer to 25 -
EMISSIONS CONTROL/
EVAPORATIVE EMISSIONS/PC

Page 1381 of 2585

CHRYSLER VOYAGER 2004  Service Manual Calibrate the tester according to the manufactur-
ers 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-
o

Page 1389 of 2585

CHRYSLER VOYAGER 2004  Service Manual DESCRIPTION SPECIFICATION
Clearance in Piston @
21É C (70É F)0.006±0.019 mm
(0.0002±0.0007 in.)
Clearance in Connecting
Rod(Interference Fit)
Diameter 22.87±22.88 mm
(0.9007±0.9009 in.)
Length

Page 1390 of 2585

CHRYSLER VOYAGER 2004  Service Manual DESCRIPTION SPECIFICATION
Main Bearing Diametrical
Clearance
ÐNo. 1, 2, 3, 4 0.011±0.055 mm
(0.0005±0.0022 in.)
Wear Limit 0.076 mm
(0.003 in.)
Camshaft
Journal Diameter
No.1 50.724±50.775 mm
(1.9

Page 1401 of 2585

CHRYSLER VOYAGER 2004  Service Manual (2) Assemble gasket to cylinder cover by inserting
the fasteners through each bolt hole on cover and
gasket (Fig. 25).
(3) Install the cylinder head cover and bolts (Fig.
26).
(4) Tighten cylinder hea
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