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 (0.0394 in.) towards the thrust side of
the piston. The connecting rods are a cracked cap
design and are not repairable. Hex head cap screws
are used to provide alignment and durability in the
assembly. The pistons and connecting rods are ser-
viced as an assembly.
STANDARD PROCEDURE - PISTON TO
CYLINDER BORE FITTING
NOTE: Pistons and cylinder bores should be mea-
sured at normal room temperature, 21ÉC (70ÉF).
Piston and cylinder wall must be clean and dry.
Piston diameter should be measured 90 degrees to
piston pin.
Piston measurement should be taken approxi-
mately 14 mm (0.551 in.) from the bottom of the skirt
as shown in (Fig. 60)Cylinder bores should be measured halfway down
the cylinder bore and transverse (measurement loca-
tion B) to the engine crankshaft center line shown in
(Fig. 61). Refer to for Engine Specifications (Refer to
9 - ENGINE - SPECIFICATIONS). Correct piston to
bore clearance must be established in order to assure
quiet and economical operation.REMOVAL
(1) Remove cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
(2) Remove oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - REMOVAL).
(3) Remove Balance Shaft Carrier Assembly (Refer
to 9 - ENGINE/VALVE TIMING/BALANCE SHAFT
CARRIER - REMOVAL).
Fig. 59 Rear Crankshaft Seal - Installation
1 - SPECIAL TOOL 6926±2 INSTALLER
Fig. 60 Piston Measurement
1 - PISTON DIAMETER
2 - 14 mm (0.551 in.)
Fig. 61 Checking Cylinder Bore
9 - 44 ENGINE 2.4LRS
CRANKSHAFT OIL SEAL - REAR (Continued)

(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)

(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)

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 bolt to assemble the cap properly.
(4) 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.
(5) Using a feeler gauge, check connecting rod side
clearance (Fig. 68). Refer to clearance specifications
(Refer to 9 - ENGINE - SPECIFICATIONS).
PISTON RINGS
STANDARD PROCEDURE
PISTON RING - FITTING
(1) Wipe cylinder bore clean. Insert ring and push
down with piston to ensure it is square in bore. The
ring gap measurement must be made with the ring
positioning at least 12 mm (0.50 inch) from bottom of
cylinder bore. Check gap with feeler gauge (Fig. 69).
Refer to Engine Specifications.
(2) Check piston ring to groove side clearance (Fig.
70). Refer to Engine Specifications.
REMOVAL
(1) Using a suitable ring expander, remove upper
and intermediate piston rings (Fig. 71).
(2) Remove the upper oil ring side rail, lower oil
ring side rail and then oil ring expander from piston.(3) Clean ring grooves of any carbon deposits.
INSTALLATION
NOTE: The identification mark on face of upper and
intermediate piston rings must point toward top of
piston.
Install rings with manufacturers identification
mark facing up, to the top of the piston (Fig. 72).
CAUTION: Install piston rings in the following
order:
1. Oil ring expander.
2. Upper oil ring side rail.
3. Lower oil ring side rail.
Fig. 68 Connecting Rod Side Clearance - Typical
Fig. 69 Piston Ring Gap
1 - FEELER GAUGE
Fig. 70 Piston Ring Side Clearance
1 - FEELER GAUGE
RSENGINE 2.4L9-47
CONNECTING ROD BEARINGS (Continued)

