engine CHRYSLER VOYAGER 1996 Service Manual

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)

PISTON AND CONNECTING ROD
REMOVAL
NOTE: Cylinder Head must be removed before Pis-
tons and Rods. Refer to Cylinder Head Removal in
this section.
(1) 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. Mark piston with
matching cylinder number (Fig. 90).
(2) Remove oil pan. Scribe the cylinder number on
the side of the rod and cap (Fig. 91) for identification.
(3) Pistons have a directional stamping in the
front half of the piston facing towards thefrontof
engine.
(4) Pistons and connecting rods must be removed
from top of cylinder block. Rotate crankshaft so that
each connecting rod is centered in cylinder bore.
(5) Remove Balance Shaft Assembly. Refer to Bal-
ance Shaft Removal in this section.
(6) Remove connecting rod cap bolts. Push each
piston and rod assembly out of cylinder bore.
NOTE: Be careful not to nick crankshaft journals.
(7) After removal, install bearing cap on the mat-
ing rod.
(8) Piston and Rods are serviced as an assembly.INSTALLATION
(1) 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. 88 Front Crankshaft SealÐInstallation
Fig. 89 Crankshaft SprocketÐInstallation
Fig. 90 Piston Markings
Fig. 91 Identify Connecting Rod to Cylinder
NS2.4L ENGINE 9 - 49
REMOVAL AND INSTALLATION (Continued)

(2) Before installing the ring compressor, make
sure the oil ring expander ends are butted and the
rail gaps located as shown in (Fig. 92). As viewed
from top.
(3) Immerse the piston head and rings in clean
engine oil, slide the ring compressor, over the piston
(Fig. 93).Be sure position of rings does not
change during this operation.
(4) The directional stamp on the piston should
face toward the front of the engine (Fig. 90).
(5) Rotate crankshaft so that the connecting rod
journal is on the center of the cylinder bore. Insert
rod and piston assembly into cylinder bore and guide
rod over the crankshaft journal.
(6) Tap the piston down in cylinder bore, using a
hammer handle. At the same time, guide connecting
rod into position on connecting rod journal.
NOTE: The rod bearing bolts should not be reused.
(7) Before installing theNEWbolts the threads
should be coated with clean engine oil.(8) Install each bolt finger tight than alternately
torque each bolt to assemble the cap properly.
CAUTION: Do not use a torque wrench for second
part of last step.
(9) Tighten the bolts to 27 N´m PLUS 1/4 turn (20
ft. lbs. PLUS 1/4 turn).
(10) Using a feeler gauge, check connecting rod
side clearance (Fig. 94).
DISASSEMBLY AND ASSEMBLY
OIL PUMP
DISASSEMBLY
(1) To remove the relief valve, proceed as follows:
(a) Remove the threaded plug and gasket from
the oil pump (Fig. 95).
(b) Remove spring and relief valve.
(2) Remove oil pump cover screws, and lift off
cover.
(3) Remove pump rotors.
Fig. 92 Piston Ring End Gap Position
Fig. 93 PistonÐInstallation
Fig. 94 Checking Connecting Rod Side Clearance
Fig. 95 Oil Pressure Relief Valve
9 - 50 2.4L ENGINENS
REMOVAL AND INSTALLATION (Continued)

(4) Wash all parts in a suitable solvent and
inspect carefully for damage or wear.
ASSEMBLY
(1) Assemble pump, using new parts as required.
Install the inner rotor with chamfer facing the
cast iron oil pump cover.
(2) Prime oil pump before installation by filling
rotor cavity with engine oil.
(3) Install cover and tighten screws to 12 N´m
(105 in. lbs.).
CAUTION: Oil pump pressure relief valve must be
installed as shown in (Fig. 95) or serious damage
may occur.
(4) Install relief valve, spring, gasket and cap as
shown in (Fig. 95). Tighten cap to 41 N´m (30 ft. lbs.)
