length CHRYSLER VOYAGER 2004 User Guide

In addition to monitoring inputs and controlling
outputs, the TCM has other important responsibili-
ties and functions:
²Storing and maintaining Clutch Volume Indices
(CVI)
²Storing and selecting appropriate Shift Sched-
ules
²System self-diagnostics
²Diagnostic capabilities (with DRB scan tool)
CLUTCH VOLUME INDEX (CVI)
An important function of the TCM is to monitor
Clutch Volume Index (CVI). CVIs represent the vol-
ume of fluid needed to compress a clutch pack.
The TCM monitors gear ratio changes by monitor-
ing the Input and Output Speed Sensors. The Input,
or Turbine Speed Sensor sends an electrical signal to
the TCM that represents input shaft rpm. The Out-
put Speed Sensor provides the TCM with output
shaft speed information.
By comparing the two inputs, the TCM can deter-
mine transaxle gear ratio. This is important to the
CVI calculation because the TCM determines CVIs
by monitoring how long it takes for a gear change to
occur (Fig. 17).
Gear ratios can be determined by using the DRB
Scan Tool and reading the Input/Output Speed Sen-
sor values in the ªMonitorsº display. Gear ratio can
be obtained by dividing the Input Speed Sensor value
by the Output Speed Sensor value.
For example, if the input shaft is rotating at 1000
rpm and the output shaft is rotating at 500 rpm,
then the TCM can determine that the gear ratio is
2:1. In direct drive (3rd gear), the gear ratio changes
to 1:1. The gear ratio changes as clutches are applied
and released. By monitoring the length of time it
takes for the gear ratio to change following a shift
request, the TCM can determine the volume of fluid
used to apply or release a friction element.
The volume of transmission fluid needed to apply
the friction elements are continuously updated foradaptive controls. As friction material wears, the vol-
ume of fluid need to apply the element increases.
Certain mechanical problems within the clutch
assemblies (broken return springs, out of position
snap rings, excessive clutch pack clearance, improper
assembly, etc.) can cause inadequate or out-of-range
clutch volumes. Also, defective Input/Output Speed
Sensors and wiring can cause these conditions. The
following chart identifies the appropriate clutch vol-
umes and when they are monitored/updated:
CLUTCH VOLUMES
ClutchWhen Updated
Proper Clutch
Volume
Shift Sequence Oil Temperature Throttle Angle
L/R2-1 or 3-1 coast
downshift>70É <5É 35to83
2/4 1-2 shift
> 110É5 - 54É20 to 77
OD 2-3 shift 48 to 150
UD 4-3 or 4-2 shift > 5É 24 to 70
Fig. 17 Example of CVI Calculation
1 - OUTPUT SPEED SENSOR
2 - OUTPUT SHAFT
3 - CLUTCH PACK
4 - SEPARATOR PLATE
5 - FRICTION DISCS
6 - INPUT SHAFT
7 - INPUT SPEED SENSOR
8 - PISTON AND SEAL
RSELECTRONIC CONTROL MODULES8E-21
TRANSMISSION CONTROL MODULE (Continued)

Calibrate the compass manually as follows:
(1) Turn the ignition switch to the On position. If
the compass/thermometer data is not currently being
displayed, momentarily depress and release the C/T
push button to reach the compass/thermometer dis-
play.
(2) On Electronic Vehicle Information Center
(EVIC) and Compass Mini-Trip Computer (CMTC)
equipped vehicles depress the Reset push button and
hold the button down until ªCALº appears in the dis-
play. This takes about ten seconds, and appears
about five seconds after ªVAR = XXº is displayed. On
Compass Temperature Module (CT) equipped vehicles
depress the C/T push button and US/M push button
down until ªCALº appears in the display. This takes
about ten seconds, and appears about five seconds
after ªVAR = XXº is displayed.
(3) Release the push button(s).
