2005 CHRYSLER VOYAGER dot 4

INSTALLATION
BALANCE SHAFT INSTALLATION/TIMING
Balance shaft and carrier assembly installation is
the reverse of the removal procedure.During instal-
lation crankshaft-to-balance shaft timing must
be established. Refer to Timing procedure in
this section.
(1) With balance shafts installed in carrier (Fig.
134) position carrier on crankcase and install four
attaching bolts and tighten to 54 N´m (40 ft. lbs.).
(2) Turn balance shafts until both shaft key ways
are up, parallel to vertical centerline of engine.
Install short hub drive gear on sprocket driven shaft
and long hub gear on gear driven shaft. After instal-
lation gear and balance shaft keyways must be up
with gear timing marks meshed as shown in (Fig.
139).
(3) Install gear cover and tighten double ended
stud/washer fastener to 12 N´m (105 in. lbs.).
(4) Align flat on balance shaft drive sprocket to the
flat on crankshaft (Fig. 140).
(5) Install balance shaft drive sprocket on crank-
shaft using Special Tool 6052 (Fig. 141).
Fig. 137 Gear Cover and Gears
1 - STUD (DOUBLE ENDED)
2 - DRIVE GEAR
3 - DRIVEN GEAR
4 - CARRIER DOWEL
5 - GEAR(S)
6 - GEAR COVER
Fig. 138 Balance Shaft - Removal/Installation
1 - REAR COVER
2 - CARRIER
3 - BALANCE SHAFT
Fig. 139 Gear Timing
1 - KEY WAYS UP
2 - GEAR ALIGNMENT DOTS
RSENGINE 2.4L9-73
BALANCE SHAFTS AND CARRIER ASSEMBLY (Continued)

(6) Turn crankshaft until number 1 cylinder is at
top dead center (TDC). The timing marks on the
chain sprocket should line up with the parting line
on the left side of number one main bearing cap.
(Fig. 142).(7) Place chain over crankshaft sprocket so that
the plated link of the chain is over the number 1 cyl-
inder timing mark on the balance shaft crankshaft
sprocket (Fig. 142).
(8) Place balance shaft sprocket into the timing
chain (Fig. 142) and align the timing mark on the
sprocket (dot) with the (lower) plated link on the
chain.
NOTE: The lower plated link is 8 links from the
upper link.
(9) With balance shaft keyways pointing up (12
o'clock) slide the balance shaft sprocket onto the nose
of the balance shaft. The balance shaft may have to
be pushed in slightly to allow for clearance.
Fig. 140 Balance Shaft Sprocket Alignment to
Crankshaft
1 - ALIGN FLATS
Fig. 141 Balance Shaft Drive
1 - SPROCKET
2 - SPECIAL TOOL 6052Fig. 142 Balance Shaft Timing
1 - MARK ON SPROCKET
2 - KEYWAYS UP
3 - ALIGN MARKS
4 - PLATED LINK
5 - PARTING LINE (BEDPLATE TO BLOCK)
6 - PLATED LINK
9 - 74 ENGINE 2.4LRS
BALANCE SHAFTS AND CARRIER ASSEMBLY (Continued)

(17) Install accessory drive belt. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION)
(18) Install oil pump pick-up tube with new
O-ring. Tighten attaching bolt to 28 N´m (250 in.
lbs.).
(19) Install oil pan. (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION)
(20) Install inner splash shield and right front
wheel.
(21) Fill crankcase with engine oil to proper level.
(22) Fill cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(23) Connect negative cable to battery.
TIMING CHAIN AND
SPROCKETS
REMOVAL
REMOVAL - TIMING CHAIN AND CAMSHAFT
SPROCKET
(1) Disconnect negative cable from battery.
(2) Remove the timing chain cover. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL)
(3) Rotate engine by turning crankshaft until the
timing marks are aligned as shown in (Fig. 141).
(4) Remove camshaft sprocket attaching bolt.
(5) Remove the timing chain with camshaft
sprocket.
(6) Remove the crankshaft sprocket. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - REMOVAL)
REMOVAL - CRANKSHAFT SPROCKET
(1) Remove the timing chain. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - REMOVAL)
(2) Using Special Tools 8539, 5048-6, and 5048-1,
remove the crankshaft sprocket while holding the
crankshaft from turning (Fig. 142). Be careful not to
damage the crankshaft surfaces.
Fig. 141 Timing Mark Alignment
1 - CAMSHAFT SPROCKET TIMING MARK (DOT)
2 - PLATED LINK
3 - CRANKSHAFT SPROCKET TIMING MARK (DOT)
4 - ARROWS
Fig. 142 CRANKSHAFT SPROCKET - REMOVAL
1 - SPECIAL TOOL 5048-6
2 - SPECIAL TOOL 5048-1
3 - SPECIAL TOOL 8450
4 - CRANKSHAFT SPROCKET
5 - SPECIAL TOOL 8539
RSENGINE 3.3/3.8L9 - 159
TIMING CHAIN COVER (Continued)

