seats CHRYSLER VOYAGER 2002 Owner's Manual
[x] Cancel search | Manufacturer: CHRYSLER, Model Year: 2002, Model line: VOYAGER, Model: CHRYSLER VOYAGER 2002Pages: 2399, PDF Size: 57.96 MB
Page 617 of 2399
(8) Install shoulder harness height adjuster knob
by pushing onto the adjuster.
SEAT BELT FIRST ROW
ANCHOR BRACKET - LWB
REMOVAL
(1) Remove lower quarter trim panel.
(2) Remove bolt attaching first row seat belt
anchor bracket to floor.
(3) Remove bracket from vehicle.
INSTALLATION
(1) Position bracket to vehicle.
(2) Install bolt attaching first row seat belt anchor
bracket to floor.
(3) Install lower quarter trim panel.
NOTE: The tightening specification for all seat belt
anchor bolts is 39 N´m (29 ft. lbs.) torque.
SEAT BELT LEFT FIRST ROW
OUTBOARD - SWB THREE
DOOR
REMOVAL
(1) Remove first and second row seats. Refer to
Owner's manual for proper procedures.
(2) Remove shoulder harness height adjuster knob
by pulling it straight away from adjuster.
(3) Slide floor anchor cover from over the anchor
bolt.
(4) Remove floor anchor bolt (Fig. 3).
(5) Remove anchor from floor.
(6) Open clam shell cover from over seat belt turn-
ing loop.
(7) Remove bolt attaching turning loop to shoulder
belt height adjuster.
(8) Remove turning loop from C-pillar.
(9) Remove B-pillar upper trim cover.
(10) Remove C-pillar upper trim cover.
(11) Remove lower quarter trim panel.
(12) Route seat belt webbing and turning loop
through access hole in lower quarter trim panel.
(13) Remove bolt attaching seat belt retractor to
quarter panel.
(14) Lift retractor upward and disengage arrow
head retainer attaching retractor to quarter panel
(Fig. 3).
(15) Remove seat belt from vehicle.
INSTALLATION
(1) Install seat belt into position.
(2) Lower retractor into position to quarter panel.
(3) Install bolt attaching seat belt retractor to
quarter panel. Tighten all seat belt anchor bolts to 39
N´m (29 ft. lbs.) torque.
(4) Install lower quarter trim panel.
(5) Install C-pillar upper trim cover.
(6) Route seat belt webbing and turning loop
through access hole in lower quarter trim panel.
(7) Install B-pillar upper trim cover.
(8) Install turning loop onto C-pillar. Tighten all
seat belt anchor bolts to 39 N´m (29 ft. lbs.) torque.
(9) Press clam shell cover over seat belt turning
loop.
(10) Install anchor to floor.
(11) Slide floor anchor cover over the anchor bolt.
(12) Install shoulder harness height adjuster knob
by pushing it onto adjuster.
Fig. 2 SEAT BELT - OUTBOARD FRONT
1 - B-PILLAR TRIM LOWER
2 - BELT
3 - B-PILLAR TRIM UPPER
4 - HEIGHT ADJUSTER
5 - KNOB
6 - B-PILLAR TRIM LOWER
7 - FLOOR ANCHOR
8 - FLOOR ANCHOR
9 - 30É OUTBOARD
10 - RETRACTOR
8O - 8 RESTRAINTSRS
SEAT BELT OUTBOARD FRONT (Continued)
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Page 618 of 2399
(13) Install first and second row seats.
SEAT BELT FIRST ROW
OUTBOARD - SWB FOUR
DOOR
REMOVAL
(1) Remove first and second row seats. Refer to
Owner's manual for proper procedures.
(2) Remove shoulder harness height adjuster knob
by pulling it straight away from adjuster.
(3) Slide floor anchor cover from over the anchor
bolt.
(4) Remove floor anchor bolt (Fig. 4).
(5) Remove anchor from floor.
(6) Open clam shell cover from over seat belt turn-
ing loop.
(7) Remove bolt attaching turning loop to shoulder
belt height adjuster (Fig. 4).
(8) Remove turning loop from C-pillar.
(9) Remove lower quarter trim panel.
(10) Route seat belt webbing and turning loop
through access hole in lower quarter trim panel.(11) Remove bolt attaching seat belt retractor to
quarter panel (Fig. 4).
(12) Lift retractor upward and disengage arrow
head retainer holding retractor to quarter panel.
(13) Remove seat belt from vehicle.
INSTALLATION
(1) Install seat belt into position.
