lock CHRYSLER VOYAGER 2001 Service Manual

Component/Ground Color Location Fig.
Power Liftgate Module C1 BK Left Quarter 35, 36
Power Liftgate Module C2 BK Left Quarter 35, 36
Power Liftgate Motor BK Left Quarter 36
Power Mirror Switch BK Rear of Switch 25
Power Outlet NAT Instrument Panel N/S
Power Seat Circuit Breaker GY Under Seat N/S
Powertrain Control Module C1 GY/BK LT Fender Side Shield N/S
Powertrain Control Module C2 GY LT Fender Side Shield N/S
Power Window Circuit Breaker GY Left Side Kick Panel 31, 32
Radiator Fan No.1 BK Left Side At Motor 1
Radiator Fan No.1 (Diesel) GY Left Side At Motor 3
Radiator Fan No.2 BK Right Side At Motor 1
Radiator Fan No.2 (Diesel) GY Right Side At Motor N/S
Radiator Fan Relay BK Top of Left Front Frame Rail 1
Radiator Fan Relay No. 1
(Diesel)BL Left Front Engine Compartment 3
Radiator Fan Relay No. 2
(Diesel)BL Left Front Engine Compartment 3
Radiator Fan Relay No. 3
(Diesel)BL Left Front Engine Compartment 3
Radio C1 GY Rear of Radio 16, 19, 21
Radio C2 BK Rear of Radio 16, 19, 21
Radio C3 WT/RD Rear of Radio 16, 21
Radio C4 Rear of Radio 16
Radio Choke LTGY Rear of Radio 31, 32
Rear A/C-Heater Unit LT/GN Right Quarter Panel N/S
Rear Automatic Temperature
Control Switch (ATC)BK Rear of Switch 30
Rear Blower Front Control Switch BK Rear of Switch
Rear Blower Rear Control Switch
C1BK At Switch In Headliner
Rear Blower Rear Control Switch
C2BK At Switch In Headliner
Rear Power Outlet RD Left Quarter Panel 36
Rear Washer Pump Motor BK Right Fender Well 4
Rear Wiper Motor BK At Motor 38
Recirculation Door Actuator NAT Right Side of HVAC
Remote Keyless Entry Antenna
(JAPAN)BK Right Upper Instrument Panel 23
Remote Keyless Entry Module BK/RD Top Left of I.P. 16, 17, 23
Right B-Pillar Switch GY Right B Pillar 29
Right Cinch/Release Motor BK Rear of Sliding Door 34
Right Combination Relay BK Left Quarter Panel N/S
Right Cylinder Lock Switch BK Right Front Door 33
RG8W-90 CONNECTOR/GROUND LOCATIONS BUX8Wa-90-9
CONNECTOR/GROUND LOCATIONS BUX (Continued)

Component/Ground Color Location Fig.
Right Door Speaker BK/RD At Speaker N/S
Right Fog Lamp WT At Lamp 4
Right Front Door Ajar Switch BK At B Pillar N/S
Right Front Door Lock Motor/Ajar
SwitchRight Front Door 33
Right Front Park/Turn Signal
LampBK At Lamp 1, 4
Right Front Wheel Speed Sensor BK Right Fender Side Shield 10, 13, 14
Right Full Open Switch BK Right Sliding Door 34
Right Headlamp BK At Lamp 1, 4
Right Headlamp Leveling Motor WT At Right Headlamp N/S
Right High Beam Lamp BK At Right Headlamp N/S
Right Instrument Panel Speaker BK At Speaker 16, 19, 20
Right Lavalier Module BK At Module 2
Right Liftgate Flood Lamp BK At Lamp 38
Right Low Beam Lamp BK At Right Headlamp N/S
Right Mid Reading Lamp GY At Lamp N/S
Right Park Lamp BK AT Lamp N/S
Right Power Mirror BK At Mirror 16, 20, 23
Right Rear Lamp Assembly BK At Lamp 37
Right Rear Pillar Speaker BK At Speaker 37
Right Rear Reading Lamp GY At Lamp N/S
Right Rear Speaker BK At Speaker 37
Right Rear Vent Motor NAT At Motor 37
Right Rear Wheel Speed Sensor BK Center Rear of Floor Pan 37
Right Remote Radio Switch BK At Steering Wheel N/S
Right Repeater GY Right Front Fender 29
Right Seat Airbag YL At Passenger Seat N/S
Right Side Impact Airbag Control
ModuleYL Right B Pillar 29
Right Sliding Door Control
Module C1BK Rear of Door 34, 35
Right Sliding Door Control
Module C2BK/RD Rear of Door 34, 35
Right Sliding Door Latch Sensing
SwitchBK At Sliding Door 34
Right Sliding Door Lock Motor BK Rear of Door 34
Right Sliding Door Lock
Motor/Ajar SwitchBK At Latch N/S
Right Sliding Door Motor BK At Sliding Door 34
Right Speed Control Switch BK At Steering Wheel N/S
Right Stop/Turn Signal Relay BK LT Quarter Panel N/S
Right Turn Signal Lamp OR At Lamp N/S
Right Visor/Vanity Lamp BK At Lamp N/S
8Wa - 90 - 10 8W-90 CONNECTOR/GROUND LOCATIONS BUXRG
CONNECTOR/GROUND LOCATIONS BUX (Continued)

Component/Ground Color Location Fig.
