torque CHRYSLER VOYAGER 1996 Service Manual

ENGINE MOUNTÐREAR
REMOVAL
(1) Raise vehicle on hoist and remove the left
front wheel.
(2) Support the transaxle with a jack so it will not
rotate.
(3) Remove the insulator thru bolt from the
mount and rear suspension crossmember.
(4) Remove the four mount fasteners and remove
the mount.
INSTALLATION
(1) Reverse the removal procedure for installation.
Refer to (Fig. 25).
STRUCTURAL COLLAR
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove front engine mounting bracket from
bending strut and front insulator mount.
(3) Remove bolts attaching bending strut to engine
and transaxle.
(4) Remove bolts attaching collar and strut to
engine, oil pan, and transaxle. Remove strut and col-
lar.
INSTALLATION
CAUTION: Torque procedure for the structural col-
lar and bending strut must be followed or damage
could occur to oil pan, collar, and/or bending strut.
(1) Perform the following steps for installing struc-
tural collar and bending strut. Refer to (Fig. 26):
²Step 1: Place collar into position between tran-
saxle and oil pan. Hand start only, collar to transaxle
bolt 1.
²Step 2: Install bolt 4, collar to oil pan,hand
tight only.
²Step 3: Position bending strut in place and hand
start bolt 3 into the upper transaxle hole.
²Step 4: Install bolt 2, through strut and collar.
Hand starting only.
²Step 5: Install bolt 6, strut to cylinder block,
hand tight only.
²Step 6: Install the remaining collar to oil pan
bolt 5,hand tight only.
²Step 7: Final torque collar to transaxle bolts 1 ±
3, to 101 N´m (75 ft. lbs.)
²Step 8: Install bolts 7 and 8, through strut and
into cylinder block.
²Step 9: Final torque bolts4±8to61N´m(45ft.
lbs.).
(2) Lower vehicle.
Fig. 24 Engine MountingÐRight Side
Fig. 25 Engine MountingÐRear
Fig. 26 Structural Collar and Bending StrutÐ
Removal and Installation
NS2.4L ENGINE 9 - 25
REMOVAL AND INSTALLATION (Continued)

ENGINE ASSEMBLY
REMOVAL
(1) Perform fuel pressure release procedure. Refer
to Group 14, Fuel System for procedure. Remove fuel
line to fuel rail.
(2) Disconnect battery.
(3) Remove Air cleaner and hoses.
(4) Drain cooling system. Refer to Group 7, Cooling
System for procedure.
(5) Remove upper radiator hose and remove radia-
tor fans. Refer to Group 7, Cooling System for proce-
dure.
(6) Remove lower radiator hose.
(7) Disconnect automatic transmission cooler lines
and plug, if equipped.
(8) Disconnect transmission shift linkage.
(9) Disconnect throttle body linkage.
(10) Disconnect engine wiring harness.
(11) Disconnect heater hoses.
(12) Discharge Air Conditioning System. Refer to
Group 24, Air Conditioning for procedure.
(13) Hoist vehicle and remove right inner splash
shield. Remove wheels and tires.
(14) Loosen power steering belt for pump removal.
Refer to Group 7, Cooling System for procedure.
(15) Remove axle shafts. Refer to Group 2, Suspen-
sion and Driveshafts for procedure.
(16) Disconnect exhaust pipe from manifold.
(17) Remove front and rear engine mount brackets
from the body.
(18) Remove bending braces and front engine
mount bracket. Remove transmission inspection
cover.
(19) Mark flexplate to torque converter and
remove torque converter bolts.
(20) Install front engine mount bracket.
(21) Lower vehicle.
(22) Remove power steering pump. Set pump
aside.
(23) Remove A/C lines at compressor and cap.
(24) Remove ground straps to body.
(25) Raise vehicle enough to allow engine dolly
Special Tool 6135, cradle Special Tool 6710 with
Posts Special Tool 6848 and Adaptor Special Tool
8130 to be installed under vehicle (Fig. 27).
(26) Loosen cradle posts to allow movement for
proper positioning. Locate two rear posts (right side
of engine) into the holes on the engine bedplate.
Locate the two front posts (left side of engine) on the
front engine bracket and A/C compressor bracket
(Fig. 27). Lower vehicle and position cradle mounts
until the engine is resting on mounts. Tighten
mounts to cradle frame. This will keep mounts from
moving when removing or installing engine and
transmission.(27) Lower vehicle so the weight ofONLY THE
ENGINE AND TRANSMISSIONare on the cradle.
(28) Remove engine and transmission mount bolts.
(29) Raise vehicle slowly. It may be necessary to
move the engine/transmission assembly on the cradle
to allow for removal around the body.
INSTALLATION
(1) Position engine and transmission assembly
under vehicle and slowly lower the vehicle over the
engine and transmission.
(2) Align engine and transmission mounts to
attaching points. Install mounting bolts at the right
engine and left transmission mounts. Refer to proce-
dures outlined in this section.
(3) Slowly raise vehicle enough to remove the
engine dolly and cradle Special Tools 6135 and 6710.
(4) Install axle shafts. Refer to Group 2, Suspen-
sion and Driveshafts for procedure.
(5) Install transmission and engine braces and
splash shields.
(6) Connect exhaust system to manifold. Refer to
Group 11, Exhaust System and Intake Manifold for
procedure and torque specifications.
(7) Install power steering pump. Refer to Cooling
System Group 7, Accessory Drive Section for belt ten-
sion adjustment.
(8) Install A/C compressor hoses. Refer to Group
24, Heater and Air Conditioning for procedure.
(9) Install accessory drive belts. Refer to Group 7,
Cooling System Accessory Drive Section for belt ten-
sion adjustment.
(10) Install front and rear engine mounts. Refer to
this section for procedure.
(11) Install inner splash shield. Install wheels and
tires.
(12) Connect automatic transmission cooler lines,
and shift linkage. Refer to Group 21, Transmission
for procedures.
(13) Connect fuel line and heater hoses.
(14) Install ground straps. Connect engine and
throttle body connections and harnesses. Refer to
Group 8, Electrical for procedure.
(15) Connect throttle body linkage. Refer to Group
14, Fuel System for procedure.
(16) Install radiator fans. Install radiator hoses.
Fill cooling system. Refer to Group 7, Cooling System
for filling procedure.
(17) Connect battery.
(18) Install air cleaner and hoses.
(19) Install oil filter. Fill engine crankcase with
proper oil to correct level.
(20) Start engine and run until operating temper-
ature is reached.
(21) Adjust transmission linkage, if necessary.
9 - 26 2.4L ENGINENS
REMOVAL AND INSTALLATION (Continued)

