2005 CHRYSLER VOYAGER Service Manual

USB clutch fuel additives TPMS reset flat tire instrument panel

Page 1217 of 2339

CHRYSLER VOYAGER 2005 Service Manual (6) Oil the bearings and journals. Install crank-
shaft in the engine block.
CAUTION: Use only MoparTBed Plate Sealant on
the bed plate or damage may occur to the engine.
(7) Install lower main bearin

Page 1218 of 2339

CHRYSLER VOYAGER 2005 Service Manual (14) Turn bolts (1±10) an additional 1/4 turn in
sequence shown in (Fig. 51).
(15) Install main bearing bed plate to engine
block bolts (11±20), and torque each bolt to 28 N´m
(250 in. lbs.) in seq

(14) Turn bolts (1±10) an additional 1/4 turn in
sequence shown in (Fig. 51).
(15) Install main bearing bed plate to engine
block bolts (11±20), and torque each bolt to 28 N´m
(250 in. lbs.) in sequence shown in. (Fig. 51)
(16) Tighten bolts (11±20) again to 28 N´m (250 in.
lbs.) in sequence shown in (Fig. 51).
(17) After the main bearing bed plate is installed,
check the crankshaft turning torque. The turning
torque should not exceed 5.6 N´m (50 in. lbs.).
(18) Check crankshaft end play (Refer to 9 -
ENGINE/ENGINE BLOCK/CRANKSHAFT - STAN-
DARD PROCEDURE).
(19) Install connecting rod bearings and caps.Do
Not Reuse Connecting Rod Bolts.Torque connect-
ing rod bolts to 27 N´m (20 ft. lbs.) plus 1/4 turn.
(20) Install balance shafts and housing assembly
(Refer to 9 - ENGINE/VALVE TIMING/BALANCE
SHAFT - INSTALLATION).
(21) Install the oil pump (Refer to 9 - ENGINE/
LUBRICATION/OIL PUMP - INSTALLATION).
(22) Install oil pump pick-up tube. Torque fastener
to 28 N´m (20 ft.. lbs.).
(23) Install the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - INSTALLATION).
(24) Install crankshaft position sensor.
(25) Install cylinder head if it was removed (Refer
to 9 - ENGINE/CYLINDER HEAD - INSTALLA-
TION).
(26) Install the timing belt rear cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT COVER(S)
- INSTALLATION).
(27) Install crankshaft sprocket (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT AND
SPROCKETS - INSTALLATION).
(28) Install the timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
INSTALLATION).
(29) Install the timing belt front covers (Refer to 9
- ENGINE/VALVE TIMING/TIMING BELT COV-
ER(S) - INSTALLATION).
(30) Install engine mount support bracket.
(31) InstallNEWoil filter.
(32) Install crankshaft rear oil seal (Refer to 9 -
ENGINE/ENGINE BLOCK/CRANKSHAFT OIL
SEAL - REAR - INSTALLATION).
(33) Install flex plate. Apply MopartLock & Seal
Adhesive to bolt threads and tighten to 95 N´m (70
ft. lbs.).
(34) Attach transaxle to engine. Tighten attaching
bolts to 101 N´m (75 ft. lbs.).
(35) Install the engine assembly (Refer to 9 -
ENGINE - INSTALLATION).CRANKSHAFT OIL SEAL -
FRONT
REMOVAL
(1) Remove the crankshaft vibration damper.
(Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL)
(2) Remove timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL)
(3) Remove crankshaft sprocket using Special Tool
6793 and insert C-4685-C2 (Fig. 52).
CAUTION: Do not nick shaft seal surface or seal
bore.
(4) Using Tool 6771 to remove front crankshaft oil
seal (Fig. 53). Be careful not to damage the seal sur-
face of cover.
Fig. 52 Crankshaft Sprocket - Removal
1 - SPECIAL TOOL 6793
2 - SPECIAL TOOL C-4685±C2
3 - CRANKSHAFT SPROCKET
Fig. 53 Front Crankshaft Oil Seal - Removal
1 - SPECIAL TOOL 6771
2 - REAR TIMING BELT COVER
RSENGINE 2.4L9-41
CRANKSHAFT (Continued)

Page 1219 of 2339

CHRYSLER VOYAGER 2005 Service Manual INSTALLATION
(1) Install new seal by using Special Tool 6780
(Fig. 54).
(2) Place seal into opening with seal spring
towards the inside of engine. Install seal until flush
with cover.
(3) Install cran

Page 1220 of 2339

CHRYSLER VOYAGER 2005 Service Manual NOTE: When installing seal, no lube on seal is
needed.
(1) Place Special Tool 6926-1 Seal Guide on crank-
shaft (Fig. 57).
(2) Position seal over guide tool (Fig. 57). Guide
tool should remain on cran

Page 1221 of 2339

CHRYSLER VOYAGER 2005 Service Manual 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 is
offset 1 mm (0

Page 1222 of 2339

CHRYSLER VOYAGER 2005 Service Manual (4) 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.
(5) Pistons have a di