CLEANING AND INSPECTION
CYLINDER HEAD
CLEANING
Remove all gasket material from cylinder head and
block. Be careful not to gouge or scratch the alumi-
num head sealing surface.
INSPECTION
(1) Cylinder head must be flat within 0.1 mm
(0.004 inch) (Fig. 96).
(2) Inspect camshaft bearing journals for scoring.
VALVE GUIDES
(1) Remove carbon and varnish deposits from
inside of valve guides with a reliable guide cleaner.
(2) Using a small hole gauge and a micrometer,
measure valve guides in 3 places top, middle and bot-
tom (Fig. 97). Refer to Valve Guide SpecificationChart. Replace guides if they are not within specifi-
cation.
(3) Check valve guide height (Fig. 98).
VALVE AND VALVE SPRING
VALVES
(1) Clean valves thoroughly and discard burned,
warped and cracked valves.
(2) Measure valve stems for wear. Measure stem
about 60 mm beneath the valve lock grooves.
Fig. 96 Checking Cylinder Head Flatness
Fig. 97 Checking Wear on Valve GuideÐTypical
VALVE GUIDE SPECIFICATION CHART
Valve Guide Diameter
Intake and
Exhaust Valve:5.975 - 6.000 mm
(0.2352 - 0.2362 in.)
Valve Guide Clearance
New Service
Limit
Intake Valve: 0.048 - 0.066 mm
(0.0018 - 0.0025 in.)
0.25 mm
(0.010 in.)
Exhaust Valve: 0.0736 - 0.094 mm
(0.0029 - 0.0037 in.)
Fig. 98 Valve Guide Height
NS2.4L ENGINE 9 - 51
DISASSEMBLY AND ASSEMBLY (Continued)

(3) If valve stems are worn more than 0.05 mm
(.002 in.), replace valve.
VALVE SPRINGS
(1) Whenever valves have been removed for
inspection, reconditioning or replacement, valve
springs should be tested for correct tension. Discard
the springs that do not meet specifications. The fol-
lowing specifications apply to both intake and
exhaust valves springs:
²Valve Closed Nominal TensionÐ 76 lbs. @ 38.0
mm (1.50 in.)
²Valve Open Nominal TensionÐ 136 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.
CRANKSHAFT
The crankshaft journals should be checked for
excessive wear, taper and scoring (Fig. 99). Limits of
taper or out-of-round on any crankshaft journals
should be held to .025 mm (.001 inch). Journal grind-
ing should not exceed .305 mm (.012 inch) under the
standard journal diameter.DO NOTgrind thrust
faces of Number 3 main bearing.DO NOTnick
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
used it is important that the final paper or cloth pol-
ish after any journal regrind be in the same direc-
tion as normal rotation in the engine.
OIL PUMP
(1) Clean all parts thoroughly. Mating surface of
the oil pump should be smooth (Fig. 100). Replace
pump cover if scratched or grooved.(2) Lay a straightedge across the pump cover sur-
face (Fig. 101). If a 0.025 mm (0.001 in.) feeler gauge
can be inserted between cover and straight edge,
cover should be replaced.
(3) Measure thickness and diameter of outer rotor.
If outer rotor thickness measures 9.40 mm (0.370 in.)
or less (Fig. 102), or if the diameter is 79.95 mm
(3.148 in.) or less, replace outer rotor.
(4) If inner rotor measures 9.40 mm (0.370 in.) or
less replace inner rotor (Fig. 103).
(5) Slide outer rotor into pump housing, press to
one side with fingers and measure clearance between
rotor and housing (Fig. 104). If measurement is 0.39
mm (0.015 in.) or more, replace housing only if outer
rotor is in specification.
(6) Install inner rotor into pump housing. If clear-
ance between inner and outer rotors (Fig. 105) is
0.203 mm (0.008 in.) or more, replace both rotors.