CYLINDER HEAD COVER
REMOVAL
(1) Remove upper intake manifold. Refer to Group
11, Exhaust System and Intake Manifold.
(2) Remove nuts attaching front and rear intake
manifold supports from cylinder head cover attaching
studs.
(3) Remove ignition coil pack and plug wires (Fig.
28). Remove ground strap.
(4) Remove the cylinder head cover fasteners.
(5) Remove cylinder head cover from cylinder
head.
INSTALLATION
NOTE: Replace spark plug well seals when install-
ing a new cylinder head cover gasket.
(1) Clean all sealing surfaces.
(2) Install new cylinder head cover gaskets and
spark plug seals (Fig. 29).CAUTION: Do not allow oil or solvents to contact
the timing belt as they can deteriorate the rubber
and cause tooth skipping.
(3) Apply MopartSilicone Rubber Adhesive Seal-
ant at the camshaft cap corners and at the top edge
of the 1/2 round seal.
(4) Install cylinder head cover assembly to head
and tighten fasteners in sequence shown in (Fig. 30).
Using the 3 step torque method:
(a) Tighten all fasteners to 4.5 N´m (40 in. lbs.)
(b) Tighten all fasteners to 9.0 N´m (80 in. lbs.)
(c) Tighten all fasteners to 12 N´m (105 in. lbs.)
(5) Install ignition coil pack and plug wires.
Tighten fasteners to 12 N´m (105 in. lbs.).
(6) Install ground strap.
(7) Install front and rear intake manifold support
brackets and attaching nuts, but do not tighten at
this time.
(8) Install upper intake manifold. Refer to Group
11, Exhaust System and Intake Manifold for proce-
dure.
(9) Final torque intake manifold support nuts to
28 N´m (250 in. lbs.).
CAMSHAFT
REMOVAL
(1) Remove cylinder head cover using procedure
outlined in this section.
(2) Remove timing belt, sprockets and covers.
Refer to Timing Belt Service outlined in this section.
(3) Bearing caps are identified for location.
Remove the outside bearing caps first (Fig. 31).
(4) Loosen the camshaft bearing cap attaching
fasteners in sequence shown (Fig. 32) one camshaft
at a time.
CAUTION: Camshafts are not interchangeable. The
intake cam number 6 thrust bearing face spacing is
wider.
Fig. 28 Ignition Coil Pack and Ground Strap
Fig. 29 Cylinder Head Cover Gasket and Spark Plug
Seals
Fig. 30 Cylinder Head Cover Tightening Sequence
9 - 28 2.4L ENGINENS
REMOVAL AND INSTALLATION (Continued)