(2) Lower retractor into position to quarter panel.
(3) Install bolt attaching seat belt retractor to
quarter panel. Tighten seat belt anchor bolts to 39
N´m (29 ft. lbs.) torque.
(4) Route seat belt webbing and turning loop
through access hole in lower quarter trim panel.
(5) Install lower quarter trim panel.
(6) Install turning loop in position on C-pillar.
Tighten seat belt anchor bolts to 39 N´m (29 ft. lbs.)
torque.
(7) Install bolt attaching turning loop to shoulder
belt height adjuster. Tighten seat belt anchor bolts to
39 N´m (29 ft. lbs.) torque.
(8) Close clam shell cover over seat belt turning
loop.
(9) Place anchor in position on floor.
Fig. 3 SEAT BELT LEFT FIRST ROW OUTBOARD ±
SWB THREE DOOR
1 - C-PILLAR TRIM
2 - KNOB
3 - RETRACTOR
4 - LOWER ANCHOR
5 - QUARTER TRIM
Fig. 4 SEAT BELT FIRST ROW OUTBOARD - SWB
FOUR DOOR
1 - UPPER C-PILLAR TRIM
2 - KNOB
3 - HEIGHT ADJUSTER
4 - C-PILLAR
5 - RETRACTOR
6 - FLOOR ANCHOR
7 - QUARTER TRIM PANEL
8 - TURNING LOOP
RSRESTRAINTS8O-9
SEAT BELT LEFT FIRST ROW OUTBOARD - SWB THREE DOOR (Continued)
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Page 619 of 2399
(10) Install floor anchor bolt. Tighten seat belt
anchor bolts to 39 N´m (29 ft. lbs.) torque.
(11) Slide floor anchor cover over the anchor bolt.
(12) Install shoulder harness height adjuster knob
by pushing knob on the adjuster.
SEAT BELT FIRST ROW
OUTBOARD - LWB FOUR DOOR
REMOVAL
(1) Remove first and second row seats. Refer to
Owner's manual for proper procedures.
(2) Remove shoulder harness height adjuster knob
by pulling it straight away from adjuster.
(3) Slide floor anchor cover from over the anchor
bolt.
(4) Remove floor anchor bolt.
(5) Remove anchor from floor.
(6) Open clam shell cover from over seat belt turn-
ing loop.
(7) Remove bolt attaching turning loop to shoulder
belt height adjuster.
(8) Remove turning loop from C-pillar.
(9) Remove lower quarter trim panel.
(10) Route seat belt webbing and turning loop
through access hole in lower quarter trim panel.
(11) Remove bolt attaching seat belt retractor to
quarter panel.
(12) Lift retractor upward and disengage arrow
head retainer attaching retractor to quarter panel.
(13) Remove seat belt from vehicle.
INSTALLATION
(1) Position seat belt to vehicle.
(2) Install arrow head retainer to quarter panel
and push downward to seat retainer.
(3) Install bolt attaching seat belt retractor to
quarter panel.
(4) Route seat belt webbing and turning loop
through access hole in lower quarter trim panel.
(5) Install lower quarter trim panel.
(6) Position turning loop to C-pillar.
(7) Install bolt attaching turning loop to shoulder
belt height adjuster.
(8) Close clam shell cover from over seat belt turn-
ing loop.
(9) Position anchor to floor.
(10) Install floor anchor bolt.
(11) Slide floor anchor cover over the anchor bolt.
(12) Install shoulder harness height adjuster knob
by pushing it straight onto adjuster.
(13) Install first and second row seats. Refer to
Owner's manual for proper procedures.NOTE: The tightening specification for all seat belt
anchor bolts is 39 N´m (29 ft. lbs.) torque.
SEAT BELT SECOND RIGHT
ROW OUTBOARD - LWB
REMOVAL
(1) Remove second row seat from vehicle. Refer to
Owner's Manual for proper procedures.
(2) Slide lower anchor cover from over the anchor
shoulder-nut.
(3) Remove lower anchor shoulder-nut (Fig. 5).
(4) Remove lower anchor from wheelhouse.
(5) Fold upper turning loop extension cover down-
ward to gain access to anchor bolt.
(6) Remove bolt attaching turning loop to exten-
sion bracket above quarter glass (Fig. 5).
(7) Remove turning loop from extension bracket.
(8) Remove D-pillar trim panel.
(9) Remove quarter trim bolster.
(10) Route seat belt webbing and turning loop
through access hole in quarter trim.