(4) Drive the vehicle on a level surface, away from
large metal objects and power lines, through three or
more complete circles at between five and eight kilo-
meters-per-hour (three and five miles-per-hour) in
not less than 48 seconds. The ªCALº message will
disappear from the display to indicate that the com-
pass is now calibrated.
NOTE: If the ªCALº message remains in the display,
either there is excessive magnetism near the com-
pass, or the unit is faulty. Repeat the calibration
procedure one more time.
NOTE: If the wrong direction is still indicated in the
compass display, the area selected for calibration
may be too close to a strong magnetic field. Repeat
the calibration procedure in another location.
STANDARD PROCEDURE - COMPASS
DEMAGNETIZING
A degaussing tool (Special Tool 6029) is used to
demagnetize, or degauss, the overhead console for-
ward mounting screw and the roof panel above the
overhead console. Equivalent units must be rated as
continuous duty for 110/115 volts and 60 Hz. They
must also have a field strength of over 350 gauss at 7
millimeters (0.25 inch) beyond the tip of the probe.
To demagnetize the roof panel and the overhead
console forward mounting screw, proceed as follows:
(1) Be certain that the ignition switch is in the Off
position, before you begin the demagnetizing proce-
dure.
(2) Connect the degaussing tool (Fig. 2) to an elec-
trical outlet, while keeping the tool at least 61 centi-
meters (2 feet) away from the compass unit.(3) Slowly approach the head of the overhead con-
sole forward mounting screw with the degaussing
tool connected.
(4) Contact the head of the screw with the plastic
coated tip of the degaussing tool for about two sec-
onds.
(5) With the degaussing tool still energized, slowly
back it away from the screw. When the tip of the tool
is at least 61 centimeters (2 feet) from the screw
head, disconnect the tool.
(6) Place a piece of paper approximately 22 by 28
centimeters (8.5 by 11 inches), oriented on the vehicle
lengthwise from front to rear, on the center line of
the roof at the windshield header (Fig. 3). The pur-
pose of the paper is to protect the roof panel from
scratches, and to define the area to be demagnetized.
Fig. 2 Degaussing Tool 6029
Fig. 3 Roof Demagnetizing Pattern
8M - 4 MESSAGE SYSTEMSRS
OVERHEAD CONSOLE (Continued)

PROGRAMMABLE FEATURES
NOTE: Tire pressure monitoring (TPM) system infor-
mation is not covered in this section of the service
manual. Refer to the tires/wheels section of this
manual for detailed tire pressure monitoring system
information.
²LANGUAGE?- The options include English,
Francaise, Deutsch, Italiana, or Espanol. The default
is English. All EVIC display nomenclature, including
the trip computer functions, warning messages and
the programmable features appear in the selected
language.
²DISPLAY U.S. OR METRIC?- The options
include U.S. and M. The default is U.S. This feature
toggles the trip computer temperature, fuel economy
and odometer display readings between U.S. and
metric units of measure. It also changes the odome-
ter display in the instrument cluster.
²SERVICE INTV. =- The options include from
1000 to 12000 kilometers in 1000 kilometer incre-
ments (2000 to 7500 miles in 500 mile increments).
The default is 12000 kilometers (7500 miles). The
selected distance becomes the interval at which the
Perform Service warning message will be displayed
by the EVIC. If a new distance is selected, a second
programmable feature appears,RESET SERVICE
DISTANCE?- The options include No and Yes. The
default is Yes. When Yes is selected, the accumulated
distance since the last previous Perform Service
warning message will be reset to zero because the
service interval has been changed. When No is
selected, the distance until the next Perform Service
warning message is reduced by the accumulated dis-
tance since the last previous message.
²USE FACTORY SETTINGS?- The options
include Yes and No. The default is Yes. When yes is
selected all the programmable features will return to
there defaults and the rest of the programmable fea-
tures will not be displayed. If No is selected the rest
of the programmable features will be displayed at
there default values. This feature will automatically
return to the Yes default under two conditions. First,
if no programmable features are changed from there
defaults. Second, if all the programmable features
equal there defaults.