Sentry Key Immobilizer Module BK At Steering Column 16, 17, 18,
26
Siren (United Kingdom) BK Left Front Body N/S
Solenoid/Pressure Switch
Assembly (EATX)BK Side of Transmission N/S
Speed Control Servo BK Near Controller Antilock Brake 15
Thatcham Alarm Module C1 BK Top Right Side of Instrument Panel Near
SpeakerN/S
Thatcham Alarm Module C1 WT Top Right Side of Instrument Panel Near
SpeakerN/S
Throttle Position Sensor GY On Throttle Body 10, 14
Torque Converter Clutch Solenoid BK Front of Transmission 11
Traction Control Switch BK Rear of Swtich 17, 18, 26
Trailer Tow Connector BK LT Quarter Panel N/S
Transmission Control Module BK Top of Transmission 15
Transmission Range Sensor GY Top of Transmission 15
Vehicle Speed Sensor BK Rear of Transmission 10, 13
Washer Fluid Level Switch BK Bottom of Reservoir 4
Water in Fuel Sensor (Diesel) Left Rear Engine Compartment N/S
Wiper Module BK Left Side Cowl 7
RG8W-90 CONNECTOR/GROUND LOCATIONS BUX8Wa-90-11
CONNECTOR/GROUND LOCATIONS BUX (Continued)

Splice Number Location Fig.
S204 Near T/O to Instrument Panel Speaker 9, 10
S205 Near T/O for C201 9
S206 Near T/O for Instrument Cluster 9
S207 In A/C Unit Assembly N/S
S208 (RHD) Between T/O for Antenna Connector and T/O for Front
Cigar Lighter10
S209 (RHD) Between T/O for Front Cigar Lighter and T/O for Brake
Transmission Shift Interlock Solenoid10
S210 (RHD) Near T/O for C203 10
S302 In Floor Pan Track Wiring 13
S303 In T/O to Data Link Connector 13
S304 Near T/O for C307 11
S305 Near T/O for Memory Seat/Mirror Module - C2 N/S
S306 In Floor Pan Track Wiring 11
S307 Near T/O for Memory Power Seat Switch N/S
S308 In Floor Pan Track Wiring 13
S309 In Floor Pan Track Wiring 13
S310 Near T/O for C301 14
S311 In Floor Pan Track Wiring 12
S312 Near T/O for C320 N/S
S313 Near T/O for Power Liftgate Module 18
S314 In Floor Pan Track Wiring 12
S315 In Floor Pan Track Wiring 12
S316 In Floor Pan Track Wiring 12
S317 Near T/O for C101 14
S318 Near T/O for Power Seat Circuit Breaker N/S
S319 In Floor Pan Track Wiring 11
S320 Near T/O for C200 13
S321 In T/O to Data Link Connector 13
S322 Near T/O for C301 14
S323 In Floor Pan Track Wiring 13
S324 In Floor Pan Track Wiring 12
S325 In Floor Pan Track Wiring 12
S326 Near T/O for C101 14
S327 Near Left Side Impact Airbag Module 13
S328 (RS) In Floor Pan Track Wiring 11
S329 Near T/O to Left Rear Pillar Speaker 18
S330 Near T/O for Power Liftgate Module 18
S331 Near T/O for Power Liftgate Motor 18
S332 In Floor Pan Track Wiring 12
S333 (RS) In Floor Pan Track Wiring 11
S334 Near T/O to G301 12
S335 Near T/O for Left Rear Reading Lamp N/S
RG8W-95 SPLICE LOCATIONS BUX8Wa-95-3
SPLICE LOCATIONS BUX (Continued)

Splice Number Location Fig.