(5) Identify the camshafts before removing from
the head. The camshafts are not interchangeable.
CAMSHAFT END PLAY
(1) Oil camshaft journals and install camshaft
WITHOUTcam follower assemblies. Install rear cam
caps and tighten screws to specified torque.
(2) Using a suitable tool, move camshaft as far
rearward as it will go.
(3) Zero dial indicator (Fig. 33).
(4) Move camshaft as far forward as it will go.
(5) End play travel: 0.05±0.15 mm (0.002±0.010
in.).
(6) If end play is excessive check cylinder head
and camshaft for wear; replace as necessary.
INSTALLATION
CAUTION: Ensure that NONE of the pistons are at
top dead center when installing the camshafts.
(1) Remove camshaft retaining caps and lubricate
bearing journals. Install cam followers and camshafts
with clean oil. Install right and left camshaft bearing
caps #2 thru #5 and right #6. Tighten M6 fasteners
to 12 N´m (105 in. lbs.) in sequence shown in (Fig.
34).
(2) Apply MopartGasket Maker to No. 1 and No.
6 bearing caps (Fig. 35). Install bearing caps and
tighten M8 fasteners to 28 N´m (250 in. lbs.).
(3) Bearing end caps must be installed before
seals can be installed.
(4) Install timing belt, sprockets and covers. Refer
to timing belt service outlined in this section.
(5) Install cylinder head cover using procedure
outlined in this section.Fig. 31 Camshaft Bearing Cap Identification
Fig. 32 Camshaft Bearing CapÐ Removal
Fig. 33 Camshaft End Play
Fig. 34 Camshaft Bearing Cap Tightening Sequence
NS2.4L ENGINE 9 - 29
REMOVAL AND INSTALLATION (Continued)

CYLINDER HEAD
REMOVAL
(1) Perform fuel system pressure release proce-
durebefore attempting any repairs.Refer to
Group 14, Fuel System for procedure.
(2) Disconnect negative battery cable. Drain cool-
ing system. Refer to Group 7, Cooling System for pro-
cedure.
(3) Remove air cleaner and disconnect all vacuum
lines, electrical wiring and fuel lines from throttle
body.
(4) Remove throttle linkage. Refer to Group 14,
Fuel System for procedures
(5) Remove accessory drive belts. Refer to Group
7, Cooling System for procedure.
(6) Remove power brake vacuum hose from intake
manifold.
(7) Raise vehicle and remove exhaust pipe from
manifold.(8) Remove power steering pump assembly and
set aside.
(9) Disconnect coil pack wiring connector and
remove coil pack and plug wires from engine.
(10) Remove cam sensor and fuel injectors wiring
connectors.
(11) Remove timing belt and camshaft sprocket.
Refer to procedure outlined in this section.
(12) Remove timing belt idler pulley and rear tim-
ing belt cover.
(13) Remove cylinder head cover using procedure
outlined in this section.
(14) Remove camshafts and cam followers. Refer to
procedures outlined in this section for procedures.
(15) Remove cylinder head bolts and remove cyl-
inder head from engine block.
(16) Inspect and clean cylinder head. Refer to
Cleaning and Inspection outlined in this section for
procedures.
INSTALLATION
NOTE: The Cylinder head bolts should be exam-
ined BEFORE reuse. If the threads are necked
down, the bolts should be replaced (Fig. 49).
Necking can be checked by holding a scale or
straight edge against the threads. If all the threads
do not contact the scale the bolt should be replaced.
(1) Before installing the bolts, the threads should
be coated with engine oil.
(2) Tighten the cylinder head bolts in the
sequence shown in (Fig. 50). Using the 4 step torque
turn method, tighten according to the following val-
ues:
²First All to 34 N´m (25 ft. lbs.)
²Second All to 68 N´m (50 ft. lbs.)
²Third All to 68 N´m (50 ft. lbs.)
CAUTION: Do not use a torque wrench for the fol-
lowing step.
²Fourth Turn an additional 1/4 Turn,
(3) Install camshafts and cam followers. Refer to
procedures outlined in this section for procedures.
Fig. 47 Valve SpringÐRemoval/Installation
Fig. 48 Valve Stem Seal/Valve Spring Seat
Fig. 49 Checking Bolts for Stretching (Necking)
9 - 34 2.4L ENGINENS
REMOVAL AND INSTALLATION (Continued)

