torque CHRYSLER VOYAGER 2005 Service Manual

(21) Disconnect exhaust pipe from manifold (Fig.
7).
(22) Remove engine front mount and bracket from
engine. (Refer to 9 - ENGINE/ENGINE MOUNTING/
FRONT MOUNT - REMOVAL)
(23) Remove structural collar. (Refer to 9 -
ENGINE/ENGINE BLOCK/STRUCTURAL COVER -
REMOVAL)
(24) Remove rear engine mount bracket. (Refer to
9 - ENGINE/ENGINE MOUNTING/REAR MOUNT -
REMOVAL)
(25) Mark flex plate to torque converter and
remove torque converter bolts.
(26) Pinch-off power steering supply hose at pump.
Remove hose from pump.
(27) Remove and set aside the power steering
pump and bracket. Do not disconnect pressure line.
(28) Lower vehicle.
(29) Remove A/C lines at compressor and cap open-
ings.
(30) Remove engine ground straps (strap at engine
right mount and at starter).
(31) Raise vehicle enough to allow engine dolly
Special Tool 6135, cradle Special Tool 6710 with
Posts Special Tool 6848 to be installed under vehicle
(Fig. 8).
(32) Loosen cradle posts to allow movement for
proper positioning. Locate two rear posts (right side
of engine) into the holes on the engine bedplate.
Locate the two front posts (left side of engine) on the
oil pan rails (Fig. 8). Lower vehicle and position cra-
dle mounts until the engine is resting on mounts.Tighten mounts to cradle frame. This will keep
mounts from moving when removing or installing
engine and transmission.
(33) Install safety straps around the engine to cra-
dle. Tighten straps and lock.
(34) Lower vehicle so the weight ofONLY THE
ENGINE AND TRANSMISSIONare on the cradle.
(35) Remove engine and transmission mount bolts.
(36) Raise vehicle slowly. It may be necessary to
move the engine/transmission assembly with the
dolly to allow for removal around the body.
INSTALLATION - ENGINE ASSEMBLY
(1) Position engine and transmission assembly
under vehicle and slowly lower the vehicle over the
engine and transmission.
(2) Align engine and transmission mounts to
attaching points. Install mounting bolts at the right
(Fig. 9) and left mounts (Fig. 10).
(3) Remove safety straps.
(4) Slowly raise vehicle enough to remove the
engine dolly and cradle Special Tools 6135 and 6710.
(5) Install rear mount bracket and rear mount
through bolt. (Refer to 9 - ENGINE/ENGINE
MOUNTING/REAR MOUNT - INSTALLATION)
(6) Install the flex plate to torque converter bolts.
(7) Install structural collar. (Refer to 9 - ENGINE/
ENGINE BLOCK/STRUCTURAL COVER - INSTAL-
LATION)
(8) Install front mount bracket and front mount
through bolt. (Refer to 9 - ENGINE/ENGINE
MOUNTING/FRONT MOUNT - INSTALLATION)
(9) Connect exhaust system to manifold (Fig. 7).
(10) Install crossmember cradle plate (Fig. 6).
(11) Install new oil filter.
(12) Install power steering pump and bracket.
(13) Connect power steering supply line to pump
and remove pinch-off pliers.
(14) Connect A/C compressor hoses to compressor.
(15) Install accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION)
(16) Install axle shafts. (Refer to 3 - DIFFEREN-
TIAL & DRIVELINE/HALF SHAFT - INSTALLA-
TION)
(17) Install accessory drive belt splash shield.
(18) Install front wheels and tires.
(19) Remove plugs from transmission cooler hoses
and install transaxle oil cooler line service splice kit.
Refer to instructions included with kit.
(20) Connect the transaxle shift linkage and elec-
trical connectors.
(21) Connect heater hoses (Fig. 5).
(22) Install ground straps.
(23) Connect all engine and throttle body electrical
connections.
