lock CHRYSLER VOYAGER 1996 Service Manual

(4) Apply 1.5 to 2.0 mm (0.059 to 0.078 in.) bead
of anaerobic sealer MopartTorque Cure Gasket
Maker to cylinder block as shown in (Fig. 12).
(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 bolts, lubricate the threads
with clean engine oil, wipe off any excess oil.
(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,
perform the following steps:
²Step 1: Rotate crankshaft until number 4 piston
is at TDC.
²Step 2: Move crankshaft rearward to limits of
travel.²Step 3: Then, move crankshaft forward to limits
of travel.
²Step 4: Wedge an appropriate 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. 13) to 41 N´m (30 ft. lbs.).
²Step 6: Remove wedge tool used to hold crank-
shaft.
(9) Tighten bolts (1 ± 10) again to 41 N´m (30 ft.
lbs.) + 1/4 turn in sequence shown in (Fig. 13).
(10) Install main bearing bedplate to engine block
bolts (11 through 20), and torque each bolt to 28 N´m
(20 ft. lbs.) in sequence shown in (Fig. 13).
(11) After the main bearing bedplate is installed,
check the crankshaft turning torque. The turning
torque should not exceed 5.6 N´m (50 in. lbs.).
CRANKSHAFT END PLAY
(1) Mount a dial indicator to front of engine, locat-
ing probe on nose of crankshaft (Fig. 14).
(2) Move crankshaft all the way to the rear of its
travel.
(3) Zero the dial indicator.
(4) Move crankshaft all the way to the front and
read the dial indicator. Refer to Crankshaft Specifi-
cation Chart for end-play specification.
Fig. 12 Main Bearing Caps/Bedplate Sealing
Fig. 13 Main Bearing Caps/Bedplate Torque
SequenceFig. 14 Checking Crankshaft End PlayÐTypical
CRANKSHAFT SPECIFICATION CHART
Crankshaft End-Play
New Part: 0.09 - 0.24mm
(0.0035 - 0.0094 in.)
Wear Limit: 0.37 mm
(0.015 in.)
9 - 20 2.4L ENGINENS
SERVICE PROCEDURES (Continued)

OPTIONAL CRANKSHAFT END PLAY CHECK
(1) Move crankshaft all the way to the rear of its
travel using a lever inserted between a main bearing
cap and a crankshaft cheek, using care not to dam-
age any bearing surface.DO NOTloosen main bear-
ing cap.
(2) Use a feeler gauge between number three
thrust bearing and machined crankshaft surface to
determine end play.
VALVE SERVICE RECONDITION
VALVE REMOVAL
(1) With cylinder head removed, compress valve
springs using Special Tool C-3422-B or equivalent.
(2) Remove valve retaining locks, valve spring
retainers, valve stem seals and valve springs.
(3) Before removing valves,remove any burrs
from valve stem lock grooves to prevent dam-
age to the valve guides.Identify valves to insure
installation in original location.
VALVE INSPECTION
(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.
(3) If valve stems are worn more than 0.05 mm
(0.002 in.), replace valve.
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. 15). Refer to Valve Guide Specification
Chart. Replace guides if they are not within specifi-
cation.
(3) Check valve guide height (Fig. 16).
TESTING VALVE SPRINGS
(1) Whenever valves have been removed for inspec-
tion, reconditioning or replacement, valve springs
should be tested. As an example, the compression
length of the spring to be tested is 33.34 mm (1 5/16inches). Turn tool table until surface is in line with
the 33.34 mm (1 5/16 in.) mark on the threaded stud
and the zero mark on the front. Place spring over
stud on the table and lift compressing lever to set
tone device (Fig. 17). Pull on torque wrench until
ping is heard. Take reading on torque wrench at this
instant. Multiply this reading by two. This will give
the spring load at test length. Fractional measure-
ments are indicated on the table for finer adjust-
ments. Discard the springs that do not meet
specifications. The Following specifications apply to
both intake and exhaust valve 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.
REFACING VALVES AND VALVE SEATS
(1) The intake and exhaust valve seats and valve
face have a 45 and a 45 1/2 degree angles.
Fig. 15 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. 16 Valve Guide Height
NS2.4L ENGINE 9 - 21
SERVICE PROCEDURES (Continued)