INSTALLATION
INSTALLATION - CRANKSHAFT SPROCKET
(1) Position the sprocket on the crankshaft (timing
mark out) with the timing slot aligned with the tim-
ing pin.
(2) Install sprocket using Special Tool 8452 (Fig.
143). Install sprocket until it is fully seats on the
crankshaft.(3) Install the timing chain and camshaft sprocket.
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT/CHAIN AND SPROCKETS - INSTALLATION)INSTALLATION - TIMING CHAIN AND
CAMSHAFT SPROCKET
(1) Rotate crankshaft so the timing arrow is to the
12 o'clock position (Fig. 141).
NOTE: Lubricate timing chain and sprockets with
clean engine oil before installation.
(2) While holding camshaft sprocket and chain in
hand, place timing chain around the sprocket, align-
ing the plated link with the dot on the sprocket. Posi-
tion the timing arrow to the 6 o'clock position (Fig.
141).
(3) Place timing chain around crankshaft sprocket
with the plated link lined up with the dot on the
sprocket. Install camshaft sprocket into position.
(4) Use a straight edge to check alignment of tim-
ing marks.
(5) Install camshaft sprocket bolt and washer.
Tighten bolt to 54 N´m (40 ft. lbs.).
(6) Rotate crankshaft 2 revolutions and check tim-
ing mark alignment (Fig. 141). If timing marks do
not line up, remove camshaft sprocket and realign.
(7) Install the timing chain cover. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION)
(8) Connect negative cable to battery.
Fig. 143 CRANKSHAFT SPROCKET - INSTALLATION
1 - SPECIAL TOOL 8452-3
2 - SPECIAL TOOL 8452-1
3 - CRANKSHAFT SPROCKET
4 - THRUST BEARING / WASHER
9 - 160 ENGINE 3.3/3.8LRS
TIMING CHAIN AND SPROCKETS (Continued)

If difficult to balance, break down the wheel and
tire assembly and check for loose debris inside tire.
Prior to disassembly, mark (index) the tire at the
valve stem. Use this mark in order to remount the
tire in its original orientation with respect to the
wheel.
STANDARD PROCEDURE - TIRE AND WHEEL
MATCH MOUNTING
Wheels and tires are match mounted at the factory.
This means that the high spot of the tire is matched
to the low spot on the wheel rim. This technique is
used to reduce runout in the wheel and tire assem-
bly. The high spot on the tire is marked with a paint
mark or a bright colored adhesive label on the out-
board sidewall. The low spot on the wheel is identi-
fied with a label on the outside of the rim and a dot
or line in the drop well area of the rim (inside where
the tire mounts). If the outside label has been
removed, the tire will have to be removed to locate
the dot or line on the inside of the rim. The tire can
then be match mounted to the tire.
Information on match mounting the tire to the
wheel can be found in Tire and Wheel Runout/Match
Mounting, items (2) through (5), within Diagnosis
And Testing - Tire And Wheel Vibration. (Refer to 22
- TIRES/WHEELS - DIAGNOSIS AND TESTING)
STANDARD PROCEDURE - TIRE AND WHEEL
ROTATION
NON-DIRECTIONAL TREAD PATTERN TIRES
Tires on the front and rear axles operate at differ-
ent loads and perform different functions. For these
reasons, they wear at unequal rates, and tend to
develop irregular wear patterns. These effects can bereduced by timely rotation of tires. The benefits of
rotation are especially worthwhile. Rotation will
increase tread life, help to maintain mud, snow, and
wet traction levels, and contribute to a smooth, quiet
ride.
The suggested rotation method is the forward-cross
tire rotation method (Fig. 11). This method takes
advantage of current tire industry practice which
allows rotation of radial-ply tires. Other rotation
methods may be used, but may not have all the ben-
efits of the recommended method.
NOTE: Only the 4 tire rotation method may be used
if the vehicle is equipped with a low mileage or tem-
porary spare tire.
DIRECTIONAL TREAD PATTERN TIRES
Some vehicles are fitted with special high-perfor-
mance tires having a directional tread pattern. These
tires are designed to improve traction on wet pave-
ment. To obtain the full benefits of this design, the
tires must be installed so that they rotate in the cor-
rect direction. This is indicated by arrows on the tire
sidewalls.
When wheels and tires are being installed, extra
care is needed to ensure that this direction of rota-
tion is maintained.
Refer to Owner's Manual for rotation schedule.
Fig. 10 Aluminum Wheel Weight
1 - TIRE
2 - WHEEL
3 - WHEEL WEIGHT
Fig. 11 Forward-Cross Tire Rotation Method
RSTIRES/WHEELS22-7
TIRES/WHEELS (Continued)