oil pressure CHRYSLER VOYAGER 2002 Workshop Manual

ENGINE CONTROL MODULE C1 (DIESEL) - BLACK 81 WAY
CAV CIRCUIT FUNCTION
55 N7 20DB/OR VEHICLE SPEED SENSOR SIGNAL
56 C918 20BK/LB A/C PRESSURE SENSOR GROUND
57 - -
58 K4 20BK/LB LOW IDLE POSITION SWITCH GROUND
59 - -
60 K9 20LB FUEL PRESSURE SENSOR 5 VOLT SUPPLY
61 K51 20BR/WT ECM/PCM RELAY CONTROL
62 - -
63 D21 20WT/BR SCI TRANSMIT
64 K151 20WT LOW IDLE POSITION SWITCH SENSE
65 - -
66 K936 20BR/YL ENGINE OIL PRESSURE SENSOR GROUND
67 - -
68 - -
69 C13 20LB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL
70 N210 20DB/DG LOW SPEED RADIATOR FAN RELAY CONTROL
71 - -
72 N21 20DB/TN LIFT PUMP RELAY CONTROL
73 - -
74 T752 20DG/OR ENGINE STARTER MOTOR RELAY CONTROL
75 - -
76 - -
77 K152 20DB/WT GLOW PLUG RELAY CONTROL
78 N122 20DB/YL HIGH SPEED RADIATOR FAN DUAL RELAY CONTROL
79 - -
80 K87 20BR FUEL PRESSURE SOLENOID CONTROL
81 K87 20BR FUEL PRESSURE SOLENOID CONTROL
8W - 80 - 56 8W-80 CONNECTOR PIN-OUTSRS
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ENGINE COOLANT TEMP SENSOR (GAS) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 K900 18DB/DG SENSOR GROUND
2 K2 18VT/OR ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
ENGINE OIL PRESSURE SENSOR (DIESEL) - BLACK 3 WAY
CAV CIRCUIT FUNCTION
1 F855 20PK/YL SENSOR REFERENCE VOLTAGE A
2 G6 20VT/GY ENGINE OIL PRESSURE SENSOR SIGNAL
3 K936 20BR/YL ENGINE OIL PRESSURE SENSOR GROUND
ENGINE OIL PRESSURE SWITCH (GAS) - LT. GREEN 2 WAY
CAV CIRCUIT FUNCTION
1 G6 16VT/GY ENGINE OIL PRESSURE SWITCH SENSE
2- -
ENGINE OIL TEMPERATURE SENSOR (DIESEL) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 K89 20DB/WT ENGINE OIL TEMPERATURE SENSOR SIGNAL
2 K900 20DB/OR SENSOR GROUND
EVAP/PURGE SOLENOID (GAS) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 K52 18DB/WT EVAPORATIVE EMISSION SOLENOID CONTROL
2 K70 18DB/BR EVAPORATIVE EMISSION SOLENOID SENSE
8W - 80 - 58 8W-80 CONNECTOR PIN-OUTSRS
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INPUT SPEED SENSOR (EATX) - GRAY 2 WAY
CAV CIRCUIT FUNCTION
1 T13 18DG/VT SPEED SENSOR GROUND
2 T52 18DG/WT INPUT SPEED SENSOR SIGNAL
INSTRUMENT CLUSTER - BLACK 13 WAY
CAV CIRCUIT FUNCTION
1 E13 20OR/YL PANEL LAMPS DRIVER
2 L160 20WT/TN (LOW LINE) RIGHT TURN INDICATOR DRIVER
3 G7 20VT/GY (HIGH LINE) LOW OIL PRESSURE INDICATOR DRIVER
4 G3 20VT/LB (HIGH LINE) MALFUNCTION INDICATOR LAMP DRIVER
5 L134 20WT/GY (HIGH LINE) HIGH BEAM INDICATOR DRIVER
6 A701 16BR/RD FUSED B(+) (HAZARD)
7 Z108 18BK/LG GROUND
8 L161 20WT/LG (LOW LINE) LEFT TURN INDICATOR DRIVER
9 D25 20WT/VT PCI BUS
10 B25 18DG/WT (LHD BUILT-UP-EXPORT) PARK BRAKE SWITCH SENSE
10 B25 20DG/WT (RHD) PARK BRAKE SWITCH SENSE
10 B25 16DG/WT (LHD EXCEPT
BUILT-UP-EXPORT)PARK BRAKE SWITCH SENSE
11 G26 20VT/OR CHIME DRIVER
12 G150 20VT/BR INSTRUMENT CLUSTER WAKE UP SENSE
13 Z18 18BK/LB GROUND
INSTRUMENT PANEL SWITCH BANK - BLACK 13 WAY