(11) Remove bolt attaching retractor to inner quar-
ter panel (Fig. 5).
(12) Remove screw attaching retractor to inner
quarter panel.
(13) Remove second row seat belt retractor from
vehicle.
INSTALLATION
(1) Position second row seat belt retractor in vehi-
cle.
(2) Install screw attaching retractor to inner quar-
ter panel.
(3) Install bolt attaching retractor to inner quarter
panel. Tightening specifications for all seat belt bolts
is 39 N´m (29 ft. lbs.) torque.
(4) Route seat belt webbing and turning loop
through access hole in quarter trim.
(5) Install quarter trim bolster.
(6) Install D-pillar trim panel.
(7) Position turning loop to extension bracket.
(8) Install bolt attaching turning loop to extension
bracket above quarter glass. Tightening specifications
for all seat belt bolts is 39 N´m (29 ft. lbs.) torque.
(9) Install upper turning loop extension cover.
(10) Position lower anchor to wheelhouse.
(11) Install lower anchor shoulder-nut. Tightening
shoulder nut to 39 N´m (29 ft. lbs.) torque.
(12) Install lower anchor cover over the anchor
shoulder-nut.
8O - 10 RESTRAINTSRS
SEAT BELT FIRST ROW OUTBOARD - SWB FOUR DOOR (Continued)
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WIRING
TABLE OF CONTENTS
page page
WIRING DIAGRAM INFORMATION....... 8W-01-1
COMPONENT INDEX.................. 8W-02-1
POWER DISTRIBUTION............... 8W-10-1
GROUND DISTRIBUTION.............. 8W-15-1
BUS COMMUNICATIONS.............. 8W-18-1
CHARGING SYSTEM.................. 8W-20-1
STARTING SYSTEM.................. 8W-21-1
FUEL/IGNITION SYSTEM.............. 8W-30-1
TRANSMISSION CONTROL SYSTEM..... 8W-31-1
VEHICLE SPEED CONTROL............ 8W-33-1
ANTILOCK BRAKES................... 8W-35-1
VEHICLE THEFT SECURITY SYSTEM..... 8W-39-1
INSTRUMENT CLUSTER............... 8W-40-1
HORN/CIGAR LIGHTER/POWER OUTLET . . 8W-41-1
AIR CONDITIONING-HEATER........... 8W-42-1
AIRBAG SYSTEM.................... 8W-43-1
INTERIOR LIGHTING.................. 8W-44-1
BODY CONTROL MODULE............. 8W-45-1MESSAGE CENTER................... 8W-46-1
AUDIO SYSTEM..................... 8W-47-1
REAR WINDOW DEFOGGER............ 8W-48-1
OVERHEAD CONSOLE................. 8W-49-1
FRONT LIGHTING.................... 8W-50-1
REAR LIGHTING..................... 8W-51-1
TURN SIGNALS...................... 8W-52-1
WIPERS............................ 8W-53-1
TRAILER TOW....................... 8W-54-1
POWER WINDOWS................... 8W-60-1
POWER DOOR LOCKS................ 8W-61-1
POWER MIRRORS................... 8W-62-1
POWER SEATS...................... 8W-63-1
SPLICE INFORMATION................ 8W-70-1
CONNECTOR PIN-OUTS............... 8W-80-1
CONNECTOR/GROUND/SPLICE
LOCATION........................ 8W-91-1
POWER DISTRIBUTION SYSTEM........ 8W-97-1 RSWIRING
8W-1
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Page 1016 of 2399
8W-63 POWER SEATS
Component Page
Body Control Module............... 8W-63-5, 9
Diagnostic Junction Port............... 8W-63-5
Driver Heated Seat Back.............. 8W-63-9
Driver Heated Seat Cushion............ 8W-63-9
Driver Heated Seat Module......... 8W-63-3, 4, 9
Driver Power Seat Front Riser Motor . . . 8W-63-2, 7
Driver Power Seat Front Riser
Position Sensor.................... 8W-63-8
Driver Power Seat Horizontal Motor.... 8W-63-2, 7
Driver Power Seat Horizontal
Position Sensor.................... 8W-63-8
Driver Power Seat Rear Riser Motor . . . 8W-63-2, 7
Driver Power Seat Rear Riser
Position Sensor.................... 8W-63-8
Driver Power Seat Recliner Motor..... 8W-63-2, 7
Driver Power Seat Recliner
Position Sensor.................... 8W-63-8Component Page
Driver Power Seat Switch............ 8W-63-2, 6
Fuse 22.......................... 8W-63-2, 4
G200........................ 8W-63-2, 4, 6, 9
G301........................... 8W-63-3, 10
Instrument Panel Switch Bank.......... 8W-63-9
Integrated Power Module............ 8W-63-2, 4
Memory Seat/Mirror Module.... 8W-63-4, 5, 6, 7, 8
Memory Set Switch................... 8W-63-5
Passenger Heated Seat Back........... 8W-63-10
Passenger Heated Seat Cushion........ 8W-63-10
Passenger Heated Seat Module......... 8W-63-10
Passenger Power Seat Front Riser Motor . . 8W-63-3
Passenger Power Seat Horizontal Motor . . . 8W-63-3
Passenger Power Seat Rear Riser Motor . . . 8W-63-3
Passenger Power Seat Recliner Motor.... 8W-63-3
Passenger Power Seat Switch........... 8W-63-3
Power Seat Circuit Breaker........ 8W-63-2, 3, 4
RS8W-63 POWER SEATS8W-63-1
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Page 1200 of 2399
tion. The IOD fuse is a 15 ampere blade-type car-
tridge fuse and, when removed, it is stored in a fuse
cavity adjacent to the washer fuse within the IPM.