need to be reground to prevent seal damage when
the valve is installed.
VALVE INSTALLATION
(1) Coat valve stems with clean engine oil and
insert in cylinder head.
(2) Install new valve stem seals on all valves using
a valve stem seal tool (Fig. 21). The valve stem seals
should be pushed firmly and squarely over valve
guide.CAUTION: When oversize valves are used, the cor-
responding oversize valve seal must also be used.
Excessive guide wear may result if oversize seals
are not used with oversize valves.
(3) Install valve springs and retainers. Compress
valve springs only enough to install locks, taking
care not to misalign the direction of compression.
Nicked valve stems may result from misalignment of
the valve spring compressor.
CAUTION: When depressing the valve spring
retainers with valve spring compressor the locks
can become dislocated. Check to make sure both
locks are in their correct location after removing
tool.
(4) Check the valve spring installed height B after
refacing the valve and seat (Fig. 20). Make sure mea-
surements are taken from top of spring seat to the
bottom surface of spring retainer. If height is greater
than 38.75 mm (1.525 in.), install a .762 mm (0.030
inch.) spacer under the valve spring seat to bring
spring height back within specification.
(5) Install rocker arm shafts as previously
described in this section.
(6) Checking dry lash. Dry lash is the amount of
clearance that exists between the base circle of an
installed cam and the rocker arm roller when the
adjuster is drained of oil and completely collapsed.
Specified dry lash is 1.17 mm (0.046 in.) for intake
and 1.28 mm (0.050 in.) for exhaust. After performing
dry lash check, refill adjuster with oil and allow 10
minutes for adjuster/s to bleed down before rotating
cam.
REMOVAL AND INSTALLATION
ENGINE MOUNTÐFRONT
REMOVAL
(1) Support the engine and transaxle assembly
with a floor jack so it will not rotate.
(2) Remove the front engine mount through bolt
from the insulator and front crossmember mounting
bracket (Fig. 22).
(3) Remove six screws from air dam to allow
access to the front mount screws.
(4) Remove the front engine mount screws and
remove the insulator assembly.
(5) Remove the front mounting bracket, if neces-
sary (Fig. 22).
INSTALLATION
(1) Reverse removal procedure for installation and
tighten fasteners in this order. For engine mount
Fig. 19 Refacing Valve Seats
Fig. 20 Checking Spring Installed Height and Valve
Tip Height Dimensions
Fig. 21 Valve Stem Oil Seal Special Tool C4745
NS2.4L ENGINE 9 - 23
SERVICE PROCEDURES (Continued)

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)

(3) Install gear cover and tighten double ended
stud/washer fastener to 12 N´m (105 in. lbs.).
(4) Install crankshaft sprocket using Special Tool
6052 (Fig. 44).
(5) Turn crankshaft until number one 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. 45).
(6) Place chain over crankshaft sprocket so that
the nickel plated link of the chain is over the number
1 cylinder timing mark on the crankshaft sprocket
(Fig. 45).
(7) Place balance shaft sprocket into the timing
chain (Fig. 45) so that the timing mark on the
sprocket (yellow dot) mates with the (lower) nickel
plated link on the chain
(8) With balance shaft keyways pointing up (12
o'clock) slide the balance shaft sprocket onto the noseof the balance shaft. The balance shaft may have to
be pushed in slightly to allow for clearance.
Fig. 42 Balance Shaft(s)ÐRemoval/Installation
Fig. 43 Gear Timing
Fig. 44 Crankshaft SprocketÐInstallation
Fig. 45 Balance Shaft Timing
9 - 32 2.4L ENGINENS
REMOVAL AND INSTALLATION (Continued)