S336 Near T/O for Left Rear Reading Lamp 12
S337 Near T/O for Right Mid Reading Lamp N/S
S338 Near T/O for Right Visor/Vanity Lamp N/S
S339 Near T/O for C312 N/S
S340 Near T/O for Passenger Power Window Switch 15, 16
S342 (LHD) Near T/O for Passenger Power Window Motor 15
S343 (LHD) Near T/O for Driver Power Window Motor 15
S344 In T/O to Right Sliding Door Control Module C2 17
S345 Near T/O for Right Sliding Door Motor 17
S346 Near T/O for Driver Power Window Switch 15, 16
S347 Near T/O for Right Sliding Door Lock Motor 17
S348 Near T/O for Left Sliding Door Lock Motor 17
S349 In T/O to Left Sliding Door Control Module - C2 17
S350 Near T/O for Left Sliding Door Motor 17
S351 Near T/O for Liftgate Cylinder Lock Switch 19
S352 Near T/O for Liftgate Cinch/Release Motor 19
S353 Near T/O for C318 18
S354 (RG) Near T/O for C301 N/S
S354 (RS) Near T/O for Driver Heated Seat Module 13
S355 Near T/O for Passenger Heated Seat Module N/S
S356 (RG) In Floor Pan Track Wiring 13
S356 (RS) Near T/O for Passenger Heated Seat Back N/S
S358 (RG) In T/O for Data Link Connector 13
S364 (RHD) Near T/O for Passenger Power Window Window 16
S365 (LHD) Near T/O for Driver Power Window Window 16
S368 Near T/O for C101 14
8Wa - 95 - 4 8W-95 SPLICE LOCATIONS BUXRG
SPLICE LOCATIONS BUX (Continued)

ENGINE 2.4L
TABLE OF CONTENTS
page page
ENGINE 2.4L.............................. 1ENGINE 3.3/3.8L......................... 71
ENGINE 2.4L
TABLE OF CONTENTS
page page
ENGINE 2.4L
DESCRIPTION............................3
DIAGNOSIS AND TESTING..................3
CYLINDER COMBUSTION PRESSURE
LEAKAGE TEST.........................3
CYLINDER COMPRESSION PRESSURE
TEST.................................3
ENGINE OIL LEAK INSPECTION............4
ENGINE...............................5
ENGINE DIAGNOSIS - PERFORMANCE......5
ENGINE DIAGNOSIS - MECHANICAL.........7
STANDARD PROCEDURE...................9
ENGINE CORE AND OIL GALLERY PLUGS....9
REPAIR OF DAMAGED OR WORN
THREADS..............................9
HYDROSTATIC LOCKED ENGINE...........9
FORM-IN-PLACE GASKETS AND SEALERS. . . 10
ENGINE GASKET SURFACE PREPARATION . . 11
MEASURING WITH PLASTIGAGE..........11
REMOVAL..............................12
INSTALLATION...........................13
SPECIFICATIONS........................16
SPECIAL TOOLS.........................19
AIR CLEANER ELEMENT
REMOVAL..............................22
INSTALLATION...........................22
AIR CLEANER HOUSING
REMOVAL..............................22
INSTALLATION...........................22
CYLINDER HEAD
DESCRIPTION...........................22
OPERATION.............................23
DIAGNOSIS AND TESTING.................23
CYLINDER HEAD GASKET...............23
REMOVAL..............................23
CLEANING..............................24
INSPECTION............................24
INSTALLATION...........................24CAMSHAFT OIL SEAL(S)
REMOVAL..............................26
INSTALLATION...........................26
CAMSHAFT(S)
DESCRIPTION...........................26
OPERATION.............................27
STANDARD PROCEDURE..................27
CAMSHAFT END-PLAY..................27
REMOVAL..............................27
CLEANING..............................28
INSPECTION............................28
INSTALLATION...........................28
CYLINDER HEAD COVER
REMOVAL..............................29
CLEANING..............................29
INSPECTION............................29
INSTALLATION...........................29
INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION...........................30
CLEANING..............................30
VALVE SPRINGS