CAV CIRCUIT FUNCTION
1- -
2- -
3 P7 20LG/DG (RHD) DRIVER HEATED SEAT SWITCH
3 P8 20LG/WT (LHD) PASSENGER HEATED SEAT SWITCH
4 F504 20GY/PK FUSED IGNITION SWITCH OUTPUT (RUN)
5 P8 20LG/WT (RHD) PASSENGER HEATED SEAT SWITCH
5 P7 20LG/DG (LHD) DRIVER HEATED SEAT SWITCH
6- -
7- -
8 L91 20WT/DB HAZARD SWITCH SENSE
9 W26 20BR/DB REAR WIPER SWITCH MUX
10 Z406 20BK/BR GROUND
11 G926 20VT/WT REAR WIPER SWITCH MUX RETURN
12 E14 20OR/TN PANEL LAMPS DRIVER
13 - -
8W - 80 - 66 8W-80 CONNECTOR PIN-OUTSRS
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MESSAGE CENTER (HIGH LINE) - WHITE 14 WAY
CAV CIRCUIT FUNCTION
1 L160 20WT/TN (LHD) RIGHT TURN INDICATOR DRIVER
2 G3 20VT/LB (LHD) MALFUNCTION INDICATOR LAMP DRIVER
3 L134 20WT/GY (RHD) HIGH BEAM INDICATOR DRIVER
4 G69 20VT/WT (LHD) VTSS INDICATOR DRIVER
4 L160 20WT/TN (RHD) RIGHT TURN INDICATOR DRIVER
5- -
6 G7 20VT/GY (LHD) LOW OIL PRESSURE INDICATOR DRIVER
7 A701 16BR/RD (LHD) FUSED B(+) (HAZARD)
8 A701 16BR/RD (RHD) FUSED B(+) (HAZARD)
9 G7 20VT/GY (RHD) LOW OIL PRESSURE INDICATOR DRIVER
10 - -
11 L161 20WT/LG (LHD) LEFT TURN INDICATOR DRIVER
11 G69 20VT/WT (RHD) VTSS INDICATOR DRIVER
12 L134 20WT/GY (LHD) HIGH BEAM INDICATOR DRIVER
13 G3 20VT/LB (RHD) MALFUNCTION INDICATOR LAMP DRIVER
14 L161 20WT/LG (RHD) LEFT TURN INDICATOR DRIVER
MODE DOOR ACTUATOR (ATC) - GRAY 2 WAY
CAV CIRCUIT FUNCTION
1 C135 20DB/GY MODE DOOR DRIVER (B)
2 C35 20LB/OR MODE DOOR DRIVER (A)
MODE DOOR ACTUATOR (MTC) - GRAY 2 WAY
CAV CIRCUIT FUNCTION
1 C34 20DB/LB COMMON DOOR DRIVER (B)
2 C35 20LB/OR MODE DOOR DRIVER (A)
MULTI-FUNCTION SWITCH - BLACK 4 WAY
CAV CIRCUIT FUNCTION
1 W52 20BR/YL FRONT WIPER SWITCH MUX
2 G902 20VT/OR MULTI-FUNCTION SWITCH MUX RETURN
3 L305 20WT/LB TURN SIGNAL SWITCH MUX
4 G194 20VT/LG HIGH BEAM/FRONT WASHER SWITCH MUX
RS8W-80 CONNECTOR PIN-OUTS8W-80-85
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POWER WINDOW SWITCH (LOWLINE) - BLACK 8 WAY
CAV CIRCUIT FUNCTION
1 F304 16WT/PK FUSED WINDOW CIRCUIT BREAKER OUTPUT
2 Z421 12BK/BR GROUND
3 Z421 12BK/BR GROUND
4- -
5 Q26 12OR/GY MASTER WINDOW SWITCH PASSENGER DOWN
6 F304 16WT/PK FUSED WINDOW CIRCUIT BREAKER OUTPUT
7 Z421 20BK/BR GROUND
8 Q16 12OR/TN MASTER WINDOW SWITCH PASSENGER UP
POWERTRAIN CONTROL MODULE C1 (GAS) - GRAY/BLACK 40-WAY
CAV CIRCUIT FUNCTION
1- -
2 K18 16DB/OR (3.3L/3.8L) IGNITION COIL NO. 3 DRIVER
3 K17 16DB/TN IGNITION COIL NO. 2 DRIVER
4- -
5 V32 18VT/YL SPEED CONTROL ON/OFF SWITCH SENSE
6 K342 16BR/WT AUTOMATIC SHUT DOWN RELAY OUTPUT
7 K13 16BR/LB FUEL INJECTOR NO. 3 DRIVER
8 K20 18BR/GY GENERATOR FIELD CONTROL
9- -
10 Z130 18BK/BR GROUND
11 K19 16DB/DG IGNITION COIL NO. 1 DRIVER
12 G6 16VT/GY ENGINE OIL PRESSURE SWITCH SENSE
13 K11 16BR/YL FUEL INJECTOR NO. 1 DRIVER
14 K58 16BR/VT (3.3L/3.8L) FUEL INJECTOR NO. 6 DRIVER
15 K38 16BR/OR (3.3L/3.8L) FUEL INJECTOR NO. 5 DRIVER
16 K14 16BR/TN FUEL INJECTOR NO. 4 DRIVER