4. No. 2 Intermediate piston ring.
5. No. 1 Upper piston ring.
(1) Install oil ring expander (Fig. 72).
(2) Install upper side rail first and then the lower
side rail. Install the side rails by placing one end
between the piston ring groove and the oil ring
expander. Hold end firmly and press down the por-
tion to be installed until side rail is in position.Do
not use a piston ring expander (Fig. 73).
(3) Install No. 2 piston ring and then No. 1 piston
ring (Fig. 72).(4) Position piston ring end gaps as shown in (Fig.
74).
(5) Position oil ring expander gap at least 45É from
the side rail gaps butnoton the piston pin center or
on the thrust direction. Staggering ring gap is impor-
tant for oil control.VIBRATION DAMPER
REMOVAL
(1) Remove accesory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)
(2) Remove crankshaft damper bolt.
(3) Remove damper using Special Tool 3-Jaw
Puller 1026 and Insert 6827±A (Fig. 75).
Fig. 71 Piston RingsÐRemoving and Installing
Fig. 72 Piston Ring Installation
1 - NO. 1 PISTON RING
2 - NO. 2 PISTON RING
3 - SIDE RAIL
4 - OIL RING
5 - SPACER EXPANDER
Fig. 73 Installing Side Rail
1 - SIDE RAIL END
Fig. 74 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
9 - 48 ENGINE 2.4LRS
PISTON RINGS (Continued)

INSTALLATION
(1) Install crankshaft vibration damper using M12
1.75 x 150 mm bolt, washer, thrust bearing and nut
from Special Tool 6792 (Fig. 76).
(2) Install crankshaft vibration damper bolt and
tighten to 142 N´m (105 ft. lbs.).
(3) Install accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION)
STRUCTURAL COLLAR
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove engine front mount bracket and front
insulator mount. (Refer to 9 - ENGINE/ENGINE
MOUNTING/FRONT MOUNT - REMOVAL)(3) Remove structural collar attaching bolts (Fig.
77).
(4) Remove collar.
INSTALLATION
CAUTION: Torque procedure for the structural collar
must be followed or damage could occur to oil pan
and collar.
(1) Perform the following steps for installing struc-
tural collar. Refer to (Fig. 77):
²Step 1: Position collar between transaxle and oil
pan. Install collar to transaxle bolt,hand start
only.
²Step 2: Install collar to oil pan bolts,hand snug
only.
²Step 3: Final torque collar to transaxle bolts to
101 N´m (75 ft. lbs.)
²Step 4: Final torque collar to oil pan bolts to 54
N´m (40 ft. lbs.).
(2) Install engine front mount bracket and insula-
tor. (Refer to 9 - ENGINE/ENGINE MOUNTING/
FRONT MOUNT - INSTALLATION)
(3) Lower vehicle.
Fig. 75 Crankshaft Vibration Damper - Removal
1 - SPECIAL TOOL 1026 3-JAW PULLER
2 - SPECIAL TOOL 6827±A INSERT
Fig. 76 Crankshaft Vibration Damper - Installation
1 - M12±1.75 ý 150 MM BOLT, WASHER AND THRUST BEARING
FROM SPECIAL TOOL 6792
Fig. 77 Structural Collar
1 - BOLT - COLLAR TO OIL PAN
2 - BOLT - COLLAR TO TRANSAXLE
3 - STRUCTURAL COLLAR
4 - OIL PAN
RSENGINE 2.4L9-49
VIBRATION DAMPER (Continued)