NOTE: THE TIMING MARK ON THE SPROCKET,
THE (LOWER) NICKEL PLATED LINK, AND THE
ARROW ON THE SIDE OF THE GEAR COVER
SHOULD LINE UP WHEN THE BALANCE SHAFTS
ARE TIMED CORRECTLY.
(9) If the sprockets are timed correctly install the
balance shaft bolts and tighten to 28 N´m (250 in.
lbs.). A wood block placed between crankcase and
crankshaft counterbalance will prevent crankshaft
and gear rotation.
CHAIN TENSIONING
(1) Install chain tensioner loosely assembled.
(2) Position guide on double ended stud making
sure tab on the guide fits into slot on the gear cover.
Install and tighten nut/washer assembly to 12 N´m
(105 in. lbs.).
(3) Place a shim 1 mm (0.039 in.) thick x 70 mm
(2.75 in.) long or between tensioner and chain. Push
tensioner and shim up against the chain.Apply firm
pressure (5.5 to 6.6 lbs.) directly behind the
adjustment slot to take up all slack.Chain must
have shoe radius contact as shown in (Fig. 46).
(4) With the load applied, tighten top tensioner
bolt first, then bottom pivot bolt. Tighten bolts to 12
N´m (105 in. lbs.). Remove shim.
(5) Install carrier covers and tighten screws to 12
N´m (105 in. lbs.).HYDRAULIC LASH ADJUSTER
REMOVAL
(1) Remove cylinder head cover. Refer to procedure
outlined in this section.
(2) Remove cam follower assembly. Refer to cam-
shaft removal procedure outlined in this section to
gain access to cam followers and lash adjusters.
(3) Mark hydraulic lash adjusters for reassembly
in their original position. Lash adjusters are serviced
as an assembly.
INSTALLATION
(1) Install hydraulic lash adjuster assembly mak-
ing sure adjusters are at least partially full of oil.
This is indicated by little or no plunger travel when
the lash adjuster is depressed.
(2) Install cam follower assembly as previously
outlined in this section.
(3) Install camshaft as previously outlined in this
section.
(4) Install cylinder head cover as previously out-
lined in this section.
VALVE SPRINGS AND VALVE SEALS IN VEHICLE
REMOVAL
(1) Remove camshafts as previously outlined in
this section.
(2) Rotate crankshaft until piston is at TDC on
compression.
(3) With air hose attached to adapter tool
installed in spark plug hole, apply 90-120 psi air
pressure.
(4) Using Special Tool MD-998772-A with adapter
6779 (Fig. 47) compress valve springs and remove
valve locks.
(5) Remove valve spring.
(6) Remove valve stem seal by a using valve stem
seal tool.
INSTALLATION
(1) Install valve seal/valve spring seat assembly
(Fig. 48). Push the assembly down to seat it onto the
valve guide.
(2) Install valve spring and retainer, use Special
Tool MD-998772-A with adapter 6779 to compress
valve springs only enough to install locks (Fig. 47).
Correct alignment of tool is necessary to avoid nick-
ing valve stems.
(3) Remove air hose and install spark plugs.
(4) Install camshafts as previously outlined in this
section.
(5) Install cylinder head cover as previously out-
lined in this section.
Fig. 46 Chain Tension Adjustment
NS2.4L ENGINE 9 - 33
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)

(4) Install cylinder head cover using procedure out-
lined in this section.
(5) Install rear timing belt cover and timing belt
idler pulley.
(6) Install timing belt and camshaft sprocket.
Refer to procedure outlined in this section.
(7) Install cam sensor and fuel injectors wiring
connectors.
(8) Install coil pack and plug wires onto the
engine. Connect coil pack wiring connector.
(9) Install power steering pump assembly.
(10) Raise vehicle and install the exhaust pipe to
the manifold.
(11) Install power brake vacuum hose to the intake
manifold.
(12) Install accessory drive belts. Refer to Group 7,
Cooling System for procedure.
(13) Install throttle linkage. Refer to Group 14,
Fuel System for procedures.
(14) Install air cleaner and connect all vacuum
lines, electrical wiring and fuel lines to the throttle
body.
(15) Fill cooling system. Refer to Group 7, Cooling
System for procedure. Connect negative battery
cable.
VALVES AND VALVE SPRINGS
REMOVAL
(1) With cylinder head removed, compress valve
springs using a universal valve spring compressor.
(2) Remove valve retaining locks, valve spring
retainers, valve stem seals and valve springs.(3) Before removing valves,remove any burrs
from valve stem lock grooves to prevent dam-
age to the valve guides.Identify valves to insure
installation in original location.
(4) Inspect and clean the valves. Refer to Cleaning
and Inspection outlined in this section for procedure.
INSTALLATION
(1) Coat valve stems with clean engine oil and
insert in cylinder head.
(2) Install new valve stem seals on all valves
using a valve stem seal tool (Fig. 51). The valve stem
seals should be pushed firmly and squarely over
valve guide.
CAUTION: When oversize valves are used, the cor-
responding oversize valve seal must also be used.
Excessive guide wear may result if oversize seals
are not used with oversize valves.
(3) Install valve springs and retainers. Compress
valve springs only enough to install locks, taking
care not to misalign the direction of compression.
Nicked valve stems may result from misalignment of
the valve spring compressor.
CAUTION: When depressing the valve spring
retainers with valve spring compressor the locks
can become dislocated. Ensure both locks are in
the correct location after removing tool.
(4) Check the valve spring installed height B after
refacing the valve and seat (Fig. 52). Make sure mea-
surements are taken from top of spring seat to the
bottom surface of spring retainer. If height is greater
than 38.75 mm (1.525 in.), install a .762 mm (0.030
in.) spacer under the valve spring seat to bring
spring height back within specification.
Fig. 50 Cylinder Head Tightening Sequence
Fig. 51 Valve Stem Oil Seal Tool
NS2.4L ENGINE 9 - 35
REMOVAL AND INSTALLATION (Continued)