(7) Place a straightedge across the face of the
pump housing, between bolt holes. If a feeler gauge
of 0.102 mm (0.004 in.), or more can be inserted
Fig. 99 Crankshaft Journal Measurements
Fig. 100 Oil Pump
Fig. 101 Checking Oil Pump Cover Flatness
9 - 52 2.4L ENGINENS
CLEANING AND INSPECTION (Continued)

between rotors and the straightedge, replace pump
assembly (Fig. 106),ONLYif rotors are in specs.
(8) Inspect oil pressure relief valve plunger for
scoring and free operation in its bore. Small marks
may be removed with 400 grit wet or dry sandpaper.
(9) The relief valve spring has a free length of
approximately 60.7 mm (2.39 inches) it should test
between 18 and 19 pounds when compressed to 40.5
mm (1.60 inches). Replace spring that fails to meet
specifications.
(10) If oil pressure is low and pump is within
specifications, inspect for worn engine bearings or
other reasons for oil pressure loss.
Fig. 102 Measuring Outer Rotor Thickness
Fig. 103 Measuring Inner Rotor Thickness
Fig. 104 Measuring Outer Rotor Clearance in
Housing
Fig. 105 Measuring Clearance Between Rotors
Fig. 106 Measuring Clearance Over Rotors
NS2.4L ENGINE 9 - 53
CLEANING AND INSPECTION (Continued)

CYLINDER BLOCK
(1) Clean cylinder block thoroughly and check all
core hole plugs for evidence of leaking.
(2) If new core plugs are installed, refer to Engine
Core Plugs outlined in this section.
(3) Examine block and cylinder bores for cracks or
fractures.
CYLINDER BORE INSPECTION
The cylinder walls should be checked for out-of-
round and taper with Tool C119 (Fig. 107). The cyl-
inder bore out-of-round is 0.050 mm (0.002 in.)
maximum and cylinder bore taper is 0.051 mm (0.002
in.) maximum. 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. 107). 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 Cylinder Bore and Piston Specification
Chart.
ADJUSTMENTS
ENGINE MOUNTS
ENGINE MOUNT INSULATOR ADJUSTMENT
(1) Remove the load on the engine motor mounts
by carefully supporting the engine and transmission
assembly with a floor jack.
(2) Loosen the right engine mount insulator verti-
cal fastener and the fore and aft fasteners, and the
front engine mount bracket to front crossmember
screws.
(3) Pry the engine right or left as required to
achieve the proper drive shaft assembly length. Refer
to Group 2, Suspension and Driveshafts for drive-
shaft identification and related assembly length mea-
suring.
(4) Tighten engine mounts and fasteners in the
following order:
(a) Right engine mount insulator vertical bolts
to 102 N´m (75 ft. lbs.) and the fore and aft bolts to
150 N´m (110 ft. lbs.).
(b) Front engine mount screws to 54 N´m (40 ft.
lbs.) the clearance between the snubbers and the
engine should be 2 mm (0.078 inch.) each side.
(c) Left engine mount through bolt to 75 N´m (55
ft. lbs.).
(5) Recheck driveshaft length.
Fig. 107 Checking Cylinder Bore Size
CYLINDER BORE AND PISTON
SPECIFICATION CHART
Standard Bore Maximum Out-
Of-RoundMaximum-
Taper
87.5 mm 0.051 mm 0.051 mm
(3.445 in.) (0.002 in.) (0.002 in.)
Standard Piston Size
87.450 - 87.468 mm (3.4434 - 3.4441 in.)
Piston To Bore Clearance
0.024 - 0.057 mm (0.0009 - 0.0022 in.)
Measurements taken at Piston Size Location.
9 - 54 2.4L ENGINENS
CLEANING AND INSPECTION (Continued)

SPECIFICATIONS
2.4L ENGINE
Type....................In-Line OHV, DOHC
Number of Cylinder.......................4
Bore.....................87.5 mm (3.445 in.)
Stroke....................101 mm (3.976 in.)