17 K12 16BR/DB FUEL INJECTOR NO. 2 DRIVER
18 K99 18BR/LG OXYGEN SENSOR 1/1 HEATER CONTROL
19 - -
20 F202 18PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START)
21 - -
22 - -
23 - -
24 - -
25 K42 18DB/YL (EXCEPT 3.3L/3.8L
BUILT-UP-EXPORT)KNOCK SENSOR SIGNAL
26 K2 18VT/OR ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
27 K902 18BR/DG OXYGEN SENSOR GROUND
28 - -
29 - -
30 K41 18DB/LB OXYGEN SENSOR 1/1 SIGNAL
31 T752 18DG/OR ENGINE STARTER MOTOR RELAY CONTROL
32 K24 18BR/LB CRANKSHAFT POSITION SENSOR SIGNAL
33 K44 18DB/GY CAMSHAFT POSITION SENSOR SIGNAL
34 - -
35 K22 18BR/OR THROTTLE POSITION SENSOR SIGNAL
36 K1 18VT/BR MANIFOLD ABSOLUTE PRESSURE SENSOR SIGNAL
37 K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL
38 - -
39 - -
40 K35 18DB/VT EGR SOLENOID CONTROL
8W - 80 - 94 8W-80 CONNECTOR PIN-OUTSRS
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CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Driver Power Seat Front Riser
MotorRD At Seat N/S
Driver Power Seat Horizontal Motor BK At Seat N/S
Driver Power Seat Rear Riser
MotorRD At Seat N/S
Driver Power Seat Recliner Motor GN At Seat N/S
Driver Power Seat Switch GN At Switch N/S
Driver Power Window Motor RD At Motor N/S
Driver Power Window Switch GN At Switch N/S
Driver Power Window Switch
(RHD)NAT At Switch N/S
Driver Seatbelt Switch WT At Switch on Seat Harness N/S
Driver Seatbelt Tensioner On Seat Harness N/S
EGR Solenoid (Diesel) BK Above Transmission
Right Side of EngineN/S
EGR Solenoid GY Above Transmission
Right Side of Engine9, 10, 11, 13
Electric Wiper De-Icer-C1 WT Right Side Instrument Panel 15, 1923
Electric Wiper De-Icer-C2 WT Left Side Instrument Panel 15, 16, 22
Engine Control Module C1 (Diesel) BK Right Side of Engine 11
Engine Control Module C2 (Diesel) BK Right Side of Engine 11
Engine Coolant Temperature
Sensor (Gas)BK On Cylinder Block N/S
Engine Coolant Temperature
Sensor (Diesel)BL On Cylinder Block 11
Engine Oil Pressure Sensor
(Diesel)BK Rear of Engine 12
Engine Oil Pressure Switch (Gas) LTGN On Cylinder Block 9
Engine Oil Temperature Sensor
(Diesel)BK Rear of Engine 12
EVAP/Purge Solenoid BK Right Motor Mount 9, 13
Evaporator Temperature Sensor BK Right Side of HVAC N/S
Floor Console Lamp BK At Lamp N/S
Floor Console Power Outlet RD At Front Console N/S
Front Blower Module C1 (ATC) BK On HVAC N/S
Front Blower Module C2 (ATC) BK On HVAC N/S
Front Cigar Lighter RD/NAT Rear of Lighter 15, 18, 20
Front Reading Lamps/Switch BK At Switch N/S
Front Washer Pump Motor BK Right Fender Well 3
Fuel Heater (Diesel) BK Left Rear Engine Compartment N/S
Fuel Injector No.1 BK At Fuel Injector N/S
Fuel Injector No.1 (Diesel) BK At Fuel Injector 11
Fuel Injector No.2 BK At Fuel Injector N/S
Fuel Injector No.2 (Diesel) BK At Fuel Injector 11
8W - 91 - 4 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