ENGINE MOUNTING
DESCRIPTION
The engine mounting system consist of four
mounts; right and a left side support the powertrain,
and a front and a rear mount control powertrain
torque. The right side mount is a hydro-type (Fig.
78), all others are of molded rubber material.
FRONT MOUNT
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove the front engine mount through bolt
from the insulator (Fig. 79).
(3) Remove the engine front mount bolts and
remove the insulator assembly (Fig. 79).
(4) Remove the front mounting bracket from
engine, if necessary (Fig. 79).
INSTALLATION
(1) Install the front mount bracket to engine, if
removed (Fig. 79).
(2) Install the insulator mount assembly (Fig. 79).
(3) Install the front engine mount through bolt to
the insulator (Fig. 79).
(4) Lower the vehicle.
LEFT MOUNT
REMOVAL
(1) Raise the vehicle on hoist.
(2) Remove the left front wheel.
(3) Remove the left mount through bolt access
cover.
(4) Support the transaxle with a suitable jack.
(5) Remove the engine front mount through bolt to
allow left mount removal clearance (Fig. 79).
(6) Remove the left mount through frame rail bolt
(Fig. 80).
(7) Lower transaxle for access to horizontal bolts.
(8) Remove the horizontal bolts from the mount to
the transaxle (Fig. 81).
NOTE: To remove mount, additional lowering of
transaxle may be required.
(9) Remove left mount.
INSTALLATION
(1) Install left mount on transaxle (Fig. 81).
(2) Raise transaxle with jack until left mount is in
position.
(3) Install left mount through bolt (Fig. 80).
Fig. 78 Engine Hydro-type Mount - Right Side
1 - BOLT
2 - BOLT
3 - FRAME RAIL
4 - RIGHT MOUNT - 2.4L ENGINE
5 - RIGHT MOUNT - 3.3/3.8L ENGINE
Fig. 79 Front Mount and Bracket
1 - BRACKET - FRONT MOUNT
2 - NUT - 68 N´m (50 ft. lbs.)
3 - BOLT - 54 N´m (40 ft. lbs.)
4 - MOUNT - FRONT INSULATOR
5 - BOLT - 68 N´m (50 ft. lbs.)
6 - BOLT - 68 N´m (50 ft. lbs.)
7 - FRONT CROSSMEMBER
9 - 50 ENGINE 2.4LRS

(4) Install left mount through bolt access cover.
(5) Install front mount through bolt (Fig. 79).
(6) Install left front wheel.
(7) Lower vehicle.
REAR MOUNT
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove the rear mount heat shield (Fig. 82).
(3) Remove the through bolt from the mount and
rear mount bracket (Fig. 83).
(4) Remove the mount bolts (Fig. 83).
(5) Remove the rear mount (Fig. 83).
(6) For rear mount bracket removal, remove the
bolts attaching bracket to transaxle (Fig. 84).
(7) Remove rear mount bracket.
Fig. 80 Left Mount To Bracket
1 - BOLT - BRACKET TO FRAME RAIL 68 N´m (50 ft. lbs.)
2 - BOLT - MOUNT TO RAIL THRU 75 N´m (55 ft. lbs.)
3 - BOLT - LEFT MOUNT TO TRANSAXLE 54 N´m (40 ft. lbs.)
4 - TRANSAXLE
5 - MOUNT - LEFT
6 - BRACKET - LEFT MOUNT
Fig. 81 Left Mount - 41TE Transaxle
1 - LEFT MOUNT ASSEMBLY
2 - BOLT - 54 N´m (40 ft. lbs.)
3 - TRANSAXLE - 41TE
Fig. 82 Rear Mount Heat Shield
1 - BOLT - HEAT SHIELD 11 N´m (100 in. lbs.)
2 - HEAT SHIELD
3 - CLIP
4 - REAR MOUNT
Fig. 83 Rear Mount
1 - BOLT 54 N´m (40 ft. lbs.)
2 - REAR MOUNT BRACKET
3 - THRU-BOLT 54 N´m (40 ft. lbs.)
4 - REAR MOUNT
RSENGINE 2.4L9-51
LEFT MOUNT (Continued)