REMOVAL..............................30
INSPECTION............................31
INSTALLATION...........................31
HYDRAULIC LIFTERS
DIAGNOSIS AND TESTING.................32
LASH ADJUSTER (TAPPET) NOISE
DIAGNOSIS...........................32
REMOVAL..............................32
INSTALLATION...........................32
ROCKER ARMS
REMOVAL..............................33
INSPECTION............................33
INSTALLATION...........................33
ENGINE BLOCK
DESCRIPTION...........................33
STANDARD PROCEDURE..................33
CYLINDER BORE AND PISTON - FITTING....33
CYLINDER BORE HONING...............34
RSENGINE 2.4L9-1

ENGINE 2.4L
DESCRIPTION
The 2.4 Liter (148 cu. in.) in-line four cylinder
engine is a double over head camshaft with hydraulic
lifters and four valve per cylinder design. The engine
is free-wheeling; meaning it has provisions for piston-
to-valve clearance. However valve-to-valve interfer-
ence can occur, if camshafts are rotated
independently.
The cylinders are numbered from front of the
engine to the rear. The firing order is 1±3±4±2.
The engine identification number is located on the
rear of the cylinder block (Fig. 1).
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE
The combustion pressure leakage test provides an
accurate means for determining engine condition.
Combustion pressure leakage testing will detect:
²Exhaust and intake valve leaks (improper seat-
ing).
²Leaks between adjacent cylinders or into water
jacket.
²Any causes for combustion/compression pressure
loss.
WARNING: DO NOT REMOVE THE RADIATOR CAP
WITH THE SYSTEM HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM COOLANT CAN
OCCUR.
Check the coolant level and fill as required. DO
NOT install the radiator cap.
Start and operate the engine until it attains nor-
mal operating temperature, then turn the engine
OFF.
Clean spark plug recesses with compressed air.
Remove the spark plugs.
Remove the oil filler cap.Remove the air cleaner.
Calibrate the tester according to the manufactur-
er's instructions. The shop air source for testing
should maintain 483 kPa (70 psi) minimum, 1,379
kPa (200 psi) maximum, with 552 kPa (80 psi) rec-
ommended.
Perform the test procedures on each cylinder
according to the tester manufacturer's instructions.
While testing, listen for pressurized air escaping
through the throttle body, tailpipe and oil filler cap
opening. Check for bubbles in the radiator coolant.
All gauge pressure indications should be equal,
with no more than 25% leakage per cylinder.
FOR EXAMPLE:At 552 kPa (80 psi) input pres-
sure, a minimum of 414 kPa (60 psi) should be main-
tained in the cylinder.
DIAGNOSIS AND TESTING - CYLINDER
COMPRESSION PRESSURE
The results of a cylinder compression pressure test
can be utilized to diagnose several engine malfunc-
tions.
Ensure the battery is completely charged and the
engine starter motor is in good operating condition.
Otherwise the indicated compression pressures may
not be valid for diagnosis purposes.
(1) Check engine oil level and add oil if necessary.
(2) Drive the vehicle until engine reaches normal
operating temperature. Select a route free from traf-
fic and other forms of congestion, observe all traffic
laws, and accelerate through the gears several times
briskly.
(3) Remove all spark plugs from engine. As spark
plugs are being removed, check electrodes for abnor-
mal firing indicators fouled, hot, oily, etc. Record cyl-
inder number of spark plug for future reference.
(4) Disconnect the ignition coil electrical connector.
(5) Be sure throttle blade is fully open during the
compression check.