Fig. 7 Catalytic Converter to Exhaust Manifold
1 - CATALYTIC CONVERTER
2 - BOLT
3 - GASKET
4 - FLAG NUT
9 - 14 ENGINE 2.4LRS
ENGINE 2.4L (Continued)

VALVE SPRINGS
DESCRIPTION SPECIFICATION
Metric Standard
Free Length
(Approx.)48.4 mm 1.905 in.
Nominal Force
(Valve Closed)338 N @ 38.0
mm75.98 lbs. @
1.496 in.
Nominal Force
(Valve Open)607 N @ 29.75
mm136 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
DESCRIPTION SPECIFICATION
Metric Standard
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
DESCRIPTION SPECIFICATION
Metric Standard
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.
SPECIFICATIONS - TORQUE
DESCRIPTION N´m Ft.
Lbs.In.
Lbs.
Balance Shaft Carrier to
BlockÐBolts54 40 Ð
Balance Shaft Gear
CoverÐDouble Ended
Fastener12 Ð 105
Balance Shaft SprocketÐ
Bolt28 Ð 250
Balance Shaft Chain
TensionerÐBolts12 Ð 105
Balance Shaft Carrier
CoverÐBolts12 Ð 105
Camshaft SprocketÐBolt 101 75 Ð
Connecting Rod
CapÐBolts27 +
1¤4
turn20
+1¤4
turnÐ
Crankshaft Main Bearing
Cap/Bedplate
ÐM8 Bolts 28 250
ÐM11 Bolts 41 +
1¤4
Turn30
+1¤4
TurnÐ
Crankshaft Damper 136 100 Ð
Cylinder HeadÐBolts (Refer to 9 - ENGINE/
CYLINDER HEAD -
INSTALLATION)
Cylinder Head CoverÐ
Bolts12 Ð 105
Flex Plate to Crankshaft 95 70 Ð
Engine Mount Bracket
RightÐBolts61 45 Ð
Engine MountingÐBolts (Refer to 9 ENGINE/
ENGINE MOUNTING)
Exhaust Manifold to
Cylinder HeadÐBolts19 Ð 170
Exhaust Manifold Heat
ShieldÐBolts12 Ð 105
Intake Manifold - Lower
ÐBolts28 Ð 250
Intake Manifold -
UpperÐBolts28 Ð 250
Oil Filter 12 Ð 105
Oil PanÐBolts 12 Ð 105
Oil Pan DrainÐPlug 28 20 Ð
Oil Pressure Switch 21 Ð 190
9 - 20 ENGINE 2.4LRS
ENGINE 2.4L (Continued)

INSPECTION
(1) Cylinder head must be flat within 0.1 mm
(0.004 in.) (Fig. 14).
(2) Inspect camshaft bearing journals for scoring.
(3) Remove carbon and varnish deposits from
inside of valve guides with a reliable guide cleaner.
(4) Using a small hole gauge and a micrometer,
measure valve guides in 3 places top, middle and bot-
tom (Fig. 15). (Refer to 9 - ENGINE - SPECIFICA-
TIONS) Replace guides if they are not within
specification.
(5) Check valve guide height (Fig. 16).
INSTALLATION - CYLINDER HEAD
NOTE: The Cylinder head bolts should be examined
BEFORE reuse. If the threads are necked down, the
bolts must be replaced (Fig. 17).Necking can be checked by holding a scale or
straight edge against the threads. If all the threads
do not contact the scale, the bolt should be replaced.
(1) Before installing the bolts, the threads should
be coated with engine oil.
(2) Position cylinder head gasket on engine block
(Fig. 18).
(3) Install cylinder head on engine block.
(4) Tighten the cylinder head bolts in the sequence
shown in (Fig. 19). Using the 4 step torque turn
method, tighten according to the following values:
²First All to 34 N´m (25 ft. lbs.)
²Second All to 68 N´m (50 ft. lbs.)
²Third All to 68 N´m (50 ft. lbs.)
CAUTION: Do not use a torque wrench for the fol-
lowing step.