TIMING BELT TENSIONER ASSEMBLY
REMOVAL
(1) Remove timing belt. Refer to Removal and
Installation procedure in this section.
(2) Remove timing belt idler pulley.
(3) Hold camshaft sprocket with Special Tools
C-4687 and C-4687-1 Adapter, while removing bolt
(Fig. 63). Remove both cam sprockets.(4) Remove rear timing belt cover fasteners and
remove cover from engine (Fig. 64).
(5) Remove lower bolt attaching timing belt ten-
sioner assembly to engine and remove tensioneras
an assembly(Fig. 65).INSTALLATION
(1) Align timing belt tensioner assembly to engine
and install lower mounting boltbut do not tighten
(Fig. 65). To properly align tensioner assemblyÐin-
stall one of the engine bracket mounting bolts (M10)
5 to 7 turns into the tensioner's upper mounting loca-
tion (Fig. 65).
(2) Torque the tensioner's lower mounting bolt to
61 N´m (45 ft. lbs.). Remove the upper bolt used for
tensioner alignment.
(3) Install rear timing belt cover and fasteners.
(4) Install timing belt idler pulley and tighten
mounting bolt to 61 N´m (45 ft. lbs.).
(5) Install camshaft sprockets. Use Special Tools
C-4687 and C-4687-1 Adapter to hold camshaft
sprockets (Fig. 63) and tighten attaching bolts to 101
N´m (75 ft. lbs.).
(6) Install timing belt. Refer to procedure outlined
in this section.
Fig. 62 Timing BeltÐInstallation
Fig. 63 Camshaft SprocketsÐRemoval/Installation
Fig. 64 Rear Timing Belt Cover Fasteners
9 - 40 2.4L ENGINENS
REMOVAL AND INSTALLATION (Continued)

OIL PAN
REMOVAL
(1) Raise vehicle on hoist and drain engine oil.
(2) Remove front engine mount bracket from
engine and insulator mount.
(3) Remove bolts attaching bending strut to engine
and transaxle.
(4) Remove bolts attaching collar and bending
strut to engine, oil pan, and transaxle (Fig. 79).
Remove strut and collar.
(5) Remove oil pan.
(6) Clean oil pan and all gasket surfaces.
INSTALLATION
(1) Apply MopartSilicone Rubber Adhesive Seal-
ant or equivalent at the oil pump to engine block
parting line (Fig. 80).
(2) Install the oil pan gasket to the block (Fig.
81).(3) Install pan and tighten the screws to 12 N´m
(105 in. lbs.).
CAUTION: Torque procedure for the structural col-
lar and bending strut must be followed or damage
could occur to oil pan, collar, and/or bending strut.
(4) Perform the following steps for installing struc-
tural collar and bending strut. Refer to (Fig. 79):
²Step 1: Place collar into position between tran-
saxle and oil pan. Hand start only, collar to transaxle
bolt 1.
²Step 2: Install bolt 4, collar to oil pan,hand
tight only.
²Step 3: Position bending strut in place and hand
start bolt 3 into the upper transaxle hole.
²Step 4: Install bolt 2, through strut and collar.
Hand starting only.
²Step 5: Install bolt 6, strut to cylinder block,
hand tight only.
²Step 6: Install the remaining collar to oil pan
bolt 5,hand tight only.
²Step 7: Final torque collar to transaxle bolts 1 ±
3, to 101 N´m (75 ft. lbs.)
²Step 8: Install bolts 7 and 8, through strut and
into cylinder block.
²Step 9: Final torque bolts4±8to61N´m(45ft.
lbs.).
(5) Install front mount bracket to engine and front
insulator. Refer to procedure in the section.
(6) Lower vehicle and fill engine crankcase with
proper oil to correct level.
Fig. 79 Structural Collar and Bending StrutÐ
Removal and Installation
Fig. 80 Oil Pan Sealing
Fig. 81 Oil Pan Gasket Installation
NS2.4L ENGINE 9 - 45
REMOVAL AND INSTALLATION (Continued)