(6) Insert compression gage adaptor Special Tool
8116 or the equivalent, into the #1 spark plug hole in
cylinder head. Connect the 0±500 psi (Blue) pressure
transducer with cable adaptors to the DRBIIIt.
(7) Crank engine until maximum pressure is
reached on gage. Record this pressure as #1 cylinder
pressure.
(8) Repeat the previous step for all remaining cyl-
inders.
(9) Compression should not be less than 689 kPa
(100 psi) and not vary more than 25 percent from cyl-
inder to cylinder.
(10) If one or more cylinders have abnormally low
compression pressures, repeat the compression test.
(11) If the same cylinder or cylinders repeat an
abnormally low reading on the second compression
test, it could indicate the existence of a problem in
Fig. 1 Engine Identification
1 - ENGINE IDENTIFICATION LOCATION
RSENGINE 2.4L9-3

the cylinder in question.The recommended com-
pression pressures are to be used only as a
guide to diagnosing engine problems. An engine
should not be disassembled to determine the
cause of low compression unless some malfunc-
tion is present.
DIAGNOSIS AND TESTING - ENGINE OIL LEAK
Begin with a thorough visual inspection of the
engine, particularly at the area of the suspected leak.
If an oil leak source is not readily identifiable, the
following steps should be followed:
(1) Do not clean or degrease the engine at this
time because some solvents may cause rubber to
swell, temporarily stopping the leak.
(2) Add an oil soluble dye (use as recommended by
manufacturer). Start the engine and let idle for
approximately 15 minutes. Check the oil dipstick to
make sure the dye is thoroughly mixed as indicated
with a bright yellow color under a black light.
(3) Using a black light, inspect the entire engine
for fluorescent dye, particularly at the suspected area
of oil leak. If the oil leak is found and identified,
repair as necessary.
(4) If dye is not observed, drive the vehicle at var-
ious speeds for approximately 24 km (15 miles), and
repeat inspection.
(5)If the oil leak source is not positively
identified at this time, proceed with the air leak
detection test method as follows:
²Disconnect the fresh air hose (make-up air) at
the cylinder head cover and plug or cap the nipple on
the cover.
²Remove the PCV valve hose from the cylinder
head cover. Cap or plug the PCV valve nipple on the
cover.
²Attach an air hose with pressure gauge and reg-
ulator to the dipstick tube.
CAUTION: Do not subject the engine assembly to
more than 20.6 kpa (3 PSI) of test pressure.
²Gradually apply air pressure from 1 psi to 2.5
psi maximum while applying soapy water at the sus-
pected source. Adjust the regulator to the suitable
test pressure that provides the best bubbles which
will pinpoint the leak source. If the oil leak is
detected and identified, repair per service manual
procedures.
²If the leakage occurs at the crankshaft rear oil
seal area, refer to the section, Inspection for Rear
Seal Area Leak.
(6) If no leaks are detected, turn off the air supply.
Remove the air hose, all plugs, and caps. Install the
PCV valve and fresh air hose (make-up air). Proceed
to next step.(7) Clean the oil off the suspect oil leak area using
a suitable solvent. Drive the vehicle at various
speeds approximately 24 km (15 miles). Inspect the
engine for signs of an oil leak by using a black light.
NOTE: If oil leakage is observed at the dipstick tube
to block location; remove the tube, clean and reseal
using MoparTStud & Bearing Mount (press fit tube
applications only), and for O-ring style tubes,
remove tube and replace the O-ring seal.
INSPECTION FOR REAR SEAL AREA LEAKS
Since it is sometimes difficult to determine the
source of an oil leak in the rear seal area of the
engine, a more involved inspection is necessary. The
following steps should be followed to help pinpoint
the source of the leak.
If the leakage occurs at the crankshaft rear oil seal
area:
(1) Disconnect the battery.
(2) Raise the vehicle.
(3) Remove torque converter or clutch housing
cover and inspect rear of block for evidence of oil.
Use a black light to check for the oil leak. If a leak is
present in this area, remove transmission for further
inspection.
(a) Circular spray pattern generally indicates
seal leakage or crankshaft damage.