Compression Ratio......................9.4:1
Displacement.......2.4 Liters (148 Cubic Inches)
Firing Order.......................1,3,4,2
Compression Pressure...........1172-1551 kPa
(170-225 psi)
Maximum Variation Between Cylinder......25%
Lubrication. . . .Pressure Feed-Full Flow Filtration
(Direct Crankshaft Driven Pump)
Cylinder Block
Cylinder Bore Diameter. . . .87.4924 - 87.5076 mm
(3.4446 - 3.4452 in.)
Out-of-Round (Max.)........0.051 mm (0.002 in.)
Taper (Max.)..............0.051 mm (0.002 in.)
Pistons
Clearance at 14 mm (9/16 in.)
From Bottom of Skirt.........0.024 - 0.057 mm
(0.0009 - 0.0022 in.)
Weight......................332 - 346 grams
(11.85 - 12.20 oz.)
Top Land Clearance
(Diametrical)................0.614 - 0.664 mm
(0.024 - 0.026 in.)
Piston Length.............60.30 mm (2.374 in.)
Piston Ring Groove Depth
No.1........4.640 - 4.784 mm (0.182 - 0.188 in.)
No.2........4.575 - 4.719 mm (0.180 - 0.185 in.)
No.3........4.097 - 4.236 mm (0.161 - 0.166 in.)
Piston Pins
Clearance in Piston...........0.005 - 0.018 mm
In Rod (Interference)..........0.018 - 0.043 mm
(0.0007 - 0.0017 in.)
Diameter.................21.998 - 22.003 mm
(0.8660 - 0.8662 in.)
End Play.............................None
Length.....................72.75 - 73.25 mm
(2.864 - 2.883 in.)
Piston Ring Gap
Top Compression Ring...........0.25 - 0.51 mm
(0.0098 - 0.020 in.)
2nd Compression Ring...........0.23 - 0.48 mm
(0.009 - 0.018 in.)
Oil Control (Steel Rails).........0.25 - 0.64 mm
(0.0098 - 0.025 in.)
Piston Ring Side Clearance
Top and Second
Compression Rings...........0.030 - 0.080 mm
(0.0011 - 0.0031 in.)Oil Ring (Pack)..............0.012 - 0.178 mm
(0.0004 - 0.0070 in.)
Piston Ring Width
Compression Rings.............1.47 - 1.50 mm
(0.057 - 0.059 in.)
Oil Ring (Pack)................2.72 - 2.88 mm
(0.107 - 0.1133 in.)
Connecting Rod
Bearing Clearance............0.025 - 0.071 mm
(0.0009 - 0.0027 in.)
Piston Pin Bore Diameter......20.96 - 20.98 mm
(0.8252 - 0.8260 in.)
Large End Bore Diameter. . . .53.007 - 52.993 mm
(2.0868 - 2.0863)
Side Clearance..............0.013 - 0.0150 mm
(0.0051 - 0.0150 in.)
Total Weight (Less Bearing).........565.8 grams
(19.96 oz.)
Crankshaft
Connecting Rod
Journal Diameter..........49.984 - 50.000 mm
(1.967 - 1.9685 in.)
Out-of-Round (Max.)......0.0035 mm (0.0001 in.)
Taper (Max.)............0.0038 mm (0.0001 in.)
Main Bearing Diametrical
Clearance No.1-5...........0.018 - 0.058 mm
(0.0007 - 0.0023 in.)
End Play.....................0.09 - 0.24 mm
(0.0035 - 0.0094 in.)
Main Bearing Journals
Diameter.................59.992 - 60.008 mm
(2.361 - 2.3625 in.)
Out-of-Round (Max.)......0.0035 mm (0.0001 in.)
Taper (Max.)...............0.0038 (0.0001 in.)
Hydraulic Lash Adjusters
Body Diameter.............15.901 - 15.913 mm
(0.626 - 0.6264 in.)
Plunger Travel Minimum (Dry)..........3.0 mm
(0.118 in.)