(6) Lower vehicle and remove upper timing belt
cover fasteners and remove cover.
(7) Remove right engine mount and support
bracket. Refer to Removal and Installation procedure
in this section.
CAUTION: When aligning crankshaft and camshaft
timing marks always rotate engine from crankshaft.
Camshaft should not be rotated after timing belt is
removed. Damage to valve components may occur.
Always align timing marks before removing timing
belt.
(8) Before the removal of the timing belt, rotate
crankshaft until TDC mark on oil pump housing
aligns with TDC mark on crankshaft sprocket (trail-
ing edge of sprocket tooth) (Fig. 58).
NOTE: The crankshaft sprocket mark is located on
the trailing edge of the sprocket tooth. Failure to
align trailing edge of sprocket tooth to mark on oil
pump housing will cause the camshaft marks to be
misaligned (Fig. 58).
(9) Install 6 mm Allen wrench into belt tensioner.
Before rotating the tensioner insert the long end of a
1/8º or 3 mm Allen wrench into the pin hole on thefront of the tensioner (Fig. 59). While rotating the
tensioner counterclockwise push in lightly on the 1/8º
or 3 mm Allen wrench, until it slides into the locking
hole.
(10) Remove timing belt.
Fig. 57 Timing Belt Covers
Fig. 58 Crankshaft and Camshaft Timing
Fig. 59 Locking Timing Belt Tensioner
9 - 38 2.4L ENGINENS
REMOVAL AND INSTALLATION (Continued)

CAUTION: If timing belt was damaged due to incor-
rect tracking (alignment), the belt tensioner assem-
bly must be replace. Refer to Timing Belt Tensioner
Assembly Removal and Installation procedure out-
lined in this section.
INSTALLATION
(1) Set crankshaft sprocket to TDC by aligning
the sprocket with the arrow on the oil pump housing.
(2) Set camshafts timing marks so that the
exhaust camshaft sprocket is a 1/2 notch below the
intake camshaft sprocket (Fig. 61).
CAUTION: Ensure that the arrows on both cam-
shaft sprockets are facing up.
(3) Install timing belt. Starting at the crankshaft,
go around the water pump sprocket, idler pulley,
camshaft sprockets and then around the tensioner
(Fig. 62).
(4) Move the exhaust camshaft sprocket counter-
clockwise (Fig. 62) to align marks and take up belt
slack.
NOTE: A new tensioner is held in the wound posi-
tion by a pull pin.
(5) Remove the pull pin or Allen wrench from the
belt tensioner.
(6) Once timing belt has been installed and ten-
sioner released, rotate crankshaft two (2) complete
revolutions. Verify that the TDC marks on crank-
shaft and timing marks on the camshafts are aligned
as shown in (Fig. 60).
(7) Install right engine mount and support
bracket. Refer to Removal and Installation procedure
in this section.
(8) Install upper timing belt cover bolts 4.5 N´m
(40 in. lbs.).
(9) Install the lower timing belt cover bolts 4.5
N´m (40 in. lbs.).
(10) Install crankshaft damper. Refer to procedure
outlined in this section.
(11) Install accessory drive belts. Refer to Group 7,
Cooling System.
(12) Install right inner splash shield.
(13) Install right front wheel.
Fig. 60 Crankshaft and Camshaft Timing
Fig. 61 Camshaft Sprocket Alignment
NS2.4L ENGINE 9 - 39
REMOVAL AND INSTALLATION (Continued)