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CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Fuel Injector No.3 BK At Fuel Injector N/S
Fuel Injector No.3 (Diesel) BK At Fuel Injector 11
Fuel Injector No.4 BK At Fuel Injector N/S
Fuel Injector No.4 (Diesel) BK At Fuel Injector 11
Fuel Injector No.5 BK At Fuel Injector N/S
Fuel Injector No.6 BK At Fuel Injector N/S
Fuel Pump Module LTGY Side of Fuel Tank N/S
Fuel Pressure Sensor (Diesel) BK Top Left of Engine 11
Generator BK Rear of Generator 10, 11, 13, 14
Glove Box Lamp BL Rear of Glove Box 18, 24
Glow Plug Relay (Diesel) BK Near Battery N/S
Halo Lamp WT Steering Column 15, 16, 17, 18, 26
Headlamp Switch BK Rear of Switch 15, 16, 25
Headlamp Washer Pump Motor At Motor N/S
High Note Horn BK Left Frame Rail 5
High Pressure Fuel Pump (Diesel) Rear of Pump 11
Hood Ajar Switch BK Left Fender 6
Idle Air Control Motor (2.4L) BK On Throttle Body 9
Idle Air Control Motor (3.3/3.8L) BK On Throttle Body 13
Ignition Coil Pack 2.4L BK Top of Valve Cover 9, 10
Ignition Coil Pack 3.3L, 3.8L DKGY Top of Engine 14
Ignition Switch BK Rear of Switch at Steering Column 15, 16, 17, 18, 26
Inlet Air Temperature Sensor BK Top Left of Engine N/S
Instrument Cluster BK Rear of Cluster 15, 16, 23
Instrument Panel Switch Bank BK Right Center of Instrument Panel 15, 18, 20
Instrument Panel Power Outlet NAT Center of Instrument Panel N/S
Integrated Power Module C1 LTGN Left Fender Shield 7
Integrated Power Module C2 GN/BL Left Fender Shield 7
Integrated Power Module C3
(Diesel)YL/RD Left Fender Shield 7
Integrated Power Module C3 (Gas) NAT/RD Left Fender Shield 7
Integrated Power Module C4 BL Left Fender Shield 7
Integrated Power Module C5 BK Left Fender Shield 7
Integrated Power Module C6 NAT Left Fender Shield 7
Integrated Power Module C7 BK/RD Left Fender Shield 7
Integrated Power Module C8 OR Left Fender Shield 7
Integrated Power Module C9 BK Left Fender Shield 7
Knock Sensor GY Front of Cylinder Block N/S
Leak Detection Pump LTGY At Pump 9, 10 14
Left B Pillar Switch GY Left B Pillar 34
Left Cinch/Release Motor GY Left Sliding Door N/S
Left Combination Relay BK Left Rear Quarter Panel N/S
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-5
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
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SPECIAL TOOLS
POWER DISTRIBUTION SYSTEMS
ACCESSORY RELAY
DESCRIPTION
The accessory relay is an electromechanical device
that switches fused battery current to the accessory
powered vehicle circuits when the ignition switch is
turned to the Accessory or On positions. The delay
feature will maintain power to the accessories for 45
seconds after the ignition is shut off or until a door is
opened. This allows sufficient time to close windows
and park the windshield wipers. The accessory relay
is located in the Integrated Power Module (IPM) in
the engine compartment.