²AUTO DOOR LOCKS?- The options include
Yes and No. The default is Yes. When Yes is selected,
all doors and the liftgate lock automatically when
vehicle speed reaches 25 kilometers-per-hour (15
miles-per-hour). If YES is selected, a second program-
mable feature appears,AUTO UNLOCK ON EXIT?
- The options again include Yes and No. The default
is No. When Yes is selected, following each Auto Door
Lock event all doors and the liftgate will automati-
cally unlock when the driver door is opened, if thevehicle is stopped and the transmission gear selector
is in Park or Neutral. The Auto Door Unlock event
will only occur once following each Auto Door Lock
event.
²REMOTE UNLOCK- The options include
Driver Door 1st and All Doors. The default is Driver
Door 1st. When Diver Door 1st is selected, only the
driver door unlocks when the Unlock button of the
Remote Keyless Entry (RKE) transmitter is
depressed once. The Unlock button of the RKE trans-
mitter must be depressed twice to unlock all doors.
When All Doors is selected, all doors unlock when the
Unlock button of the RKE transmitter is depressed
once.
²REMOTE LINKED TO MEMORY?- This pro-
grammable feature only applies to vehicles equipped
with the optional memory / heated system. The
options include Yes and No. The default is No. When
Yes is selected, the memory system will recall the
Driver 1 or Driver 2 memory settings assigned to the
RKE transmitter being used to unlock the vehicle.
When No is selected, the memory system will only
recall memory settings when the Driver 1 or Driver 2
push buttons of the memory switch on the driver side
front door trim panel are depressed.
²SOUND HORN ON LOCK?- The options
include Yes and No. The default is No. When Yes is
selected, a short horn chirp will provide an audible
confirmation when the RKE receiver recognizes a
valid Lock signal from an RKE transmitter. When No
is selected, no horn chirp will occur with the RKE
Lock event. This feature may be selected indepen-
dent of theFLASH LIGHTS WITH LOCKS?pro-
grammable feature.
²FLASH LIGHTS WITH LOCKS?- The options
include Yes and No. The default is Yes. When Yes is
selected, a single flash of the hazard warning lamps
will provide an optical confirmation when the RKE
receiver recognizes a valid Lock signal from an RKE
transmitter, and two flashes of the same lamps will
occur when the RKE receiver recognizes a valid
Unlock signal from an RKE transmitter. When No is
selected, no lamp flash will occur with the RKE Lock
or Unlock event. This feature may be selected inde-
pendent of theSOUND HORN ON LOCK?pro-
grammable feature.
²HEADLAMP DELAY =- The options include
Off, 30 Sec, 60 Sec, and 90 Sec. The default is 90 Sec.
When a time interval is selected, the headlamps will
remain on for that length of time when the head-
lamps are turned off after the ignition is turned off,
or if the Auto mode is selected on vehicles with the
Auto Headlamps option. When Off is selected, the
headlamp delay feature is disabled.
²HEADLAMPS ON WITH WIPERS?- This pro-
grammable feature only applies to vehicles equipped
8M - 8 MESSAGE SYSTEMSRS
ELECTRONIC VEHICLE INFO CENTER (Continued)

DIODE
REMOVAL
(1) Disconnect the battery.
(2) Locate the diode in the harness, and remove
the protective covering.
(3) Remove the diode from the harness, pay atten-
tion to the current flow direction (Fig. 13).
INSTALLATION
(1) Remove the insulation from the wires in the
harness. Only remove enough insulation to solder in
the new diode.
(2) Install the new diode in the harness, making
sure current flow is correct. If necessary, refer to the
appropriate wiring diagram for current flow (Fig. 13).
(3) Solder the connection together using rosin core
type solder only.Do not use acid core solder.
(4) Tape the diode to the harness using electrical
tape. Make sure the diode is completely sealed from
the elements.
(5) Re-connect the battery and test affected sys-
tems.
