engine oil CHRYSLER VOYAGER 2002 Service Manual

(9) After removal, install bearing cap on the mat-
ing rod.
(10) Repeat procedure for each piston and connect-
ing rod assembly.
(11) Piston and connecting 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. 67).
(2) Before installing the ring compressor, make
sure the oil ring expander ends are butted and the
rail gaps located as shown in (Fig. 67). As viewed
from top.
(3) Immerse the piston head and rings in clean
engine oil, slide the ring compressor, over the piston
(Fig. 68).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. 65).
(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 connecting rod cap bolts should not be
reused.
(7) Before installing theNEWbolts the threads
should be coated with clean engine oil.
(8) Install each bolt finger tight then 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. 69).
(11) Install Balance Shaft Carrier Assembly (Refer
to 9 - ENGINE/VALVE TIMING/BALANCE SHAFT
CARRIER - INSTALLATION).
(12) Install oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION).
(13) Install cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - INSTALLATION).
Fig. 66 Identify Connecting Rod to Cylinder
Fig. 67 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. 68 PistonÐInstallation
9 - 46 ENGINE 2.4LRS
PISTON & CONNECTING ROD (Continued)
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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. 70).
Refer to Engine Specifications.
(2) Check piston ring to groove side clearance (Fig.
71). Refer to Engine Specifications.
PISTON RINGS - INSTALLATION
(1) Install rings with manufacturers I.D. mark fac-
ing up, to the top of the piston (Fig. 72).CAUTION: Install piston rings in the following
order:
²Oil ring expander.
²Upper oil ring side rail.
²Lower oil ring side rail.
²No. 2 Intermediate piston ring.
²No. 1 Upper piston ring.
(2) Install the side rail by placing one end
between the piston ring groove and the expander.
Hold end firmly and press down the portion to be
installed until side rail is in position.Do not use a
piston ring expander(Fig. 73).
Fig. 69 Checking Connecting Rod Side Clearance
Fig. 70 Piston Ring Gap
1 - FEELER GAUGE
Fig. 71 Piston Ring Side Clearance
1 - FEELER GAUGE
Fig. 72 Piston Ring Installation
1 - NO. 1 PISTON RING
2 - NO. 2 PISTON RING
3 - SIDE RAIL
4 - OIL RING
5 - SPACER EXPANDER
RSENGINE 2.4L9-47
PISTON & CONNECTING ROD (Continued)
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(3) Install upper side rail first and then the lower
side rail.
(4) Install No. 2 piston ring and then No. 1 piston
ring.
(5) Position piston ring end gaps as shown in (Fig.
74).
(6) Position oil ring expander gap at least 45É
from the side rail gaps butnoton the piston pin cen-
ter or on the thrust direction. Staggering ring gap is
important 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).
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)
Fig. 73 Installing Side Rail
1 - SIDE RAIL END
Fig. 74 Piston
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. 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
9 - 48 ENGINE 2.4LRS
PISTON RINGS (Continued)
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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.
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).
Fig. 77 Structural Collar
1 - BOLT - COLLAR TO OIL PAN
2 - BOLT - COLLAR TO TRANSAXLE
3 - STRUCTURAL COLLAR
4 - OIL PAN
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
RSENGINE 2.4L9-49
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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 galleryrunning 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.
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.
(6) Install oil pressure switch and connector. (Refer
to 9 - ENGINE/LUBRICATION/OIL PRESSURE
SENSOR/SWITCH - INSTALLATION)
OIL
STANDARD PROCEDURE
ENGINE OIL LEVEL CHECK
The best time to check engine oil level is after it
has sat overnight, or if the engine has been running,
allow the engine to be shut off for at least 5 minutes
before checking oil level.
Checking the oil while the vehicle is on level
ground will improve the accuracy of the oil level
reading. Remove dipstick and observe oil level. Add
oil only when the level is at or below the ADD mark
(Fig. 87).
Fig. 86 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
RSENGINE 2.4L9-53
RIGHT MOUNT (Continued)
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STANDARD PROCEDURE - ENGINE OIL AND
FILTER CHANGE
Change engine oil at mileage and time intervals
described in the Maintenance Schedule. (Refer to
LUBRICATION & MAINTENANCE/MAINTE-
NANCE SCHEDULES - DESCRIPTION)
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY. CONTACT YOUR DEALER OR GOVERN-
MENT AGENCY FOR LOCATION OF COLLECTION
CENTER IN YOUR AREA.
