2005 CHRYSLER VOYAGER Service Manual

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Page 1209 of 2339

CHRYSLER VOYAGER 2005 Service Manual INSTALLATION
NOTE: Replace spark plug well seals and bolt
assemblies when installing a new cylinder head
cover gasket.
(1) Install new cylinder head cover gaskets and
spark plug well seals (Fig. 30).

Page 1210 of 2339

CHRYSLER VOYAGER 2005 Service Manual 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
sea

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 & SEALS
REMOVAL
REMOVAL - CYLINDER HEAD ON
(1) Remove cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(2) Remove camshafts (Refer to 9 - ENGINE/CYL-
INDER HEAD/CAMSHAFT(S) - REMOVAL).
(3) Rotate crankshaft until piston is at TDC on
compression.
(4) With air hose attached to adapter tool installed
in spark plug hole, apply 90-120 psi air pressure.
(5) Using Special Tool MD-998772-A with adapter
6779 (Fig. 33), compress valve springs and remove
valve locks.
(6) Remove valve spring(s).
(7) Remove valve stem seal(s) by a using valve
stem seal tool (Fig. 35).
REMOVAL - CYLINDER HEAD OFF
(1) With cylinder head removed from cylinder
block, 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-
age to the valve guides.Identify valves, locks and
retainers 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
INSTALLATION - CYLINDER HEAD ON
(1) Install valve seal/valve spring seat assembly
(Fig. 34). 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. 33).
Correct alignment of tool is necessary to avoid nick-
ing valve stems.
(3) Remove air hose and install spark plugs.
(4) Install camshafts (Refer to 9 - ENGINE/CYL-
INDER HEAD/CAMSHAFT(S) - INSTALLATION).
(5) Install cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER - INSTALLATION).
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. 35). The valve stem
seals should be pushed firmly and squarely over
valve guide.
Fig. 33 Valve Spring - Removal/Installation
1 - VALVE SPRING COMPRESSOR MD 998772A
2 - AIR HOSE
RSENGINE 2.4L9-33

Page 1211 of 2339

CHRYSLER VOYAGER 2005 Service Manual 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 valv

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.
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. 36). Make sure mea-
surements are taken from top of spring seat to thebottom 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 LASH
ADJUSTERS
DIAGNOSIS AND TESTING - HYDRAULIC LASH
ADJUSTER NOISE DIAGNOSIS
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.
Fig. 34 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. 35 Valve Stem Oil Seal Tool
1 - VALVE SEAL TOOL
2 - VALVE STEM
Fig. 36 Checking Spring Installed Height and Valve
Tip Height Dimensions
1 - GARTER SPRING
2 - VALVE SPRING SEAT
3 - CYLINDER HEAD SURFACE
9 - 34 ENGINE 2.4LRS
VALVE SPRINGS & SEALS (Continued)

Page 1212 of 2339

CHRYSLER VOYAGER 2005 Service Manual 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/CYLIN

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 lash adjuster (Fig. 37).
(4) Repeat removal procedure for each hydraulic
lash adjuster.
(5) If reusing, mark each hydraulic lash adjuster
for reassembly in original position. Lash adjusters
are serviced as an assembly.
INSTALLATION
(1) Install hydraulic lash adjuster (Fig. 37).
Ensure the lash adjusters 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 lash adjuster.
(4) Install cylinder head cover. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION)
ROCKER ARMS
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 spark plugs.
(3) Rotate engine until the camshaft lobe, on the
follower being removed, is positioned on its base cir-
cle (heel). Also, the piston should be a minimum of
6.3 mm (0.25 in) below TDC position.
CAUTION: If cam follower assemblies are to be
reused, always mark position for reassembly in
their original positions.
(4) Using Special Tools 8215A and 8436 slowly
depress valve assembly until rocker arm can be
removed (Fig. 38).
(5) Repeat removal procedure for each rocker arm.
INSPECTION
Inspect the rocker arm for wear or damage (Fig.
39). Replace as necessary.
INSTALLATION
(1) Lubricate rocker arm with clean engine oil.
(2) Using Special Tools 8215A and 8436 slowly
depress valve assembly until rocker arm can be
installed on the hydraulic lifter and valve stem (Fig.
38).
(3) Repeat installation procedure for each rocker
arm.
Fig. 37 Hydraulic Lash Adjuster
Fig. 38 Rocker Arm - Removal/Installation
1 - SPECIAL TOOL 8215A
2 - SPECIAL TOOL 8436
3 - 3/89DRIVE RACHET
RSENGINE 2.4L9-35
HYDRAULIC LASH ADJUSTERS (Continued)

