Chrysler RG Voyager. Manual - part 927

(26) Connect the fuel line. (Refer to 14 - FUEL

SYSTEM/FUEL DELIVERY/QUICK CONNECT FIT-
TING - STANDARD PROCEDURE)

(27) Connect radiator lower and upper hoses.
(28) Install radiator fans. (Refer to 7 - COOLING/

ENGINE/RADIATOR FAN - INSTALLATION)

(29) Fill cooling system. (Refer to 7 - COOLING -

STANDARD PROCEDURE)

(30) Connect battery cables.
(31) Install air cleaner and inlet hose.
(32) Fill engine crankcase with proper oil to cor-

rect level.

(33) Start engine and run until operating temper-

ature is reached.

(34) Adjust transmission linkage, if necessary.

SPECIFICATIONS

2.4L ENGINE

GENERAL SPECIFICATIONS

DESCRIPTION

SPECIFICATION

Metric

Standard

Type

In-Line OHV, DOHC

Number of
Cylinders

4

Firing Order

1-3-4-2

Compression
Ratio

9.5:1

Max. Variation
Between
Cylinders

25%

Displacement

2.4 Liters

148 cu. in.

Bore

87.5 mm

3.445 in.

Stroke

101.0 mm

3.976 in.

Compression
Pressure

1172-1551 kPa

170-225 psi

CYLINDER BLOCK

DESCRIPTION

SPECIFICATION

Metric

Standard

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

DESCRIPTION

SPECIFICATION

Metric

Standard

Piston Diameter

87.456-87.474

mm

3.4431-3.4439

in.

Clearance @
24.6 mm (0.551
in.) from bottom
of skirt

0.018-0.0516

mm

0.0007-0.0020

in.

Weight

345-355 grams

12.17-12.52 oz.

Land Clearance
(Diametrical)

0.563-0.621

mm

0.022-0.024 in.

Piston Length

66.25 mm

2.608 in.

Piston Ring
Groove Depth
No. 1

3.946-4.045

mm

0.155-0.159 in.

Piston Ring
Groove Depth
No. 2

4.555-4.680

mm

0.179-0.184 in.

Piston Ring
Groove Depth
No. 3

4.108-4.220

mm

0.162-0.166 in.

PISTON PINS

DESCRIPTION

SPECIFICATION

Metric

Standard

Clearance in
Piston

0.005-0.018

mm

0.0002-0.0008

in.

Clearance in
Connecting Rod

Interference

Diameter

21.99822.003

mm

0.8660-0.8662

in.

End Play

None

Length

72.75-73.25

mm

2.864-2.883 in.

RS

ENGINE 2.4L

9 - 17

ENGINE 2.4L (Continued)

PISTON RINGS

DESCRIPTION

SPECIFICATION

Metric

Standard

Ring Gap-Top
Compression
Ring

0.25-0.51 mm

0.0098-0.020 in.

Wear Limit

0.8 mm

0.031 in.

Ring Gap-2nd
Compression
Ring

0.23-0.48 mm

0.009-0.018 in.

Wear Limit

0.8 mm

0.031 in.

Ring Gap-Oil
Control Steel
Rails

0.25-0.64 mm

0.009-0.025 in.

Wear Limit

1.0 mm

0.039 in.

Ring Side
Clearance-
Compression
Rings

0.030-0.080

mm

0.0011-0.0031

in.

Wear Limit

0.10 mm

0.004 in.

Ring Side
Clearance-Oil
Ring Pack

0.012-0.178

mm

0.0004-0.0070

in.

Ring Width-
Compression
Rings

1.47-1.50 mm

0.057-0.059 in.

Ring Width-Oil
Ring Pack

2.72–2.88 mm

0.107–0.1133

in.

CONNECTING ROD

DESCRIPTION

SPECIFICATION

Metric

Standard

Bearing
Clearance

0.025–0.071

mm

0.0009–0.0027

in.

Wear Limit

0.075 mm

0.003 in.

Bore Diameter-
Piston Pin

20.96–20.98

mm

0.8664-0.8667

in.

Bore Diameter-
Crankshaft End

52.993-53.007

mm

2.0863-2.0868

in.

Side Clearance

0.13–0.38 mm

0.005–0.015 in.

Wear Limit

0.40 mm

0.016 in.

Weight-Total
(Less Bearing)

565.8 grams

19.96 oz.

CRANKSHAFT

DESCRIPTION

SPECIFICATION

Metric

Standard

Connecting Rod
Journal
Diameter

49.984 - 50.000

mm

1.968 - 1.9685

in.

Main Bearing
Journal
Diameter

59.992 - 60.008

mm

2.362 - 2.3625

in.

Journal
Out-of-Round
(Max.)

0.0035 mm

0.0003 in.

Journal Taper
(Max.)

0.007 mm

0.0001 in.

End Play

0.09 - 0.24 mm

0.0035 - 0.0094

in.

Wear Limit

0.38 mm

0.015 in.

Main Bearing
Diametrical
Clearance

0.018 - 0.062

mm

0.0007 - 0.0024

in.