INSTALLATION
(1) Install rear mount bracket, if removed (Fig.
84).
(2) Install the rear mount and bolts (Fig. 83).
Tighten bolts to 54 N´m (40 ft. lbs.).
(3) Install the mount through bolt to the mount
and bracket (Fig. 83). Tighten through bolt to 54 N´m
(40 ft. lbs.).
(4) Install the rear mount heat shield (Fig. 82).
(5) Lower vehicle on hoist.
RIGHT MOUNT
REMOVAL
(1) Remove air cleaner housing lid and clean air
hose from throttle body.
(2) Remove air cleaner element and housing.
(3) Disconnect make-up air hose from cylinder
head cover.
(4) Remove the load on the right engine mount by
carefully supporting the engine assembly with a floor
jack.
(5) Disconnect electrical harness support clips from
engine mount bracket.(6) Remove the vertical bolts attaching the engine
mount to the frame rail (Fig. 85).
(7) Loosen the horizontal bolt attaching the engine
mount to the frame rail (Fig. 85).
(8) Remove the bolts attaching the engine mount
to the engine bracket (Fig. 85).
(9) Remove the right engine mount (Fig. 85).
INSTALLATION
(1) Position right engine mount and install frame
rail to mount vertical bolts (Fig. 85).
(2) Tighten engine right mount to rail horizontal
bolt (Fig. 85).
(3) Install mount to engine bracket bolts (Fig. 85).
(4) Connect electrical harness support clips to
engine mount bracket.
(5) Remove jack from under engine.
(6) Connect make-up air hose to cylinder head
cover.
(7) Install air cleaner housing and element.
(8) Install air cleaner housing lid and clean air
tube to throttle body.
Fig. 84 Rear Mount Bracket - (all engines)
1 - BOLT - VERTICAL 102 N´m (75 ft. lbs.)
2 - BRACKET - REAR MOUNT3 - BOLT - HORIZONTAL 102 N´m (75 ft. lbs.)
9 - 52 ENGINE 2.4LRS
REAR MOUNT (Continued)

LUBRICATION
DESCRIPTION
The lubrication system is a full-flow filtration,
pressure feed type. The oil pump is mounted in the
front engine cover and driven by the crankshaft.
OPERATION
Engine oil drawn up through the pickup tube and
is pressurized by the oil pump and routed through
the full-flow filter to the main oil gallery running the
length of the cylinder block. A diagonal hole in each
bulkhead feeds oil to each main bearing. Drilled pas-
sages within the crankshaft route oil from main bear-
ing journals to connecting rod journals. Balance shaft
lubrication is provided through an oil passage from
the number one main bearing cap through the bal-
ance shaft carrier support leg. This passage directly
supplies oil to the front bearings and internal
machined passages in the shafts that routes oil from
front to the rear shaft bearing journals. A vertical
hole at the number five bulkhead routes pressurized
oil through a restrictor (integral to the cylinder head
gasket) up past a cylinder head bolt to an oil gallery
running the length of the cylinder head. The cam-shaft journals are partially slotted to allow a prede-
termined amount of pressurized oil to pass into the
bearing cap cavities. Lubrication of the camshaft
lobes are provided by small holes in the camshaft
bearing caps that are directed towards each lobe. Oil
returning to the pan from pressurized components
supplies lubrication to the valve stems. Cylinder
bores and wrist pins are splash lubricated from
directed slots on the connecting rod thrust collars
(Fig. 86).
DIAGNOSIS AND TESTING - CHECKING
ENGINE OIL PRESSURE
(1) Disconnect and remove oil pressure switch.
(Refer to 9 - ENGINE/LUBRICATION/OIL PRES-
SURE SENSOR/SWITCH - REMOVAL)
(2) Install Special Tools C-3292 Gauge with 8406
Adaptor fitting.
(3) Start engine and record oil pressure. Refer to
Specifications for correct oil pressure requirements.
(Refer to 9 - ENGINE - SPECIFICATIONS)
CAUTION: If oil pressure is 0 at idle, do not perform
the 3000 RPM test
(4) If oil pressure is 0 at idle. Shut off engine,
check for pressure relief valve stuck open, a clogged
oil pick-up screen or a damaged oil pick-up tube
O-ring.
(5) After test is complete, remove test gauge and
fitting.
Fig. 85 Right Mount to Rail and Engine
1 - BOLT - MOUNT TO RAIL 68 N´m (50 ft. lbs.)
2 - BOLT - MOUNT TO ENGINE 54 N´m (40 ft. lbs.)
3 - BOLT - MOUNT TO RAIL (HORIZONTAL) 68 N´m (50 ft. lbs.)
4 - RIGHT ENGINE MOUNT
5 - RIGHT FRAME RAIL
Fig. 86 Engine Lubrication System
RSENGINE 2.4L9-53
RIGHT MOUNT (Continued)