Camshaft
Bearing Bore
Diameters No. 1±6..........26.020 - 26.041 mm
(1.024 - 1.025 in.)
Diametrical Bearing Clearance . .0.069 - 0.071 mm
(0.0027 - 0.003 in.)
End Play...................0.050 - 0.170 mm
(0.0019 - 0.0066 in.)
Bearing Journal
Diameter No. 1±6..........25.951 - 25.970 mm
(1.021 - 1.022 in.)
Lift (Zero Lash) Intake.......8.25 mm (0.324 in.)
Lift (Zero Lash) Exhaust.....6.52 mm (0.256 in.)
Valve Timing ± Intake Valve
Closes (ABDC)..........................51É
Opens (BTDC)...........................1É
NS2.4L ENGINE 9 - 55

Duration.............................232É
Valve Timing ± Exhaust Valve
Closes (ATDC)...........................8É
Opens (BBDC)..........................52É
Duration.............................240É
Valve Timing
Valve Overlap...........................9É
Cylinder Head
Material.....................Cast Aluminum
Gasket Thickness (Compressed)........1.15 mm
(0.045 in.)
Cylinder Head Valve Seat
Angle.................................45É
Runout (Max.).............0.050 mm (0.002 in.)
Width (Finish) Intake and Exhaust. . .0.9 - 1.3 mm
(0.035 - 0.051 in.)
Guide Bore Diameter (Std).......11.0-11.02 mm
(0.4330 - 0.4338 in.)
Finish Guide Bore ID..........5.975 - 6.000 mm
(0.235 - 0.236 in.)
Valves
Face Angle......................44-1/2É - 45É
Head Diameter Intake.........34.67 - 34.93 mm
(1.364 - 1.375 in.)
Head Diameter Exhaust.......30.37 - 30.63 mm
(1.195 - 1.205 in.)
Length±Intake (Overall)......112.76 - 113.32 mm
(4.439 - 4.461 in.)
Length±Exhaust (Overall). . . .109.59 - 110.09 mm
(4.314 - 4.334 in.)
Valve Margin±Intake..........1.285 - 1.615 mm
(0.050 - 0.063 in.)
Valve Margin±Exhaust........0.985 - 1.315 mm
(0.038 - 0.051 in.)
Valve Stem Tip Height±Intake........48.04 mm
(1.891 in.)Valves
Valve Stem Tip Height±Exhaust.......47.99 mm
(1.889 in.)
Stem Diameter±Intake........5.934 - 5.952 mm
(0.234 - 0.234 in.)
Stem Diameter±Exhaust.......5.906 - 5.924 mm
(0.233 - 0.233 in.)
Stem-to-Guide
Clearance±Intake............0.048 - 0.066 mm
(0.0018 - 0.0025 in.)
Stem-to-Guide
Clearance±Exhaust..........0.0736 - 0.094 mm
(0.0029 - 0.0037 in.)
Max. Allowable Stem-to-Guide
Clearance±Intake and Exhaust.......0.025 mm
(0.010 in.)
Valve Springs
Free Length (Approx.).......48.4 mm (1.905 in.)
Spring Tension
(Valve Closed).........338 N620 N @ 38.0 mm
(75.98 lbs.64.5 lbs. @ 1.496 in.)
Spring Tension
(Valve Open).........607 N630 N @ 29.75 mm
(136 lbs.67 @ 1.172 in.)
Number of Coils........................7.82
Wire Diameter.............3.86 mm (0.151 in.)
Installed Spring Height.....38.00 mm (1.496 in.)
Oil Pump
Clearance Over Rotors (Max.). .0.10 mm (0.004 in.)
Cover Out-of-Flat (Max.).....0.025 mm (0.001 in.)
Inner Rotor Thickness (Min.) . .9.40 mm (0.370 in.)
Outer Rotor (Oil Pump)
Clearance (Max.)...........0.39 mm (0.015 in.)