HYDRAULIC LASH ADJUSTER

DESCRIPTION

SPECIFICATION

Metric

Standard

Body Diameter

15.901 - 15.913

mm

0.626 - 0.6264

in.

Plunger Travel
Minimum (Dry)

3.0 mm

0.118 in.

CYLINDER HEAD CAMSHAFT BEARING BORE

DIAMETER

DSECRIPTION

SPECIFICATION

Metric

Standard

Journals No.1 -
6

26.020 - 26.041

mm

1.024 - 1.025 in.

9 - 18

ENGINE 2.4L

RS

ENGINE 2.4L (Continued)

CAMSHAFT

DESCRIPTION

SPECIFICATION

Metric

Standard

Journal
Diameter No.
1–6

25.976 - 25.995

mm

1.022 - 1.023 in.

Bearing
Clearance -
Diametrical

0.025 - 0.065

mm

0.0009 - 0.0025

in.

End Play

0.05 - 0.17 mm

0.0019 - 0.0066

in.

Lift (Zero Lash)

Intake

8.25 mm

(0.324 in.)

Exhaust

6.60 mm

(0.259 mm)

Intake Valve
Timing*

Closes (ABDC)

44.3°

Opens (ATDC)

6.2°

Duration

218°

Exhaust Valve
Timing*

Closes (ATDC)

0.8°

Opens (BBDC)

39.9°

Duration

220.7°

Valve Overlap

5.4°

*
All reading in crankshaft degrees at 0.5 mm (0.019
in.) valve lift.

CYLINDER HEAD

DESCRIPTION

SPECIFICATION

Metric

Standard

Material

Cast Aluminum

Gasket
Thickness
(Compressed)

0.71 mm

0.028 in.

VALVE SEAT

DESCRIPTION

SPECIFICATION

Metric

Standard

Angle

44.5 - 45°

Seat Diameter -
Intake

34.37 - 34.63

mm

1.353 - 1.363 in.

Seat Diameter -
Exhaust

27.06 - 27.32

mm

1.065 - 1.075 in.

Runout (Max.)

0.05 mm

0.002 in.

Valve Seat
Width - Intake
and Exhaust

0.9 - 1.3 mm

0.035 - 0.051 in.

Service Limit -

Intake

2.0 mm

0.079 in.

Service Limit -

Exhaust

2.5 mm

0.098 in.

VALVE GUIDE

DESCRIPTION

SPECIFICATION

Metric

Standard

Diameter I.D.

5.975 - 6.000

mm

0.235 - 0.236 in.

Guide Bore
Diameter

11.0 - 11.02

mm

0.4330 - 0.4338

in.

Guide Height
(spring seat to
guide tip)

13.25 - 13.75

mm

0.521 - 0.541 in.

VALVES

DESCRIPTION

SPECIFICATION

Metric

Standard

Face Angle -
Intake and
Exhaust

45 - 45.5°

Head Diameter
- Intake

34.67 - 34.93

mm

1.364 - 1.375

in.)

Head Diameter
- Exhaust

28.32 - 28.58

mm

1.114 - 1.125 in.

Valve Length
(Overall)

Intake

111.49 - 111.99

mm

4.389 - 4.409 in.

Exhaust

109.59 - 110.09

mm

4.314 - 4.334 in.

RS

ENGINE 2.4L

9 - 19

ENGINE 2.4L (Continued)

DESCRIPTION

SPECIFICATION

Metric

Standard

Valve Stem
Diameter

Intake

5.934 - 5.952

mm

0.2337 - 0.2344

in.

Exhaust

5.906 - 5.924

mm

0.2326 - 0.2333

in.

VALVE MARGIN

DESCRIPTION

SPECIFICATION

Metric

Standard

Intake

1.2 - 1.7 mm

0.047 - 0.066 in.

Service Limit

0.95 mm

(.0037 in.)

Exhaust

0.985 - 1.315

mm

0.038 - 0.051 in.

Service Limit

1.05 mm

.039 in.

VALVE STEM TIP HEIGHT

DESCRIPTION

SPECIFICATION

Metric

Standard

Intake

48.04 mm

1.891 in.

Exhaust

47.99 mm

1.889 in.

VALVE STEM TO GUIDE CLEARANCE

DESCRIPTION

SPECIFICATION

Metric

Standard

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.

VALVE SPRINGS

DESCRIPTION

SPECIFICATION

Metric

Standard

Free Length
(Approx.)

49.34 mm

1.943 in.

Nominal Force
(Valve Closed)

311 N @ 38.0

mm

70 lbs. @ 1.496

in.

Nominal Force
(Valve Open)

596 N ± 30.7

N@ 29.25 mm

134 lbs. @

1.152 in.

Installed Height

38.00 mm

1.496 in.

Number of Coils

7.8

Wire Diameter

3.61 mm

0.142 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.)

10.699 mm

0.421 in.

Outer Rotor
Thickness (Min.)

10.699 mm

0.421 in.

Outer Rotor
Clearance
(Max.)

0.039 mm

0.015 in.

Outer Rotor
Diameter (Min.)

85.924 mm

3.383 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.

9 - 20

ENGINE 2.4L

RS

ENGINE 2.4L (Continued)