TERMINAL
REMOVAL
(1) Follow steps for removing terminals described
in the connector removal section.
(2) Cut the wire 6 inches from the back of the con-
nector.
INSTALLATION
(1) Select a wire from the terminal repair kit that
best matches the color and gage of the wire being
repaired.
(2) Cut the repair wire to the proper length and
remove one±half (1/2) inch of insulation.
(3) Splice the repair wire to the wire harness (see
wire splicing procedure).
(4) Insert the repaired wire into the connector.
(5) Install the connector locking wedge, if required,
and reconnect the connector to its mating half/compo-
nent.
(6) Re-tape the wire harness starting at 1±1/2
inches behind the connector and 2 inches past the
repair.
(7) Connect battery and test all affected systems.
Fig. 13 DIODE IDENTIFICATION
1 - CURRENT FLOW
2 - BAND AROUND DIODE INDICATES CURRENT FLOW
3 - DIODE AS SHOWN IN THE DIAGRAMS
8W - 01 - 14 8W-01 WIRING DIAGRAM INFORMATIONRS

(33) Start engine and run until operating temper-
ature is reached.
(34) Adjust transmission linkage, if necessary.
SPECIFICATIONS
SPECIFICATIONS - 2.4L ENGINE
DESCRIPTION SPECIFICATION
General Specification
Type In-Line OHV, DOHC
Number of Cylinders 4
Displacement 2.4 Liters
(148 cu. in.)
Bore 87.5 mm
(3.445 in.)
Stroke 101.0 mm
(3.976 in.)
Compression Ratio 9.4:1
Firing Order 1-3-4-2
Compression Pressure 690 kPa (Minimum)
(100 psi Minimum)
Max. Variation Between
Cylinders25%
Cylinder Block
Cylinder Bore Diameter 87.4924±87.5076 mm
(3.4446±3.4452 in.)
Out-of-Round (Max.) 0.051 mm
(0.002 in.)
Taper (Max.) 0.051 mm
(0.002 in.)
Pistons
Piston Diameter 87.463±87.481 mm
(3.4434±3.4441 in.)
Clearance @ 14 mm
(9/16 in.) from bottom of
skirt0.024±0.057 mm
(0.0009±0.0022 in.)
Weight 346±356 grams
(12.20±12.56 oz.)
Land Clearance
(Diametrical)0.614±0.664 mm
(0.024±0.026 in.)
Piston Length 66.25 mm
(2.608 in.)
Piston Ring Groove
Depth No. 14.640±4.784 mm
(0.182±0.188 in.)
DESCRIPTION SPECIFICATION
Piston Ring Groove
Depth No. 24.575±4.719 mm
(0.180±0.185 in.)
Piston Ring Groove
Depth No. 34.097±4.236 mm
(0.161±0.166 in.)
Piston Pins
Clearance in Piston 0.005±0.018 mm
(0.0002±0.0008 in.)
Clearance in Connecting
RodInterference
Diameter 21.998±22.003 mm
(0.8660±0.8662 in.)
End Play None
Length 72.75±73.25 mm
(2.864±2.883 in.)
Piston Rings
Ring GapÐTop
Compression Ring0.25±0.51 mm
(0.0098±0.020 in.)
Wear Limit 0.8 mm
(0.031 in.)
Ring GapÐ2nd
Compression Ring0.23±0.48 mm
(0.009±0.018 in.)
Wear Limit 0.8 mm
(0.031 in.)
Ring GapÐOil Control
Steel Rails0.25±0.64 mm
(0.0098±0.025 in.)
Wear Limit 1.0 mm
(0.039 in.)
Ring Side ClearanceÐ
Compression Rings0.030±0.080 mm
(0.0011±0.0031 in.)
Wear Limit 0.10 mm
(0.004 in.)
Ring Side ClearanceÐOil
Ring Pack0.012±0.178 mm
(0.0004±0.0070 in.)
Ring WidthÐ
Compression Rings1.47±1.50 mm
(0.057±0.059 in.)