OPERATION
The term ignition-off draw identifies a normal con-
dition where power is being drained from the battery
with the ignition switch in the Off position. The IOD
fuse feeds the memory and sleep mode functions for
some of the electronic modules in the vehicle as well
as various other accessories that require battery cur-
rent when the ignition switch is in the Off position,
including the clock. The only reason the IOD fuse is
removed is to reduce the normal IOD of the vehicle
electrical system during new vehicle transportation
and pre-delivery storage to reduce battery depletion,
while still allowing vehicle operation so that the
vehicle can be loaded, unloaded and moved as needed
by both vehicle transportation company and dealer
personnel.
The IOD fuse is removed from the IPM fuse cavity
when the vehicle is shipped from the assembly plant.
Dealer personnel must install the IOD fuse when the
vehicle is being prepared for delivery in order to
restore full electrical system operation. Once the
vehicle is prepared for delivery, the IOD function of
this fuse becomes transparent and the fuse that has
been assigned the IOD designation becomes only
another Fused B(+) circuit fuse. The IOD fuse serves
no useful purpose to the dealer technician in the ser-
vice or diagnosis of any vehicle system or condition,
other than the same purpose as that of any other
standard circuit protection device.
The IOD fuse can be used by the vehicle owner as
a convenient means of reducing battery depletion
when a vehicle is to be stored for periods not to
exceed about thirty days. However, it must be
remembered that removing the IOD fuse will not
eliminate IOD, but only reduce this normal condition.
If a vehicle will be stored for more than about thirty
days, the battery negative cable should be discon-
nected to eliminate normal IOD; and, the battery
should be tested and recharged at regular intervals
during the vehicle storage period to prevent the bat-
tery from becoming discharged or damaged. Refer to
Battery Systemfor additional service information.
REMOVAL
(1) Turn the ignition switch to the Off position.
(2) Unlatch and open the cover of the intelligent
power module.
(3) Remove the IOD fuse from fuse location
markedIODof the Integrated Power Module (IPM).
(4) Store the removed IOD fuse by installing it in
the unused fuse storage markedSPAREof the IPM.
(5) Close and latch the IPM.
INSTALLATION
(1) Be certain the ignition switch is in the Off posi-
tion.
(2) Unlatch and open the cover of the Integrated
Power Module (IPM).
(3) Remove the stored 15 amp IOD fuse from fuse
storage markedSPAREof the IPM.
(4) Use a thumb to press the IOD fuse firmly down
into IPM fuse cavity markedIOD.
(5) Close and latch the IPM cover.
POWER OUTLET
DESCRIPTION
Accessory power outlets are standard equipment on
this model. Two power outlets are installed in the
instrument panel center lower bezel, which is located
near the bottom of the instrument panel center stack
area. Two additional power outlets are also incorpo-
rated into the vehicle, one on the left rear C-pillar
trim and the other in the center console, if equipped.
The power outlets bases are secured by a snap fit in
the appropriate bezels. A hinged plug flips closed to
conceal and protect the power outlet base when the
power outlet is not being used.
The power outlet receptacle unit and the power
outlet plugs are each available for service replace-
ment.
OPERATION
The power outlet base or receptacle shell is con-
nected to ground, and an insulated contact in the
bottom of the shell is connected to battery current.