Diameter (Min.)...........79.95 mm (3.148 in.)
Thickness (Min.)............9.40 mm (0.370 in.)
Tip Clearance Between Rotors (Max.). . . .0.20 mm
(0.008 in.)
Oil Pressure
At Curb Idle Speed*.............25kPa(4psi)
At 3000 rpm.........170 - 550 kPa (25 - 80 psi)
CAUTION: * If pressure is ZERO at curb Idle, DO
NOT run engine at 3,000 rpm.
9 - 56 2.4L ENGINENS
SPECIFICATIONS (Continued)

TORQUE CHART 2.4L
DESCRIPTION TORQUE
Balance Shaft Carrier to Block
Bolts.....................54N´m(40ft.lbs.)
Balance Shaft Gear Cover
Double Ended Fastener......12N´m(105 in. lbs.)
Balance Shaft Sprockets
Bolts....................28N´m(250 in. lbs.)
Balance Shaft Chain Tensioner
Bolts....................12N´m(105 in. lbs.)
Balance Shaft Carrier Cover
Fasteners................12N´m(105 in. lbs.)
Camshaft Sensor Pick Up
Bolts.....................27N´m(20ft.lbs.)
Timing Belt Cover
Outer to Inner Attaching Bolts M6.......4.5 N´m
(40 in. lbs.)
Inner Cover to Head/Oil Pump Bolts M6 . . .12 N´m
(105 in. lbs.)
Camshaft Sprocket
Bolt.....................101 N´m (75 ft. lbs.)
Connecting Rod Cap
Bolts..............................27N´m
(20 ft. lbs.) Plus 1/4 Turn
Crankshaft Main Bearing Cap/Bedplate
M8 Bedplate Bolts.........34N´m(250 in. lbs.)
Main Cap Bolts M11..................41N´m
(30 ft. lbs.) Plus 1/4 Turn
Crankshaft Damper
Bolt....................135 N´m (100 ft. lbs.)
Cylinder Head
Bolts........Refer To Cylinder Head Installation
Cylinder Head Cover
Bolts....................12N´m(105 in. lbs.)DESCRIPTION TORQUE
Engine Mount Bracket
Bolts.....................61N´m(45ft.lbs.)
Engine MountÐFront and Rear
Through Bolt...............61N´m(45ft.lbs.)
Exhaust Manifold to Cylinder Head
Bolts....................23N´m(200 in. lbs.)
Exhaust Manifold Heat Shield
Bolts....................12N´m(105 in. lbs.)
Front Torque BracketÐ2.0/2.4L Engine
Bolts.....................33N´m(24ft.lbs.)
Front Torque Bracket StrutÐ2.0/2.4L Engine
Long Bolts................110N´m(80ft.lbs.)
Short Bolt.................61N´m(45ft.lbs.)
Intake Manifold
Bolts.....................27N´m(20ft.lbs.)
Oil Filter
Filter.....................20N´m(15ft.lbs.)
Oil Pan
Oil Pan Bolts.............12N´m(105 in. lbs.)
Drain Plug.................27N´m(20ft.lbs.)
Oil Pump Attaching
Bolts....................28N´m(250 in. lbs.)
Oil Pump Cover Fastener. . . .12 N´m (105 in. lbs.)
Oil Pump Pick-up Tube Bolt . .28 N´m (250 in. lbs.)
Oil Pump Relief Valve Cap. . . .41 N´m (30 ft. lbs.)
Rear Torque Bracket
Bolts....................110N´m(80ft.lbs.)
Spark Plugs
Plugs.....................28N´m(20ft.lbs.)
Thermostat Housing
Bolts....................23N´m(200 in lbs.)
Timing Belt Tensioner Assembly
Bolts.....................61N´m(45ft.lbs.)
Water Pump Mounting
Bolts....................12N´m(105 in. lbs.)
NS2.4L ENGINE 9 - 57
SPECIFICATIONS (Continued)