Ring WidthÐOil Ring
Pack2.72±2.88 mm
(0.107±0.1133 in.)
Connecting Rod
Bearing Clearance 0.025±0.071 mm
(0.0009±0.0027 in.)
Wear Limit 0.075 mm
(0.003 in.)
RSENGINE 2.4L9-17
ENGINE 2.4L (Continued)

DESCRIPTION SPECIFICATION
Head DiameterÐExhaust 28.32±28.52 mm
(1.114±1.122 in.)
Valve Length (Overall)
ÐIntake 112.76±113.32 mm
(4.439±4.461 in.)
ÐExhaust 110.89±111.69 mm
(4.365±4.397 in.)
Valve Stem Diameter
ÐIntake 5.934±5.952 mm
(0.2337±0.2344 in.)
ÐExhaust 5.906±5.924 mm
(0.2326±0.2333 in.)
Valve Margin
Intake 1.2±1.7 mm
(0.047±0.066 in.)
Service Limit 0.95 mm
(1/32 in.)
Exhaust 0.985±1.315 mm
(0.038±0.051 in.)
Service Limit 1.05 mm
(3/64 in.)
Valve Stem Tip Height
Intake 48.04 mm
(1.891 in.)
Exhaust 47.99 mm
(1.889 in.)
Valve Stem to Guide Clearance
Intake 0.048±0.066 mm
(0.0018±0.0025 in.)
Max. Allowable 0.076 mm
(0.003 in.)
Service Limit 0.25 mm
(0.010 in.)
Exhaust 0.0736±0.094 mm
(0.0029±0.0037 in.)
Max. Allowable 0.101 mm
(0.004 in.)
Service Limit 0.25 mm
(0.010 in.)DESCRIPTION SPECIFICATION
Valve Springs
Free Length (Approx.) 48.4 mm
(1.905 in.)
Nominal Force (Valve
Closed)338 N @ 38.0 mm
(75.98 lbs. @ 1.496 in.)
Nominal Force (Valve
Open)607 N @ 29.75 mm
(136 lbs. @ 1.172 in.)
Installed Height 38.00 mm
(1.496 in.)
Number of Coils 7.82
Wire Diameter 3.86 mm
(1.496 in.)
Oil Pump
Clearance Over Rotors
(Max.)0.10 mm
(0.004 in.)
Cover Out-of-Flat (Max.) 0.025 mm
(0.001 in.)
Inner Rotor Thickness
(Min.)9.40 mm
(0.370 in.)
Outer Rotor Thickness
(Min.)9.40 mm
(0.370 in.)
Outer Rotor Clearance
(Max.)0.039 mm
(0.015 in.)
Outer Rotor Diameter
(Min.)79.95 mm
(3.148 in.)
Tip Clearance Between
Rotors (Max.)0.20 mm
(0.008 in.)
Oil Pressure
At Curb Idle Speed* 25 kPa
(4 psi)
At 3000 rpm 170±550 kPa
(25±80 psi)
CAUTION:
*If pressure is ZERO at curb idle, DO NOT run engine
at 3000 rpm.
RSENGINE 2.4L9-19
ENGINE 2.4L (Continued)

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 balance
shaft carrier support leg. This passage directly sup-
plies 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 gallery running the
length of the cylinder head. The camshaft journals arepartially slotted to allow a predetermined 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 (Fig. 85).
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)
Fig. 84 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
Fig. 85 Engine Lubrication System
9 - 52 ENGINE 2.4LRS
RIGHT MOUNT (Continued)

(9) Disconnect throttle and speed control (if
equipped) cables from throttle lever and bracket.
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
THROTTLE CONTROL CABLE - REMOVAL)
(10) Remove the EGR tube. (Refer to 25 - EMIS-
SIONS CONTROL/EXHAUST GAS RECIRCULA-
TION/TUBE - REMOVAL)
(11) Remove the upper manifold support bracket
bolt to manifold (Fig. 105).