The accessory relay is a International Standards
Organization (ISO) relay. Relays conforming to the
ISO specifications have common physical dimensions,
current capacities, terminal patterns, and terminal
functions.
The accessory relay cannot be repaired or adjusted
and, if faulty or damaged, it must be replaced.
OPERATION
The ISO relay consists of an electromagnetic coil, a
resistor or diode, and three (two fixed and one movable)
electrical contacts. The movable (common feed) relay
contact is held against one of the fixed contacts (normal-
ly closed) by spring pressure. When the electromagnetic
coil is energized, it draws the movable contact away
from the normally closed fixed contact, and holds it
against the other (normally open) fixed contact.
When the electromagnetic coil is de-energized,
spring pressure returns the movable contact to the
normally closed position. The resistor or diode is con-
nected in parallel with the electromagnetic coil in the
relay, and helps to dissipate voltage spikes that are
produced when the coil is de-energized.
DIAGNOSIS AND TESTING
DIAGNOSIS & TESTING - ACCESSORY RELAY
The accessory relay (Fig. 1) is located in the Inte-
grated Power Module (IPM), in the engine compart-
ment. For complete circuit diagrams, refer toWiring
Diagrams.
(1) Remove the accessory relay from the IPM.
Refer toAccessory Relayin the Removal and
Installation section of this group for the procedure.
(2) A relay in the de-energized position should
have continuity between terminals 87A and 30, and
no continuity between terminals 87 and 30. If OK, go
to Step 3. If not OK, replace the faulty relay.
(3) Resistance between terminals 85 and 86 (elec-
tromagnet) should be 75   5 ohms. If OK, go to Step
4. If not OK, replace the faulty relay.
(4) Connect a battery to terminals 85 and 86.
There should now be continuity between terminals
30 and 87, and no continuity between terminals 87A
and 30. If OK, perform the Relay Circuit Test that
follows. If not OK, replace the faulty relay.
DIAGNOSIS & TESTING - RELAY CIRCUIT TEST
(1) The relay common feed terminal cavity (30) of
the IPM is connected to battery voltage and should
be hot at all times. Check for battery voltage at the
fused B(+) circuit cavity in the IPM receptacle for the
accessory relay. If OK, go to Step 2. If not OK, repair
the fused B(+) circuit to the IPM fuse as required.
(2) The relay normally closed terminal (87A) is
connected to terminal 30 in the de-energized position,
but is not used for this application. Go to Step 3.
(3) The relay normally open terminal (87) is con-
nected to the common feed terminal (30) in the ener-
gized position. This terminal supplies battery voltage
to the fused B(+) fuse in the IPM that feeds the
accessories when the relay is energized by the igni-
tion switch. There should be continuity between the
IPM cavity for relay terminal 87 and the fused B(+)
fuse in the IPM at all times. If OK, go to Step 4. If
not OK, repair the open fused B(+) circuit to the IPM
fuse as required.