CRANKSHAFT
REMOVAL
NOTE: Crankshaft can not be removed when
engine is in vehicle.
(1) Remove oil filter and oil pan. Refer to proce-
dure outlined in this section.
(2) Remove Timing Belt Cover, Timing Belt and
Oil Pump. Refer to procedure outlined in this section.
(3) Remove Balance Shafts Assembly. Refer to pro-
cedure outlined in this section.
(4) Remove all main bearing cap bedplate bolts
from the engine block. Refer to procedure outlined in
this section.
(5) Using a mallet gently tap the bedplate 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.
(6) Bedplate should be removed evenly from the
cylinder block dowel pins to prevent damage to the
dowel pins and thrust bearing.
(7) Lift out crankshaft from cylinder block. Do not
damage the main bearings or journals when remov-
ing the crankshaft.
INSTALLATION
(1) Install the main bearing shells with the lubri-
cation groove in the cylinder block (Fig. 82).
(2) Make certain oil holes in block line up with oil
hole in bearings and bearing tabs seat in the block
tab slots.CAUTION: Do not get oil on the bedplate mating
surface. It will may effect the sealer ability to seal
the bedplate to cylinder block.
(3) Oil the bearings and journals. Install crank-
shaft.
CAUTION: Use only the specified anaerobic sealer
on the bedplate or damage may occur to the
engine.
(4) Apply 1.5 to 2.0 mm (0.059 to 0.078 in.) bead of
Mopar Torque Cure Gasket Maker to cylinder block
as shown in (Fig. 83).
(5) Install lower main bearings into main bearing
cap/bedplate. Make certain the bearing tabs are
seated into the bedplate slots. Install the main bear-
ing/bedplate into engine block.
(6) Before installing the bolts the threads should
be oiled with clean engine oil, wipe off any excess oil.
Fig. 82 Installing Main Bearing Upper Shell
Fig. 83 Main Bearing Caps/Bedplate Sealing
Fig. 84 Main Bearing Caps/Bedplate Torque
Sequence
9 - 46 2.4L ENGINENS
REMOVAL AND INSTALLATION (Continued)

(7) Install main bearing bedplate to engine block
bolts 11, 17 and 20 finger tight. Tighten these bolts
down together until the bedplate contacts the cylin-
der block.
(8) To ensure correct thrust bearing alignment per-
form the following steps:
²Step 1: Rotate crankshaft until number 4 pis-
ton is at TDC.
²Step 2: Move crankshaft rearward to limits of
travel.
²Step 3: Then, move crankshaft forward to lim-
its of travel.
²Step 4: Wedge an appropraite tool between the
rear of the cylinder block(NOT BED PLATE)and
the rear crankshaft counterweight. This will hold the
crankshaft in it's furthest forward position.
²Step 5: Install and tighten bolts (1-10) in
sequence shown in (Fig. 84) to 41 Nzm (30 ft. lbs.).
²Step 6: Remove wedge tool used to hold crank-
shaft.
(9) Tighten bolts (1-10) again to 41 Nzm (30 ft. lbs)
+ 1/4 turn in sequence shown in (Fig. 84).
(10) Install main bearing bedplate to engine block
bolts (11-20), and torque each bolt to 28 Nzm (20 ft.
lbs.) in sequence shown in (Fig. 84).
(11) After the main bearing bedplate is installed,
check the crankshaft turning torque. The turning
torque should not exceed 5.6 Nzm (50 in. lbs.).
OIL FILTER
CAUTION: When servicing the oil filter avoid
deforming the filter can by installing the remove/in-
stall tool band strap against the can to base lock
seam. The lock seam joining the can to the base is
reinforced by the base plate.(1) Turn counterclockwise to remove.
(2) To install, lubricate new filter gasket. Check
filter mounting surface. The surface must be smooth,
flat and free of debris or old pieces of rubber. Screw
filter on until the gasket contacts base. Tighten to 21
N´m (15 ft. lbs.).
OIL PUMP
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove Timing Belt. Refer to procedure out-
lined in this section.
(3) Remove Oil Pan. Refer to procedure outlined in
this section.
(4) Remove Crankshaft Sprocket using Special Tool
6793 and insert C-4685-C2 (Fig. 85).
(5) Remove oil pick-up tube.
(6) Remove oil pump, (Fig. 86) and front crank-
shaft seal.
Fig. 85 Crankshaft SprocketÐRemoval
NS2.4L ENGINE 9 - 47
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Make sure all surfaces are clean and free of oil
and dirt.
(2) Apply MopartGasket Maker to oil pump as
shown in (Fig. 87). Install oil ring into oil pump body
discharge passage.
(3) Prime oil pump before installation.(4) Align oil pump rotor flats with flats on crank-
shaft as you install the oil pump to the block.
NOTE: Front crankshaft seal MUST be out of pump
to align, or damage may result.
(5) Install new front crankshaft seal using Special
Tool 6780 (Fig. 88).
(6) Install crankshaft sprocket, using Special Tool
6792 (Fig. 89).
(7) Install oil pump pick-up tube.
CAUTION: Installation and torque procedure for the
collar must be followed or damage could occur to
oil pan or collar.
(8) Install oil pan and collar. Refer to procedure
outlined in this section.
(9) Install Timing Belt. Refer to procedure outlined
in this section.
Fig. 86 Oil Pump and Pick-up Tube
Fig. 87 Oil Pump Sealing
9 - 48 2.4L ENGINENS
REMOVAL AND INSTALLATION (Continued)