(b) Where leakage tends to run straight down,
possible causes are a porous block, oil gallery cup
plug, bedplate to cylinder block mating surfaces
and seal bore. See proper repair procedures for
these items.
(4) If no leaks are detected, pressurize the crank-
case as previously described.
CAUTION: Do not exceed 20.6 kPa (3 psi).
(5) If the leak is not detected, very slowly turn the
crankshaft and watch for leakage. If a leak is
detected between the crankshaft and seal while
slowly turning the crankshaft, it is possible the
crankshaft seal surface is damaged. The seal area on
the crankshaft could have minor nicks or scratches
that can be polished out with emery cloth.
CAUTION: Use extreme caution when crankshaft
polishing is necessary to remove minor nicks and
scratches. The crankshaft seal flange is especially
machined to complement the function of the rear oil
seal.
(6) For bubbles that remain steady with shaft
rotation, no further inspection can be done until dis-
assembled.
9 - 4 ENGINE 2.4LRS
ENGINE 2.4L (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
OIL CONSUMPTION OR SPARK
PLUGS FOULED1. PCV system malfunction. 1. Check system and repair as
necessary. (Refer to 25 -
EMISSIONS CONTROL/
EVAPORATIVE EMISSIONS/PCV
VALVE - DIAGNOSIS AND
TESTING)
2. Worn, scuffed or broken rings. 2. Hone cylinder bores. Install new
rings.
3. Carbon in oil ring slots. 3. Install new rings.
4. Rings fitted too tightly in grooves. 4. Remove rings and check
grooves. If groove is not proper
width, replace piston.
5. Worn valve guide(s). 5. Replace cylinder head assembly.
6. Valve stem seal(s) worn or
damaged.6. Replace seal(s).
STANDARD PROCEDURE - ENGINE CORE AND
OIL GALLERY PLUGS
Using a blunt tool such as a drift and a hammer,
strike the bottom edge of the cup plug. With the cup
plug rotated, grasp firmly with pliers or other suit-
able tool and remove plug (Fig. 2).
CAUTION: Do not drive cup plug into the casting as
restricted cooling can result and cause serious
engine problems.
Thoroughly clean inside of cup plug hole in cylin-
der block or head. Be sure to remove old sealer.Lightly coat inside of cup plug hole with Mopart
Stud and Bearing Mount. Make certain the new plug
is cleaned of all oil or grease. Using proper drive
plug, drive plug into hole so that the sharp edge of
the plug is at least 0.5 mm (0.020 in.) inside the
lead-in chamfer.
It is not necessary to wait for curing of the sealant.
The cooling system can be refilled and the vehicle
placed in service immediately.
STANDARD PROCEDURE - REPAIR OF
DAMAGED OR WORN THREADS
Damaged or worn threads (excluding spark plug
and camshaft bearing cap attaching threads) can be
repaired. Essentially, this repair consists of drilling
out worn or damaged threads, tapping the hole with
a special Heli-Coil Tap, (or equivalent) and installing
an insert into the tapped hole. This brings the hole
back to its original thread size.
CAUTION: Be sure that the tapped holes maintain
the original center line.
Heli-Coil tools and inserts are readily available
from automotive parts jobbers.
STANDARD PROCEDURE - HYDROSTATIC
LOCKED ENGINE
When an engine is suspected to be hydrostatically
locked, regardless of what caused the problem, the
following steps should be used.
CAUTION: DO NOT use starter motor to rotate the
engine, severe damage may occur.
Fig. 2 CORE HOLE PLUG REMOVAL
1 - CYLINDER BLOCK
2 - REMOVE PLUG WITH PLIERS
3 - STRIKE HERE WITH HAMMER
4 - DRIFT PUNCH
5 - CUP PLUG
RSENGINE 2.4L9-9
ENGINE 2.4L (Continued)

(1) Inspect air cleaner, induction system and
intake manifold to insure system is dry and clear of
foreign material.
(2) Remove negative battery cable.
(3) Place a shop towel around the spark plugs
when removing them from the engine. This will catch
any fluid that may possibly be in the cylinder under
pressure.
(4) With all spark plugs removed, rotate engine
crankshaft using a breaker bar and socket.