The power outlet on the instrument panel marked
with a battery receives battery voltage from a fuse in
the Integrated Power Module (IPM) at all times. The
other power outlet on the instrument panel marked
with a key receives battery voltage only when the
key is in the on position.
The power outlet located in the center console
receives battery voltage all the time when positioned
between thefront seatsand key-on voltage when
positioned between therear seats. The power outlet
located on the C-pillar receives battery voltage only
when the key is in the on position.
DIAGNOSIS AND TESTING
DIAGNOSIS & TESTING - POWER OUTLET
For complete circuit diagrams, refer toCigar
Lighter/Power Outletin Wiring Diagrams.
RS8W-97 POWER DISTRIBUTION SYSTEM8W-97-5
IOD FUSE (Continued)
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Page 1202 of 2399
ENGINE
TABLE OF CONTENTS
page page
ENGINE 2.4L.............................. 1ENGINE 3.3/3.8L......................... 74
ENGINE 2.4L
TABLE OF CONTENTS
page page
ENGINE 2.4L
DESCRIPTION..........................3
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION............3
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - PERFORMANCE............4
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - MECHANICAL..............6
DIAGNOSIS AND TESTING - ENGINE OIL
LEAK INSPECTION.....................8
DIAGNOSIS AND TESTING - CYLINDER
COMPRESSION PRESSURE TEST.........9
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE
TEST................................9
STANDARD PROCEDURE
STANDARD PROCEDURE - ENGINE CORE
AND OIL GALLERY PLUGS..............10
STANDARD PROCEDURE - REPAIR OF
DAMAGED OR WORN THREADS.........10
STANDARD PROCEDURE - HYDROSTATIC
LOCKED ENGINE.....................10
STANDARD PROCEDURE - FORM-IN-
PLACE GASKETS AND SEALERS.........11
STANDARD PROCEDURE - ENGINE
GASKET SURFACE PREPARATION........11
STANDARD PROCEDURE - MEASURING
BEARING CLEARANCE USING
PLASTIGAGE........................12
REMOVAL - ENGINE ASSEMBLY...........12
INSTALLATION - ENGINE ASSEMBLY........16
SPECIFICATIONS
SPECIFICATIONS - 2.4L ENGINE.........17
SPECIFICATIONS - TORQUE............20
SPECIAL TOOLS
2.4L ENGINE.........................21AIR CLEANER ELEMENT
REMOVAL.............................24
INSTALLATION.........................24
AIR CLEANER HOUSING
REMOVAL.............................24
INSTALLATION.........................24
CYLINDER HEAD
DESCRIPTION.........................24
OPERATION...........................24
DIAGNOSIS AND TESTINGÐCYLINDER HEAD
GASKET............................24
REMOVAL - CYLINDER HEAD.............25
CLEANING............................26
INSPECTION..........................26
INSTALLATION - CYLINDER HEAD..........26
CAMSHAFT OIL SEAL(S)
REMOVAL.............................28
INSTALLATION.........................28
CAMSHAFT(S)
DESCRIPTION.........................29
OPERATION...........................29
STANDARD PROCEDURE - MEASURING
CAMSHAFT END PLAY.................29
REMOVAL.............................29
CLEANING............................29
INSPECTION..........................30
INSTALLATION.........................30
CYLINDER HEAD COVER
REMOVAL.............................31
CLEANING............................31
INSPECTION..........................31
INSTALLATION.........................31
INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION.........................32
CLEANING............................32
RSENGINE9-1
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Page 1207 of 2399
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - MECHANICAL
CONDITION POSSIBLE CAUSES CORRECTION
NOISY VALVES 1. High or low oil level in
crankcase.1. Check and correct engine oil
level.
2. Thin or diluted oil. 2. Change oil to correct viscosity.
3. Thick oil 3. (a) Change engine oil and filter.
(b) Run engine to operating
temperature.
(c) Change engine oil and filter
again.
4. Low oil pressure. 4. Check and correct engine oil
pressure problem.
5. Dirt in hydraulic lifters/lash
adjusters.5. Replace hydraulic lifters/lash
adjusters.
6. Worn rocker arms. 6. Inspect oil supply to rocker arms.
7. Worn hydraulic lifters/lash
adjusters.7. Replace hydraulic lifters/lash
adjusters.
8. Worn valve guides. 8. Replace cylinder head assembly.
9. Excessive runout of valve seats
on valve faces.9. Grind valve seats and valves.
CONNECTING ROD NOISE 1. Insufficient oil supply. 1. Check engine oil level.