(12) Remove engine oil dipstick from tube.
(13) Remove upper intake manifold bolts (Fig.
106). Remove upper intake manifold.
CAUTION: Cover intake manifold to prevent foreign
material from entering engine.
INSPECTION
(1) Check manifold surfaces for flatness with
straight edge. Surface must be flat within 0.15 mm
per 300 mm (0.006 in. per foot) of manifold length.
(2) Inspect manifold for cracks or distortion.
Replace manifold if necessary.
INSTALLATION
(1) Clean manifold sealing surfaces.
(2) Apply a 1.5 mm (0.060 in.) bead MopartGas-
ket Maker to the perimeter of the lower intake man-
ifold runner openings.
(3) Install upper intake manifold and tighten fas-
teners to 28 N´m (250 in. lbs.) in sequence shown in
(Fig. 106). Repeat this procedures until all fasteners
are at specified torque.
(4) Install engine oil dipstick.
(5) Install upper bolt in intake manifold to front
support bracket (Fig. 105). Torque to 28 N´m (250 in.
lbs.).
(6) Install EGR tube. (Refer to 25 - EMISSIONS
CONTROL/EXHAUST GAS RECIRCULATION/
TUBE - INSTALLATION)
(7) Install throttle cables in bracket.
(8) Connect throttle and speed control (if equipped)
cables to throttle lever.
(9) Connect vacuum lines for power brake booster,
LDP, EGR transducer, and speed control vacuum res-
ervoir (if equipped) at upper intake manifold fittings.
(10) Connect vacuum lines for purge solenoid and
PCV valve.
(11) Connect electrical connectors for MAP sensor,
throttle position sensor (TPS), and idle air control
(IAC) motor.
(12) Install air cleaner upper housing and air
intake tube to throttle body.
(13) Connect inlet air temperature sensor connec-
tor (Fig. 102).
(14) Connect negative cable to battery.
Fig. 104 Throttle Body Electrical Connectors -
Typical
1 - IDLE AIR CONTROL MOTOR CONNECTOR
2 - TPS CONNECTOR
Fig. 105 Upper Intake Manifold Support Bracket
1 - NUT - BRACKET TO CYLINDER HEAD COVER
2 - BOLT - BRACKET TO UPPER INTAKE MANIFOLD
3 - UPPER INTAKE MANIFOLD SUPPORT BRACKET
Fig. 106 Upper Intake Manifold Tightening Sequence
- 2.4L
RSENGINE 2.4L9-59
INTAKE MANIFOLD - UPPER (Continued)

INTAKE MANIFOLD - LOWER
REMOVAL
(1) Perform fuel system pressure release proce-
durebefore attempting any repairs.(Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY - STANDARD
PROCEDURE)
(2) Remove upper intake manifold. (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
REMOVAL)
CAUTION: Cover intake manifold openings to pre-
vent foreign material from entering engine.
(3) Disconnect fuel line. (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/QUICK CONNECT FIT-
TING - STANDARD PROCEDURE)
(4) Drain the cooling system. (Refer to 7 - COOL-
ING - STANDARD PROCEDURE)
(5) Remove heater supply and radiator upper
hoses at intake manifold.
(6) Disconnect coolant temperature sensor/fuel
injector wire harness connector.
(7) Remove lower intake manifold support bracket
upper bolts (Fig. 107).
(8) Loosen the lower intake manfold support
bracket lower bolt (Fig. 107).
(9) Disconnect fuel injector harness.
(10) Remove the bolts attaching the power steering
reservoir to manifold. Set reservoir aside.Do not
disconnect line from reservoir.
(11) Remove lower intake manifold fasteners (Fig.
108). Remove the manifold from engine.
(12) Inspect the manifold. (Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD - INSPECTION)
INSPECTION
(1) Check manifold surfaces for flatness with
straight edge. Surface must be flat within 0.15 mm
per 300 mm (0.006 in. per foot) of manifold length.
(2) Inspect manifold for cracks or distortion.