Run engine until achieving normal operating tem-
perature.
(1) Position the vehicle on a level surface and turn
engine off.
(2) Remove oil fill cap.
(3) Hoist and support vehicle on safety stands.
Refer to Hoisting and Jacking Recommendations.
(Refer to LUBRICATION & MAINTENANCE/HOIST-
ING - STANDARD PROCEDURE)
(4) Place a suitable drain pan under crankcase
drain.
(5) Remove drain plug from crankcase and allow
oil to drain into pan. Inspect drain plug threads for
stretching or other damage. Replace drain plug and
gasket if damaged.
(6) Remove oil filter. (Refer to 9 - ENGINE/LUBRI-
CATION/OIL FILTER - REMOVAL)
(7) Install and tighten drain plug in crankcase.
(8) Install new oil filter. (Refer to 9 - ENGINE/LU-
BRICATION/OIL FILTER - INSTALLATION)
(9) Lower vehicle and fill crankcase with specified
type and amount of engine oil. (Refer to LUBRICA-
TION & MAINTENANCE/FLUID TYPES -
DESCRIPTION)
(10) Install oil fill cap.
(11) Start engine and inspect for leaks.(12) Stop engine and inspect oil level.
NOTE: Care should be exercised when disposing
used engine oil after it has been drained from a
vehicle engine. Refer to the WARNING listed above.
OIL FILTER
DESCRIPTION
The engine oil filter (Fig. 88) is a high quality full-
flow, disposable type. Replace the oil filter with a
Mopartor the equivalent.
REMOVAL
(1) Raise vehicle on hoist.
(2) Position an oil collecting container under oil fil-
ter location.
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.
(3) Using a suitable filter wrench, turn oil filter
(Fig. 88) counterclockwise to remove.
Fig. 87 Oil Level
1 - ENGINE OIL LEVEL DIPSTICK
Fig. 88 Oil Filter
9 - 54 ENGINE 2.4LRS
OIL (Continued)
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INSTALLATION
(1) Clean and check filter mounting surface. The
surface must be smooth, flat and free of debris or
pieces of gasket.
(2) Lubricate new oil filter gasket with clean
engine oil.
(3) Screw oil filter (Fig. 88) on until the gasket
contacts base. Tighten to 12 N´m (105 in. lbs.).
OIL PAN
REMOVAL
(1) Raise vehicle on hoist and drain engine oil.
(2) Remove structural collar. (Refer to 9 -
ENGINE/ENGINE BLOCK/STRUCTURAL COVER -
REMOVAL)
(3) Remove air conditioning compressor bracket to
oil pan bolt.
(4) Remove bolts attaching oil pan.
(5) Remove oil pan.
(6) Clean oil pan and all gasket surfaces.
INSTALLATION
(1) Apply MopartEngine RTV GEN II at the oil
pump to engine block parting line (Fig. 89).
(2) Install the oil pan gasket to the block.
(3) Install pan and tighten the screws to 12 N´m
(105 in. lbs.).
(4) Install air conditioning compressor bracket to
oil pan bolt.
(5) Install structural collar. (Refer to 9 - ENGINE/
ENGINE BLOCK/STRUCTURAL COVER - INSTAL-
LATION)
(6) Lower vehicle and fill engine crankcase with
proper oil to correct level.
OIL PRESSURE SWITCH
REMOVAL
(1) Raise vehicle.
(2) Position oil collecting container under pressure
switch location.
(3) Disconnect oil pressure switch electrical con-
nector and remove switch (Fig. 90).
INSTALLATION
(1) Install oil pressure switch. Torque switch to 21
N´m (190 in. lbs.) (Fig. 90).
(2) Connect electrical connector
(3) Lower vehicle.
(4) Start engine and allow to run a minimum of 2
minutes.
(5) Shut engine off and check engine oil level.
Adjust level as necessary.
OIL PUMP
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
REMOVAL).
(3) Remove timing belt rear cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT COVER(S)
- REMOVAL).
(4) Remove oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - REMOVAL).