2. Low oil pressure. 2. Check engine oil level. Inspect oil
pump relief valve and spring.
3. Thin or diluted oil. 3. Change oil to correct viscosity.
4. Thick oil 4. (a) Change engine oil and filter.
(b) Run engine to operating
temperature.
(c) Change engine oil and filter
again.
5. Excessive bearing clearance. 5. Measure bearings for correct
clearance. Repair as necessary.
6. Connecting rod journal
out-of-round.6. Replace crankshaft or grind
surface.
7. Misaligned connecting rods. 7. Replace bent connecting rods.
9 - 6 ENGINE 2.4LRS
ENGINE 2.4L (Continued)
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Page 1225 of 2399
AIR CLEANER ELEMENT
REMOVAL
(1) Unsnap 2 clips.
(2) Lift cover and pull toward the engine and
remove cover tabs from air box.
(3) Lift cover and remove the element (Fig. 11).
INSTALLATION
(1) Install the air filter element into air box (Fig.
11).
(2) Move cover so that the tabs insert into the air
box.
(3) Push cover down and snap the 2 clips.
AIR CLEANER HOUSING
REMOVAL
(1) Disconnect the negative battery cable.
(2) Disconnect the inlet air temperature sensor
(Fig. 12).
(3) Remove the inlet hose to throttle body (Fig. 11).
(4) Remove the bolt for air box at upper radiator
cross member.
(5) Pull air box up and off over the single locating
pin.
(6) Remove air box from vehicle
INSTALLATION
(1) Install air box into vehicle and onto the locat-
ing pin.(2) Install bolt to hold air box to the upper radia-
tor cross member.
(3) Install the inlet hose to the throttle body.
(4) Connect the inlet air temperature sensor (Fig.
12).
(5) Connect the negative battery cable.
CYLINDER HEAD
DESCRIPTION
The cross flow designed, aluminum cylinder head
contains dual over-head camshafts with four valves
per cylinder (Fig. 13). The valves are arranged in two
in-line banks. The intake valves face toward the
front of the vehicle. The exhaust valves face the dash
panel. The cylinder head incorporates powdered
metal valve guides and seats. The cylinder head is
sealed to the block using a multi-layer steel head
gasket and retaining bolts.
Integral oil galleries provide lubrication passages
to the hydraulic lash adjusters, camshafts, and valve
mechanisms.
OPERATION
The cylinder head closes the combustion chamber,
allowing the pistons to compress the fuel/air mixture
for ignition. The valves are actuated by the lobe pro-
files on the camshaft to open and close at specified
duration to either allow clean air in the combustion
chamber or the exhaust gases out; depending on the
stroke of the engine.
DIAGNOSIS AND TESTINGÐCYLINDER HEAD
GASKET
A cylinder head gasket leak can be located between
adjacent cylinders or between a cylinder and the
adjacent water jacket.
Fig. 11 AIR BOX COVER
Fig. 12 IAT SENSOR 2.4L
9 - 24 ENGINE 2.4LRS
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INTAKE/EXHAUST VALVES &
SEATS
DESCRIPTION
The valves are made of heat resistant steel. They
have chrome plated stems to prevent scuffing. Viton
rubber valve stem seals are integral with the spring
seats. The valves have three-bead lock keepers to
retain springs and to promote valve rotation.
CLEANING
(1) Clean all valves thoroughly and discard
burned, warped and cracked valves.
VALVE SPRINGS & SEALS
REMOVAL
REMOVAL - CYLINDER HEAD ON
(1) Remove cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(2) Remove camshafts (Refer to 9 - ENGINE/CYL-
INDER HEAD/CAMSHAFT(S) - REMOVAL).
(3) Rotate crankshaft until piston is at TDC on
compression.
(4) With air hose attached to adapter tool installed
in spark plug hole, apply 90-120 psi air pressure.
(5) Using Special Tool MD-998772-A with adapter
6779 (Fig. 33), compress valve springs and remove
valve locks.
(6) Remove valve spring(s).
(7) Remove valve stem seal(s) by a using valve
stem seal tool (Fig. 35).
Fig. 31 Sealer Locations
1 ± SEALER LOCATION
Fig. 32 Cylinder Head Cover Tightening Sequence
(Typical Cover Shown)
Fig. 33 Valve Spring - Removal/Installation
1 - VALVE SPRING COMPRESSOR MD 998772A
2 - AIR HOSE
9 - 32 ENGINE 2.4LRS
CYLINDER HEAD COVER (Continued)
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