Page 1213 of 2339

CHRYSLER VOYAGER 2005 Service Manual (4) Install spark plugs.
(5) Install cylinder head cover. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION)
ENGINE BLOCK
DESCRIPTION
The cast iron cylinder block is a two-piece

(4) Install spark plugs.
(5) Install cylinder head cover. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION)
ENGINE BLOCK
DESCRIPTION
The cast iron cylinder block is a two-piece assem-
bly, consisting of the cylinder block and bed plate
(Fig. 40). The bed plate incorporates the main bear-
ing caps and bolts to the cylinder block. This design
offers a much stronger lower end and increased cyl-
inder block rigidity. The rear oil seal retainer is inte-
gral with the block. The bed plate and block are
serviced as an assembly.
STANDARD PROCEDURE - 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. 41).
(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.
Fig. 39 Rocker Arm
1 - TIP
2 - LASH ADJUSTER POCKET
3 - ROLLER
Fig. 40 Cylinder Block and Bed plate
1 - CYLINDER BLOCK
2 - BED PLATE
Fig. 41 Cylinder Bore Cross-Hatch Pattern
1 - CROSS-HATCH PATTERN
2 - 40É±60É
9 - 36 ENGINE 2.4LRS
ROCKER ARMS (Continued)

Page 1214 of 2339

CHRYSLER VOYAGER 2005 Service Manual 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

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 9
- ENGINE - STANDARD PROCEDURE - ENGINE
CORE AND OIL GALLERY PLUGS).
(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.
42) (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. 42). 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 9 - ENGINE - SPECIFICATIONS).
CRANKSHAFT
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. 43).
(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 - CRANKSHAFT
NOTE: Crankshaft can not be removed when engine
is in vehicle.
(1) Remove engine assembly from vehicle (Refer to
9 - ENGINE - REMOVAL).
(2) Separate transaxle from engine.
(3) Remove drive plate/flex plate.
(4) Remove crankshaft rear oil seal (Refer to 9 -
ENGINE/ENGINE BLOCK/CRANKSHAFT OIL
SEAL - REAR - REMOVAL).
(5) Mount engine on a suitable repair stand.
Fig. 42 Checking Cylinder Bore Size
Fig. 43 Checking Crankshaft End Play - Typical
RSENGINE 2.4L9-37
ENGINE BLOCK (Continued)

Page 1215 of 2339

CHRYSLER VOYAGER 2005 Service Manual (6) Drain engine oil and remove oil filter.
(7) Remove crankshaft vibration damper (Refer to
9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL).
(8) Remove engine mount support bracket.
(9) Remove fr