Replace manifold if necessary.
INSTALLATION
If the following items were removed, install and
torque to specifications:
²Fuel rail bolts - 22 N´m (200 in. lbs.)
²Coolant outlet connector bolts - 28 N´m (250 in.
lbs.)
²Coolant temperature sensor - 7 N´m (60 in. lbs.)
(1) Position a new gasket on cylinder head and
install lower manifold.
(2) Install and tighten intake manifold fasteners to
28 N´m (250 in. lbs.) in the sequence shown in (Fig.
108). Repeat procedure until all bolts are at specified
torque.
(3) Install lower intake manifold support bracket
bolts (Fig. 107) and tighten to:
²Bolts to intake 28 N´m (250 in. lbs.)
²Bolt to engine block 54 N´m (40 ft. lbs.)
(4) Position power steering reservoir on manifold
and install bolts.
(5) Connect the fuel line. (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/QUICK CONNECT FIT-
TING - STANDARD PROCEDURE)
(6) Connect coolant temperature sensor/fuel injec-
tor wiring harness electrical connector.
(7) Install the radiator upper and heater supply
hoses.
(8) Install the upper intake manifold. (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSTALLATION)
(9) Fill the cooling system. (Refer to 7 - COOLING
- STANDARD PROCEDURE)
Fig. 107 Lower Intake Manifold Support Bracket
1 - SUPPORT BRACKET
2 - BOLTS - UPPER TO MANIFOLD
3 - BOLT - LOWER TO ENGINE BLOCK
Fig. 108 Lower Intake Manifold Tightening
Sequence
9 - 60 ENGINE 2.4LRS

EXHAUST MANIFOLD
REMOVAL
(1) Raise vehicle and disconnect exhaust pipe from
the exhaust manifold.
(2) Disconnect upstream oxygen sensor connector
at the rear of exhaust manifold.
(3) Remove the bolts attaching the manifold to the
cylinder head.
(4) Remove exhaust manifold.
(5) Inspect the manifold. (Refer to 9 - ENGINE/
MANIFOLDS/EXHAUST MANIFOLD - INSPEC-
TION)
CLEANING
(1) Discard gasket (if equipped) and clean all sur-
faces of manifold and cylinder head.
INSPECTION
(1) Inspect manifold gasket surfaces for flatness
with straight edge. Surface must be flat within 0.15
mm per 300 mm (0.006 in. per foot) of manifold
length.
(2) Inspect manifolds for cracks or distortion.
Replace manifold as necessary.
INSTALLATION
(1) Install exhaust manifold with a new gasket.
Tighten attaching nuts in the sequence shown in
(Fig. 109) to 19 N´m (170 in. lbs.).
(2) Attach exhaust pipe to exhaust manifold and
tighten fasteners to 37 N´m (27 ft. lbs.).
(3) Install and connect the oxygen sensor. (Refer to
14 - FUEL SYSTEM/FUEL INJECTION/O2 SENSOR
- COMPONENT LOCATION)
TIMING BELT COVER(S)
REMOVAL
FRONT COVER - UPPER
(1) Remove upper timing belt cover fasteners (Fig.
110) and remove cover.
FRONT COVER - LOWER
(1) Remove crankshaft vibration damper (Refer to
9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL).
(2) Remove generator drive belt tensioner assem-
bly (Refer to 7 - COOLING/ACCESSORY DRIVE/
BELT TENSIONERS - REMOVAL).
(3) Remove timing belt front cover bolts (Fig. 110)
and remove covers.
REAR COVER
(1) Remove front covers.
(2) Remove engine mount bracket (Fig. 111).
(3) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
REMOVAL).
Fig. 109 Exhaust Manifold Tightening Sequence
Fig. 110 Front Timing Belt Covers
1 - BOLTS - UPPER FRONT COVER 6 N´m (50 in. lbs.)
2 - BOLTS - LOWER FRONT COVER 6 N´m (50 in. lbs.)
RSENGINE 2.4L9-61