Terminal Pick Kit 6680
Fig. 1 Accessory Relay
8W - 97 - 2 8W-97 POWER DISTRIBUTION SYSTEMRS
POWER DISTRIBUTION SYSTEM (Continued)
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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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VALVE SPRINGS & SEALS
REMOVAL
REMOVAL - CYLINDER HEAD ON.........32
REMOVAL - CYLINDER HEAD OFF........33
INSPECTION..........................33
INSTALLATION
INSTALLATION - CYLINDER HEAD ON.....33
INSTALLATION - CYLINDER HEAD OFF....33
HYDRAULIC LASH ADJUSTERS
DIAGNOSIS AND TESTING - HYDRAULIC
LASH ADJUSTER NOISE DIAGNOSIS......34
REMOVAL.............................34
INSTALLATION.........................34
ROCKER ARMS
REMOVAL.............................35
INSPECTION..........................35
INSTALLATION.........................35
ENGINE BLOCK
DESCRIPTION.........................35
STANDARD PROCEDURE
STANDARD PROCEDURE - PISTON TO
CYLINDER BORE FITTING..............36
STANDARD PROCEDURE - CYLINDER
BORE HONING.......................36
CLEANING............................37
INSPECTION..........................37
CONNECTING ROD BEARINGS
STANDARD PROCEDURE
CONNECTING ROD - FITTING...........37
CRANKSHAFT
DESCRIPTION.........................38
OPERATION...........................38
STANDARD PROCEDURE - CRANKSHAFT
ENDPLAY ...........................38
REMOVAL.............................38
INSPECTION..........................39
INSTALLATION.........................39
CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDURE - MAIN BEARING -
FITTING.............................41
CRANKSHAFT OIL SEAL - FRONT
REMOVAL.............................42
INSTALLATION.........................43
CRANKSHAFT OIL SEAL - REAR
REMOVAL.............................43
INSTALLATION.........................44
PISTON & CONNECTING ROD
DESCRIPTION.........................45
OPERATION...........................45
REMOVAL.............................45
INSTALLATION.........................46
PISTON RINGS
STANDARD PROCEDURE
PISTON RING - FITTING................47
VIBRATION DAMPER
REMOVAL.............................48
INSTALLATION.........................48STRUCTURAL COLLAR
REMOVAL.............................49
INSTALLATION.........................49
ENGINE MOUNTING
DESCRIPTION.........................49
FRONT MOUNT
REMOVAL.............................49
INSTALLATION.........................50
LEFT MOUNT
REMOVAL.............................50
INSTALLATION.........................50
REAR MOUNT
REMOVAL.............................51
INSTALLATION.........................51
RIGHT MOUNT
REMOVAL.............................52
INSTALLATION.........................52
LUBRICATION
DESCRIPTION.........................53
OPERATION...........................53
DIAGNOSIS AND TESTING - CHECKING
ENGINE OIL PRESSURE................53
OIL
STANDARD PROCEDURE
ENGINE OIL LEVEL CHECK.............53
STANDARD PROCEDURE - ENGINE OIL
AND FILTER CHANGE..................54
OIL FILTER
DESCRIPTION.........................54
REMOVAL.............................54
INSTALLATION.........................55
OIL PAN
REMOVAL.............................55
INSTALLATION.........................55
OIL PRESSURE SWITCH
REMOVAL.............................55
INSTALLATION.........................55
OIL PUMP
REMOVAL.............................55
DISASSEMBLY.........................56
CLEANING............................57
INSPECTION..........................57
ASSEMBLY............................58
INSTALLATION.........................58
INTAKE MANIFOLD
DESCRIPTION.........................59
OPERATION...........................59
DIAGNOSIS AND TESTING - INTAKE
MANIFOLD LEAKS.....................59
INTAKE MANIFOLD - UPPER
REMOVAL.............................60
INSPECTION..........................61
INSTALLATION.........................61
INTAKE MANIFOLD - LOWER
REMOVAL.............................61
INSPECTION..........................61
INSTALLATION.........................61
9 - 2 ENGINE 2.4LRS
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