²Fourth Turn an additional 1/4 Turn,
Fig. 14 Checking Cylinder Head Flatness
1 - FEELER GAUGE
2 - STRAIGHT EDGE
Fig. 15 Checking Wear on Valve GuideÐTypical
1-TOP
2 - MIDDLE
3 - BOTTOM
4 - CUT AWAY VIEW OF VALVE GUIDE MEASUREMENT
LOCATIONS
Fig. 16 Valve Guide Height
1 - VALVE GUIDE
2 - 13.25 - 13.75 MM (0.521 - 0.541 IN.)
3 - SPRING SEAT
Fig. 17 Checking Bolts for Stretching (Necking)
1 - STRETCHED BOLT
2 - THREADS ARE NOT STRAIGHT ON LINE
3 - THREADS ARE STRAIGHT ON LINE
4 - UNSTRETCHED BOLT
RSENGINE 2.4L9-27
CYLINDER HEAD (Continued)

CAUTION: Do not nick shaft seal surface or seal
bore.
INSTALLATION
(1) Shaft seal surface must be free of varnish, dirt
or nicks. Polish with 400 grit paper if necessary.
(2) Install camshaft seals into cylinder head using
Special Tool MD-998306 until flush with head (Fig.
22).
(3) Install timing belt rear cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT COVER(S)
- INSTALLATION).
(4) Install camshaft sprockets. Hold each sprocket
with Special Tool 6847 and tighten center bolt to 101
N´m (75 ft. lbs.) (Fig. 20).
(5) Install timing belt and front covers (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT ANDSPROCKETS - INSTALLATION) (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT COVER(S)
- INSTALLATION).
CAMSHAFT(S)
DESCRIPTION
Both camshafts have six bearing journal surfaces
and two cam lobes per cylinder (Fig. 23). Flanges at
the rear journals control camshaft end play. Provision
for a cam position sensor is located on the intake
camshaft on the rear of the cylinder head. A hydro-
dynamic oil seal is used for oil control at the front of
the camshaft.
OPERATION
The camshaft is driven by the crankshaft via drive
sprockets and belt. The camshaft has precisely
machined lobes to provide accurate valve timing and
duration.
STANDARD PROCEDURE - MEASURING
CAMSHAFT END PLAY
(1) Oil camshaft journals and install camshaft
WITHOUTrocker arms. Install rear cam caps and
tighten screws to specified torque.
(2) Using a suitable tool, move camshaft as far
rearward as it will go.
Fig. 21 Camshaft Oil Seal - Removal With C-4679A
1 - SPECIAL TOOL C-4679
Fig. 22 Camshaft Seal - Installation
1 - SPECIAL TOOL MD-998306
Fig. 23 Camshafts
1 - CAMSHAFT BEARING CAPS
2 - PLUG
3 - CAMSHAFT
4 - CYLINDER HEAD
5 - CAMSHAFT OIL SEAL
RSENGINE 2.4L9-29
CAMSHAFT OIL SEAL(S) (Continued)

INSTALLATION
NOTE: Replace spark plug well seals and bolt
assemblies when installing a new cylinder head
cover gasket.
(1) Install new cylinder head cover gaskets and
spark plug well seals (Fig. 30).
(2) Replace cylinder head cover bolt assemblies.
CAUTION: Do not allow oil or solvents to contact
the timing belt as they can deteriorate the rubber
and cause tooth skipping.
(3) Apply MopartEngine RTV GEN II at the
camshaft cap corners and at the top edges of the 1/2
round seal (Fig. 31).
(4) Install cylinder head cover assembly to cylin-
der head. Install all bolts, ensuring the single (1)
stud used to attach the upper intake manifold sup-
port bracket is located in the #8 location as shown in
torque sequence diagram (Fig. 32). Tighten bolts in
sequence shown in (Fig. 32). Using a 3 step torque
method as follows:
(a) Tighten all bolts to 4.5 N´m (40 in. lbs.).
(b) Tighten all bolts to 9.0 N´m (80 in. lbs.).
(c) Tighten all bolts to 12 N´m (105 in. lbs.).
(5) Install ignition coil and spark plug wires.
Tighten fasteners to 12 N´m (105 in. lbs.).
(6) If the PCV valve was removed, apply Mopart
Thread Sealant with Teflon to threads and install
valve to cylinder head cover. Tighten PCV valve to 8
N´m (70 in. lbs.).