(5) Remove crankshaft sprocket using Special
Tools 6793 and C-4685-C2 (Fig. 91).
(6) Remove crankshaft key (Fig. 92).
(7) Remove oil pick-up tube.
(8) Remove oil pump (Fig. 93) and front crankshaft
seal.
Fig. 89 Oil Pan Sealing - Typical
1 - SEALER LOCATIONS
Fig. 90 Engine Oil Pressure Switch
RSENGINE 2.4L9-55
OIL FILTER (Continued)
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DISASSEMBLY
(1) To remove the relief valve, proceed as follows:
(a) Remove the threaded plug and gasket from
the oil pump (Fig. 94) .
(b) Remove spring and relief valve (Fig. 94) .
(2) Remove oil pump cover fasteners, and lift off
cover (Fig. 95) .
(3) Remove pump rotors (Fig. 95) .
(4) Wash all parts in a suitable solvent and
inspect carefully for damage or wear.
Fig. 91 Crankshaft Sprocket - Removal
1 - SPECIAL TOOL 6793
2 - SPECIAL TOOL C-4685±C2
3 - CRANKSHAFT SPROCKET
Fig. 92 Crankshaft Key
1 - CRANKSHAFT KEY
Fig. 93 Oil Pump
1 - BOLTS
2 - BOLTS
3 - OIL PUMP
Fig. 94 Oil Pressure Relief Valve
1 - PLUG
2 - OIL PUMP BODY
3 - RELIEF VALVE
4 - SPRING
5 - SEAL
9 - 56 ENGINE 2.4LRS
OIL PUMP (Continued)
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CLEANING
(1) Clean all parts thoroughly in a suitable sol-
vent.
INSPECTION
(1) Inspect the mating surface of the oil pump.
Surface should be smooth (Fig. 96) . Replace pump
cover if scratched or grooved.
(2) Lay a straightedge across the pump cover sur-
face (Fig. 97) . 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. 98) , 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. 99) .
Fig. 95 Oil Pump
1 - O-RING
2 - SEAL
3 - INNER ROTOR
4 - OIL PUMP COVER
5 - FASTENER
6 - OUTER ROTOR
7 - OIL PUMP BODY
Fig. 96 Oil Pump
1 - O-RING
2 - SEAL
3 - INNER ROTOR
4 - OIL PUMP COVER
5 - FASTENER
6 - OUTER ROTOR
7 - OIL PUMP BODY
Fig. 97 Checking Oil Pump Cover Flatness
1 - STRAIGHT EDGE
2 - FEELER GAUGE
3 - OIL PUMP COVER
RSENGINE 2.4L9-57
OIL PUMP (Continued)
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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 fasteners to 12 N´m
(105 in. lbs.) (Fig. 95).
CAUTION: Oil pump pressure relief valve must be
installed as shown in (Fig. 94) or serious engine
damage may occur.
(4) Install relief valve, spring, gasket and cap as
shown in (Fig. 94). Tighten cap to 41 N´m (30 ft.
lbs.).
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. 100). Install O-ring into oil pump body
discharge passage.
(3) Prime oil pump with engine oil before installa-
tion.
(4) Align oil pump rotor flats with flats on crank-
shaft. Install the oil pump to the block (Fig. 93).
CAUTION: To align, the front crankshaft seal MUST
be out of pump, or damage may result.
(5) Install new front crankshaft seal using Special
Tool 6780 (Fig. 101).
(6) Install crankshaft key (Fig. 92).
CAUTION: The crankshaft sprocket is set to a pre-
determined depth from the factory for correct tim-
ing belt tracking. If removed, use of Special Tool
6792 is required to set the sprocket to original
installation depth. An incorrectly installed sprocket
will result in timing belt and engine damage.
(7) Install crankshaft sprocket using Special Tool
6792 (Fig. 102).
(8) Install oil pump pick-up tube.
(9) Install oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION).
(10) Install timing belt rear cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT COVER(S)
- INSTALLATION).
(11) Install timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
INSTALLATION).
Fig. 98 Measuring Outer Rotor Thickness
Fig. 99 Measuring Inner Rotor Thickness
Fig. 100 Oil Pump Sealing
1 - O-RING
2 - SEALER LOCATION
9 - 58 ENGINE 2.4LRS
OIL PUMP (Continued)
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