(4) 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.
(5) Pistons have a directional stamping in the
front half of the piston facing towards thefrontof
engine (Fig. 62).
(6) Pistons and connecting rods must be removed
from top of cylinder block. Rotate crankshaft so that
each connecting rod is centered in cylinder bore.
(7) Using a permanent ink or paint marker, iden-
tify cylinder number on each connecting rod cap (Fig.
63).
CAUTION: DO NOT use a number stamp or a punch
to mark connecting rods. Damage to connecting
rod could occur.
(8) Remove connecting rod bolts and cap. Care
should be taken not to damage the fracture rod and
cap surfaces.
NOTE: Do not reuse connecting rod bolts.
CAUTION: Care must be taken not to damage the
fractured rod and cap joint surfaces, as engine
damage many occur.
(9) To protect crankshaft journal and fractured rod
surfaces, install Special Tool 8189, connecting rod
guides onto connecting rod (Fig. 64). Carefully push
each piston and rod assembly out of cylinder bore.
(10) Remove Special Tool 8189, connecting rod
guides and re-install bearing cap on the mating rod.
NOTE: Piston and rods are serviced as an assem-
bly.(11) Repeat procedure for each piston and connect-
ing rod assembly.
(12) Remove piston rings (Refer to 9 - ENGINE/
ENGINE BLOCK/PISTON RINGS - REMOVAL).
INSTALLATION
(1) Install piston rings on piston (Refer to 9 -
ENGINE/ENGINE BLOCK/PISTON RINGS -
INSTALLATION)
(2) Before installing pistons and connecting rod
assemblies into the bore, be sure that compression
ring gaps are staggered so that neither is in line with
oil ring rail gap (Fig. 65).
(3) Before installing the ring compressor, make
sure the oil ring expander ends are butted and the
rail gaps located as shown in (Fig. 65). As viewed
from top.
(4) Immerse the piston head and rings in clean
engine oil, slide the ring compressor, over the piston
(Fig. 66).Be sure position of rings does not
change during this operation.
(5) The directional stamp on the piston should face
toward the front of the engine (Fig. 62).
Fig. 62 Piston Markings
1 - DIRECTIONAL ARROW WILL BE IMPRINTED IN THIS AREA
Fig. 63 Identify Connectng Rod to Cylinder - Typical
Fig. 64 Connecting Rod Guides - Typical
1 - SPECIAL TOOL 8189 CONNECTING ROD GUIDES
RSENGINE 2.4L9-45
PISTON & CONNECTING ROD (Continued)

Page 1223 of 2339

CHRYSLER VOYAGER 2005 Service Manual (6) Rotate crankshaft so that the connecting rod
journal is on the center of the cylinder bore. Lubri-
cate connecting rod journal with clean engine oil.
(7) Install connecting rod upper bearing half

(6) Rotate crankshaft so that the connecting rod
journal is on the center of the cylinder bore. Lubri-
cate connecting rod journal with clean engine oil.
(7) Install connecting rod upper bearing half into
connecting rod. Install Special Tool 8189, connecting
rod guides onto connecting rod (Fig. 64).
(8) Tap the piston down in cylinder bore, using a
hammer handle. At the same time, guide connecting
rod into position on connecting rod journal.
(9) Remove Special Tool 8189, connecting rod
guides.
NOTE: The connecting rod cap bolts should not be
reused.
(10) Before installing theNEWbolts, the threads
should be coated with clean engine oil.
(11) Install connecting rod lower bearing half into
connecting rod cap. Install connecting rod cap.(12) Install each bolt finger tight then alternately
torque each bolt to assemble the cap properly.
(13) Tighten the connecting rod bolts using the 2
step torque-turn method. Tighten according to the
following values:
CAUTION: Do not use a torque wrench for the sec-
ond step.
1. Tighten the bolts to 27 N´m (20 ft. lbs.).
2. Tighten the connecting rod bolts an additional
1/4 TURN.
(14) Using a feeler gauge, check connecting rod
side clearance (Fig. 67). (Refer to 9 - ENGINE -
SPECIFICATIONS) for connecting rod side clearance.
(15) Install Balance Shaft Carrier Assembly (Refer
to 9 - ENGINE/VALVE TIMING/BALANCE SHAFT
CARRIER - INSTALLATION).
(16) Install oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION).
(17) Install cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - INSTALLATION).
CONNECTING ROD BEARINGS
STANDARD PROCEDURE
CONNECTING ROD - FITTING
(1) For measuring connecting rod bearing clear-
ance procedure and use of Plastigage(Refer to 9 -
ENGINE - STANDARD PROCEDURE). For bearing
clearance refer to Engine Specifications. (Refer to 9 -
ENGINE - SPECIFICATIONS)
Fig. 65 Piston Ring End Gap Position
1 - GAP OF LOWER SIDE RAIL
2 - NO. 1 RING GAP
3 - GAP OF UPPER SIDE RAIL
4 - NO. 2 RING GAP AND SPACER EXPANDER GAP
Fig. 66 PistonÐInstallation
Fig. 67 Checking Connecting Rod Side Clearance -
Typical
9 - 46 ENGINE 2.4LRS
PISTON & CONNECTING ROD (Continued)

Page 1224 of 2339

CHRYSLER VOYAGER 2005 Service Manual NOTE: The rod bearing bolts should not be reused.
(2) Before installing theNEWbolts the threads
should be oiled with clean engine oil.
(3) Install each bolt finger tight then alternately
torque each b

Load next 8 pages

Page: < prev 1-10 ... 1185-1192 1193-1200 1201-1208 1209-1216 1217-1224 1225-1232 1233-1240 1241-1248 1249-1256 ... 2344 next >

open bonnet sport mode fuel cap release language oil pressure seat memory