(7) Connect PCV and make-up air hoses to cylin-
der head cover.(8) Install upper intake manifold. (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSTALLATION)
Fig. 30 Spark Plug Well Seals
Fig. 31 Sealer Locations
1 ± SEALER LOCATION
Fig. 32 Cylinder Head Cover Tightening Sequence
(Typical Cover Shown)
9 - 32 ENGINE 2.4LRS
CYLINDER HEAD COVER (Continued)

thrust faces of No. 3 main bearing. DO NOT nick
crank pin or bearing fillets. After grinding, remove
rough edges from crankshaft oil holes and clean out
all passages.
CAUTION: With the nodular cast iron crankshafts, it
is important that the final paper or cloth polish be
in the same direction as normal rotation in the
engine.
INSTALLATION - CRANKSHAFT
CRANKSHAFT MAIN BEARING LOCATION
The crankshaft is supported in five main bearings.
All upper bearing shells in the crankcase have oil
grooves and holes. All lower bearing shellsexcept
for the thrust bearing half have oil grooves and holes
(Fig. 47). Crankshaft end play is controlled by a
flanged bearing on the number three main bearing
journal.(1) Install the main bearing upper shells with the
lubrication groove and oil hole in the engine block
(Fig. 48).
(2) Make certain oil holes in block line up with oil
hole in bearings and bearing tabs seat in the block
tab slots.
NOTE: If the crankshaft is sent out for machine
work, it must be balenced as an assembly with the
target ring installed.
(3) Clean crankshaft and target ring with
MOPARtbrake parts cleaner and dry with com-
pressed air to ensure that the crankshaft mating sur-
face and target ring mounting holes are free from oil
and lock patch debris.
NOTE: Always use NEW mounting screws whether
installing original or new target ring.
(4) InstallNEWmounting screws finger tight
starting with the #1 location. (Fig. 49) Make sure
engagment occurs with the shoulder of the screw and
mounting hole before starting all other screws.
(5) Torque all mounting screws with T30 torx bit
to 13 Nm (110 in-lbs) following the torque sequence.
CAUTION: Use extreme care when handling crank-
shaft. Tone wheel damage can occur if crankshaft is
mis-handled.
CAUTION: Do not get oil on the bed plate mating
surface. It will affect the ability of the sealer to seal
the bed plate to cylinder block.
Fig. 46 Crankshaft Journal Measurements - Typical
Fig. 47 Main Bearing Identification
1 - OIL GROOVE
2 - MAIN BEARINGS
3 - OIL HOLE
4 - LOWER THRUST BEARING PLAIN (NO OIL HOLE OR
GROOVE)
Fig. 48 Installing Main Bearing Upper Shell
1 - LUBRICATION GROOVES
2 - OIL HOLES
RSENGINE 2.4L9-39
CRANKSHAFT (Continued)

(6) Oil the bearings and journals. Install crank-
shaft in the engine block.
CAUTION: Use only MoparTBed Plate Sealant on
the bed plate or damage may occur to the engine.
(7) Install lower main bearings into main bearing
cap/bed plate. Make certain the bearing tabs are
seated into the bed plate slots and apply oil.
(8) Apply 1.5 to 2.0 mm (0.059 to 0.078 in.) bead of
MopartBed Plate Sealant to bed plate as shown in
(Fig. 50).
(9) Install the main bearing/bed plate into engine
block.
(10) Before installing the bolts the threads should
be oiled with clean engine oil, wipe off any excess oil.
(11) Install main bearing bed plate to engine
block bolts 11, 17, and 20 finger tight. Tighten these
bolts down together until the bed plate contacts the
cylinder block.
(12) To ensure correct thrust bearing alignment,
perform the following steps:
²Step 1: Rotate crankshaft until number 4 piston
is at TDC.
²Step 2: Move crankshaft rearward to limits of
travel.
²Step 3: Then, move crankshaft forward to limits
of travel.