(5) Identify the fluid in the cylinder(s) (i.e., cool-
ant, fuel, oil or other).
(6) Make sure all fluid has been removed from the
cylinders. Inspect engine for damage (i.e., connecting
rods, pistons, valves, etc.)
(7) Repair engine or components as necessary to
prevent this problem from re-occurring.
CAUTION: Squirt approximately one teaspoon of oil
into the cylinders, rotate engine to lubricate the cyl-
inder walls to prevent damage on restart.
(8) Install new spark plugs.
(9) Drain engine oil and remove oil filter.
(10) Install a new oil filter.
(11) Fill engine with specified amount of approved
oil.
(12) Connect negative battery cable.
(13) Start engine and check for any leaks.
STANDARD PROCEDURE - FORM-IN-PLACE
GASKETS AND SEALERS
There are numerous places where form-in-place
gaskets are used on the engine. Care must be taken
when applying form-in-place gaskets to assure
obtaining the desired results.Do not use form-in-
place gasket material unless specified.Bead size,
continuity, and location are of great importance. Too
thin a bead can result in leakage while too much can
result in spill-over which can break off and obstruct
fluid feed lines. A continuous bead of the proper
width is essential to obtain a leak-free gasket.
There are numerous types of form-in-place gasket
materials that are used in the engine area. Mopart
Engine RTV GEN II, MopartATF-RTV, and Mopart
Gasket Maker gasket materials, each have different
properties and can not be used in place of the other.
MOPARtENGINE RTV GEN IIis used to seal
components exposed to engine oil. This material is a
specially designed black silicone rubber RTV that
retains adhesion and sealing properties when
exposed to engine oil. Moisture in the air causes the
material to cure. This material is available in three
ounce tubes and has a shelf life of one year. After one
year this material will not properly cure. Alwaysinspect the package for the expiration date before
use.
MOPARtATF RTVis a specifically designed
black silicone rubber RTV that retains adhesion and
sealing properties to seal components exposed to
automatic transmission fluid, engine coolants, and
moisture. This material is available in three ounce
tubes and has a shelf life of one year. After one year
this material will not properly cure. Always inspect
the package for the expiration date before use.
MOPARtGASKET MAKERis an anaerobic type
gasket material. The material cures in the absence of
air when squeezed between two metallic surfaces. It
will not cure if left in the uncovered tube. The
anaerobic material is for use between two machined
surfaces. Do not use on flexible metal flanges.
MOPARtBED PLATE SEALANTis a unique
(green-in-color) anaerobic type gasket material that
is specially made to seal the area between the bed-
plate and cylinder block without disturbing the bear-
ing clearance or alignment of these components. The
material cures slowly in the absence of air when
torqued between two metallic surfaces, and will rap-
idly cure when heat is applied.
MOPARtGASKET SEALANTis a slow drying,
permanently soft sealer. This material is recom-
mended for sealing threaded fittings and gaskets
against leakage of oil and coolant. Can be used on
threaded and machined parts under all tempera-
tures. This material is used on engines with multi-
layer steel (MLS) cylinder head gaskets. This
material also will prevent corrosion. MopartGasket
Sealant is available in a 13 oz. aerosol can or 4oz./16
oz. can w/applicator.
SEALER APPLICATION
MopartGasket Maker material should be applied
sparingly 1 mm (0.040 in.) diameter or less of sealant
to one gasket surface. Be certain the material sur-
rounds each mounting hole. Excess material can eas-
ily be wiped off. Components should be torqued in
place within 15 minutes. The use of a locating dowel
is recommended during assembly to prevent smear-
ing material off the location.
MopartEngine RTV GEN II or ATF RTV gasket
material should be applied in a continuous bead
approximately 3 mm (0.120 in.) in diameter. All
mounting holes must be circled. For corner sealing, a
3.17 or 6.35 mm (1/8 or 1/4 in.) drop is placed in the
center of the gasket contact area. Uncured sealant
may be removed with a shop towel. Components
should be torqued in place while the sealant is still
wet to the touch (within 10 minutes). The usage of a
locating dowel is recommended during assembly to
prevent smearing material off the location.
9 - 10 ENGINE 2.4LRS
ENGINE 2.4L (Continued)