(6) Drain engine oil and remove oil filter.
(7) Remove crankshaft vibration damper (Refer to
9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL).
(8) Remove engine mount support bracket.
(9) Remove front timing belt covers (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT COVER(S)
- REMOVAL).
(10) Remove the timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
REMOVAL).
(11) Remove the rear timing belt cover (Refer to 9
- ENGINE/VALVE TIMING/TIMING BELT COV-
ER(S) - REMOVAL).
(12) Remove the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL).
(13) Remove oil pump pick-up tube.
(14) Remove the crankshaft sprocket and oil pump
(Refer to 9 - ENGINE/LUBRICATION/OIL PUMP -
REMOVAL).
(15) Remove balance shafts and housing assembly
(Refer to 9 - ENGINE/VALVE TIMING/BALANCE
SHAFT - REMOVAL).
(16) Remove crankshaft position sensor.
NOTE: If piston/connecting rod replacement is nec-
essary, remove cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
(17) Using a permanent ink or paint marker, iden-
tify cylinder number on each connecting rod cap (Fig.
44).
CAUTION: DO NOT use a number stamp or a punch
to mark connecting rods. Damage to connecting
rod could occur.
(18) Remove all connecting rod bolts and caps.
Care should be taken not to damage the fracture rod
and cap surfaces.
NOTE: Do not reuse connecting rod bolts.(19) Remove all bed plate bolts from the engine
block (Fig. 45).
(20) Using a mallet gently tap the bed plate 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.
(21) Bed plate should be removed evenly from the
cylinder block dowel pins to prevent damage to the
dowel pins and thrust bearing.
CAUTION: Use extreme care when handling crank-
shaft. Tone wheel damage can occur if crankshaft is
mis-handled.
(22) Lift out crankshaft from cylinder block. Do
not damage the main bearings or journals when
removing the crankshaft.
(23) Remove the target ring mounting screws and
discard.
(24) Remove the target ring from the crankshaft.
INSPECTION
For crankshaft specifications (Refer to 9 - ENGINE
- SPECIFICATIONS).
The crankshaft journals should be checked for
excessive wear, taper and scoring (Fig. 46). Limits of
taper or out of round on any crankshaft journals
should be held to 0.025 mm (0.001 in.). Journal
grinding should not exceed 0.305 mm (0.012 in.)
under the standard journal diameter. DO NOT grind
Fig. 44 Identify Connecting Rod to Cylinder-Typical
Fig. 45 Bed Plate Bolt Removal Sequence
9 - 38 ENGINE 2.4LRS
CRANKSHAFT (Continued)

Page 1216 of 2339

CHRYSLER VOYAGER 2005 Service Manual thrust faces of No. 3 main bearing. DO NOT nick
crank pin or bearing fillets. After grinding, remove
rough edges from crankshaft oil holes and clean out
all passages.
CAUTION: With the nodular cast ir

thrust faces of No. 3 main bearing. DO NOT nick
crank pin or bearing fillets. After grinding, remove
rough edges from crankshaft 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 - CRANKSHAFT
CRANKSHAFT MAIN BEARING LOCATION
The crankshaft is supported in five main bearings.
All upper bearing shells in the crankcase have oil
grooves and holes. All lower bearing shellsexcept
for the thrust bearing half have oil grooves and holes
(Fig. 47). Crankshaft end play is controlled by a
flanged bearing on the number three main bearing
journal.(1) Install the main bearing upper shells with the
lubrication groove and oil hole in the engine block
(Fig. 48).
(2) Make certain oil holes in block line up with oil
hole in bearings and bearing tabs seat in the block
tab slots.
NOTE: If the crankshaft is sent out for machine
work, it must be balenced as an assembly with the
target ring installed.
(3) Clean crankshaft and target ring with
MOPARtbrake parts cleaner and dry with com-
pressed air to ensure that the crankshaft mating sur-
face and target ring mounting holes are free from oil
and lock patch debris.
NOTE: Always use NEW mounting screws whether
installing original or new target ring.
(4) InstallNEWmounting screws finger tight
starting with the #1 location. (Fig. 49) Make sure
engagment occurs with the shoulder of the screw and
mounting hole before starting all other screws.
(5) Torque all mounting screws with T30 torx bit
to 13 Nm (110 in-lbs) following the torque sequence.
CAUTION: Use extreme care when handling crank-
shaft. Tone wheel damage can occur if crankshaft is
mis-handled.
CAUTION: Do not get oil on the bed plate mating
surface. It will affect the ability of the sealer to seal
the bed plate to cylinder block.
Fig. 46 Crankshaft Journal Measurements - Typical
Fig. 47 Main Bearing Identification
1 - OIL GROOVE
2 - MAIN BEARINGS
3 - OIL HOLE
4 - LOWER THRUST BEARING PLAIN (NO OIL HOLE OR
GROOVE)
Fig. 48 Installing Main Bearing Upper Shell
1 - LUBRICATION GROOVES
2 - OIL HOLES
RSENGINE 2.4L9-39
CRANKSHAFT (Continued)

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