²Step 4: Wedge an appropriate tool between the
rear of the cylinder block(NOT BED PLATE)and
the rear crankshaft counterweight. This will hold the
crankshaft in it's furthest forward position.²Step 5: Install and tighten bolts (1±10) in
sequence shown in (Fig. 51) to 41 N´m (30 ft. lbs.).
²Step 6: Remove wedge tool used to hold crank-
shaft.
(13) Tighten bolts (1±10) again to 41 N´m (30 ft.
lbs.) in sequence shown in (Fig. 51).
CAUTION: Do Not use a torque wrench for the fol-
lowing step.
Fig. 49 Target Ring Torque SequenceFig. 50 Bed Plate Sealing
Fig. 51 Main Bearing Caps/Bed Plate Bolt Torque
Sequence
9 - 40 ENGINE 2.4LRS
CRANKSHAFT (Continued)

(14) Turn bolts (1±10) an additional 1/4 turn in
sequence shown in (Fig. 51).
(15) Install main bearing bed plate to engine
block bolts (11±20), and torque each bolt to 28 N´m
(250 in. lbs.) in sequence shown in. (Fig. 51)
(16) Tighten bolts (11±20) again to 28 N´m (250 in.
lbs.) in sequence shown in (Fig. 51).
(17) After the main bearing bed plate is installed,
check the crankshaft turning torque. The turning
torque should not exceed 5.6 N´m (50 in. lbs.).
(18) Check crankshaft end play (Refer to 9 -
ENGINE/ENGINE BLOCK/CRANKSHAFT - STAN-
DARD PROCEDURE).
(19) Install connecting rod bearings and caps.Do
Not Reuse Connecting Rod Bolts.Torque connect-
ing rod bolts to 27 N´m (20 ft. lbs.) plus 1/4 turn.
(20) Install balance shafts and housing assembly
(Refer to 9 - ENGINE/VALVE TIMING/BALANCE
SHAFT - INSTALLATION).
(21) Install the oil pump (Refer to 9 - ENGINE/
LUBRICATION/OIL PUMP - INSTALLATION).
(22) Install oil pump pick-up tube. Torque fastener
to 28 N´m (20 ft.. lbs.).
(23) Install the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - INSTALLATION).
(24) Install crankshaft position sensor.
(25) Install cylinder head if it was removed (Refer
to 9 - ENGINE/CYLINDER HEAD - INSTALLA-
TION).
(26) Install the timing belt rear cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT COVER(S)
- INSTALLATION).
(27) Install crankshaft sprocket (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT AND
SPROCKETS - INSTALLATION).
(28) Install the timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
INSTALLATION).
(29) Install the timing belt front covers (Refer to 9
- ENGINE/VALVE TIMING/TIMING BELT COV-
ER(S) - INSTALLATION).
(30) Install engine mount support bracket.
(31) InstallNEWoil filter.
(32) Install crankshaft rear oil seal (Refer to 9 -
ENGINE/ENGINE BLOCK/CRANKSHAFT OIL
SEAL - REAR - INSTALLATION).
(33) Install flex plate. Apply MopartLock & Seal
Adhesive to bolt threads and tighten to 95 N´m (70
ft. lbs.).
(34) Attach transaxle to engine. Tighten attaching
bolts to 101 N´m (75 ft. lbs.).
(35) Install the engine assembly (Refer to 9 -
ENGINE - INSTALLATION).CRANKSHAFT OIL SEAL -
FRONT
REMOVAL
(1) Remove the crankshaft vibration damper.
(Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL)
(2) Remove timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL)
(3) Remove crankshaft sprocket using Special Tool
6793 and insert C-4685-C2 (Fig. 52).
CAUTION: Do not nick shaft seal surface or seal
bore.
(4) Using Tool 6771 to remove front crankshaft oil
seal (Fig. 53). Be careful not to damage the seal sur-
face of cover.
Fig. 52 Crankshaft Sprocket - Removal
1 - SPECIAL TOOL 6793
2 - SPECIAL TOOL C-4685±C2
3 - CRANKSHAFT SPROCKET
Fig. 53 Front Crankshaft Oil Seal - Removal
1 - SPECIAL TOOL 6771
2 - REAR TIMING BELT COVER
RSENGINE 2.4L9-41
CRANKSHAFT (Continued)

(6) Rotate crankshaft so that the connecting rod
journal is on the center of the cylinder bore. Lubri-
cate connecting rod journal with clean engine oil.
(7) Install connecting rod upper bearing half into
connecting rod. Install Special Tool 8189, connecting
rod guides onto connecting rod (Fig. 64).
(8) Tap the piston down in cylinder bore, using a
hammer handle. At the same time, guide connecting
rod into position on connecting rod journal.
(9) Remove Special Tool 8189, connecting rod
guides.
NOTE: The connecting rod cap bolts should not be
reused.
(10) Before installing theNEWbolts, the threads
should be coated with clean engine oil.
(11) Install connecting rod lower bearing half into
connecting rod cap. Install connecting rod cap.(12) Install each bolt finger tight then alternately
torque each bolt to assemble the cap properly.
(13) Tighten the connecting rod bolts using the 2
step torque-turn method. Tighten according to the
following values:
CAUTION: Do not use a torque wrench for the sec-
ond step.
1. Tighten the bolts to 27 N´m (20 ft. lbs.).
2. Tighten the connecting rod bolts an additional
1/4 TURN.
(14) Using a feeler gauge, check connecting rod
side clearance (Fig. 67). (Refer to 9 - ENGINE -
SPECIFICATIONS) for connecting rod side clearance.
(15) Install Balance Shaft Carrier Assembly (Refer
to 9 - ENGINE/VALVE TIMING/BALANCE SHAFT
CARRIER - INSTALLATION).
(16) Install oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION).
(17) Install cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - INSTALLATION).
CONNECTING ROD BEARINGS
STANDARD PROCEDURE
CONNECTING ROD - FITTING
(1) For measuring connecting rod bearing clear-
ance procedure and use of Plastigage(Refer to 9 -
ENGINE - STANDARD PROCEDURE). For bearing
clearance refer to Engine Specifications. (Refer to 9 -
ENGINE - SPECIFICATIONS)
Fig. 65 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. 66 PistonÐInstallation
Fig. 67 Checking Connecting Rod Side Clearance -
Typical
9 - 46 ENGINE 2.4LRS
PISTON & CONNECTING ROD (Continued)

NOTE: The rod bearing bolts should not be reused.
(2) Before installing theNEWbolts the threads
should be oiled with clean engine oil.
(3) Install each bolt finger tight then alternately
torque each bolt to assemble the cap properly.
(4) Tighten the connecting rod bolts using the 2
step torque-turn method. Tighten according to the
following values:
CAUTION: Do not use a torque wrench for the sec-
ond step.
1. Tighten the bolts to 27 N´m (20 ft. lbs.).
2. Tighten the connecting rod bolts an additional
1/4 TURN.
(5) Using a feeler gauge, check connecting rod side
clearance (Fig. 68). Refer to clearance specifications
(Refer to 9 - ENGINE - SPECIFICATIONS).
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. 69).
Refer to Engine Specifications.
(2) Check piston ring to groove side clearance (Fig.
70). Refer to Engine Specifications.
REMOVAL
(1) Using a suitable ring expander, remove upper
and intermediate piston rings (Fig. 71).
(2) Remove the upper oil ring side rail, lower oil
ring side rail and then oil ring expander from piston.(3) Clean ring grooves of any carbon deposits.
INSTALLATION
NOTE: The identification mark on face of upper and
intermediate piston rings must point toward top of
piston.
Install rings with manufacturers identification
mark facing up, to the top of the piston (Fig. 72).
CAUTION: Install piston rings in the following
order:
1. Oil ring expander.
2. Upper oil ring side rail.
3. Lower oil ring side rail.
Fig. 68 Connecting Rod Side Clearance - Typical
Fig. 69 Piston Ring Gap
1 - FEELER GAUGE
Fig. 70 Piston Ring Side Clearance
1 - FEELER GAUGE
RSENGINE 2.4L9-47
CONNECTING ROD BEARINGS (Continued)