Chrysler Voyager 2001-2003 2.4L Engine Bolt Torque Specifications & Fastener Values
Chrysler Voyager 2001-2003

Chrysler Voyager 2001-2003 2.4L Engine Bolt Torque Specifications

Detailed torque specifications for various bolts on the 2.4L engine of the 2001-2003 Chrysler Voyager, including cylinder head, main bearing, connecting rod, and intake manifold bolts.

Updated

Important Information

Safety guidelines and reference information for proper torque application

Quick Reference Guide
ft-lbs → Nm
× 1.356
ft-lbs → kg-m
× 0.138
Nm → ft-lbs
× 0.738
in-lbs → ft-lbs
× 0.083

Common Torque Patterns

Star Pattern

Used for wheels and other circular bolt patterns

Star Pattern torque pattern diagram showing proper bolt tightening sequence
Cross Pattern

Used for gaskets and cover plates

Cross Pattern torque pattern diagram showing proper bolt tightening sequence
Sequential Pattern

Used for head bolts and other critical components

Sequential Pattern torque pattern diagram showing proper bolt tightening sequence

Common Mistakes to Avoid

Over-tightening

Exceeding the specified torque value can stretch or break fasteners, damage threads, or crack components.

Prevention:

Always use a calibrated torque wrench and follow specifications exactly.

Incorrect Torque Sequence

Tightening bolts in the wrong order can cause uneven pressure distribution and potential leaks or damage.

Prevention:

Follow the manufacturer's specified torque sequence pattern.

Dirty Threads

Dirt, rust, or old thread locker can affect torque readings and proper fastener tension.

Prevention:

Clean and inspect all threads before assembly. Use new thread locker if specified.

Reusing TTY Bolts

Torque-to-yield bolts are designed to stretch and must not be reused.

Prevention:

Always replace TTY bolts with new ones. They are single-use only.

Dry vs. Lubricated

Not accounting for whether torque specs are for dry or lubricated fasteners can lead to incorrect tension.

Prevention:

Check if specs are for dry or lubricated threads. Use specified lubricant when required.

Recommended Tools

Torque Wrench (1/4" Drive)

Range: 2-25 ft-lbs
Small fasteners, delicate components

Torque Wrench (3/8" Drive)

Range: 10-100 ft-lbs
Most common automotive fasteners

Torque Wrench (1/2" Drive)

Range: 30-250 ft-lbs
Large fasteners, wheels

Angle Gauge

Torque-to-yield (TTY) bolts

Torque Wrench Care

  • Calibrate annually or after 5,000 clicks
  • Store at lowest setting
  • Keep clean and lubricated

Search Specifications

Search by component name, bolt size, or description

Torque Calculator

Convert between different torque units

Cylinder Head

Fasteners related to securing the cylinder head to the engine block, ensuring proper sealing for combustion and coolant/oil passages.

1

Cylinder Head Bolts

M11 x 1.5
Important Notes
Always follow the manufacturer's recommended tightening sequence. These bolts are typically torque-to-yield and require an angle tightening step after the initial torque. Final angle value may vary, check with service manual.

Crankshaft And Rotating Assembly

Fasteners related to the crankshaft, connecting rods, and flywheel.

1

Main Bearing Bolts

M12 x 1.75
Torque Value
105 ft-lbs (142 N·m)
Important Notes
Apply engine oil to threads and under bolt heads. Tighten bolts in sequence from center outward.
2

Connecting Rod Nuts

M9 x 1.25
Important Notes
Apply engine oil to threads and under bolt heads. Often requires an additional angle tightening after initial torque
3

Flywheel Bolts

M10 x 1.5
Torque Value
75 ft-lbs (101 N·m)
Important Notes
Apply thread locker to bolt threads. Use a star pattern when tightening.
4

Crankshaft Pulley/Harmonic Balancer Bolt

M14 x 1.5
Torque Value
132 ft-lbs (180 N·m)
Important Notes
Apply thread locker to bolt threads. Use a holding tool to prevent crankshaft rotation.

Oil System

Fasteners related to the oil pan and oil pump, ensuring proper sealing and oil pressure.

1

Oil Pan Bolts

M6 x 1.0
Torque Value
8.75 ft-lbs (12 N·m)
Important Notes
Torque value is equal to 105 in-lbs. Tighten using a crisscross pattern.
2

Oil Pump Mounting Bolts

M6 x 1.0
Torque Value
6.67 ft-lbs (9 N·m)
Important Notes
Torque value is equal to 80 in-lbs. Tighten all bolts evenly.

Valve Train

Fasteners related to the valve cover, camshafts, rocker arms, and timing components.

1

Valve Cover Bolts

M6 x 1.0
Torque Value
8.75 ft-lbs (12 N·m)
Important Notes
Torque value is equal to 105 in-lbs. Tighten bolts in a crisscross pattern.
2

Camshaft Sprocket Bolt

M10 x 1.25
Torque Value
75 ft-lbs (101 N·m)
Important Notes
Use a camshaft holding tool to prevent rotation when torquing.
3

Camshaft Bearing Cap Bolts

M6 x 1.0
Torque Value
7 ft-lbs (9.5 N·m)
Important Notes
Torque value is equal to 84 in-lbs. Tighten evenly and in sequence.
4

Rocker Arms/Shafts Bolts

M8 x 1.25
Torque Value
21 ft-lbs (28 N·m)
Important Notes
Tighten evenly and in sequence

Timing System

Fasteners related to the timing belt/chain tensioner and idler pulley.

1

Timing Belt/Chain Tensioner Bolt

M8 x 1.25
Torque Value
21 ft-lbs (28 N·m)
Important Notes
Tighten to specified torque.
2

Timing Belt/Chain Idler Pulley Bolt

M10 x 1.25
Torque Value
30 ft-lbs (40 N·m)
Important Notes
Ensure correct pulley position before tightening.

Intake And Exhaust

Fasteners related to the intake manifold, throttle body, exhaust manifold, and EGR valve.

1

Intake Manifold Bolts

M6 x 1.0
Torque Value
8.75 ft-lbs (12 N·m)
Important Notes
Torque value is equal to 105 in-lbs. Tighten in a crisscross pattern. Ensure all mating surfaces are clean.
2

Exhaust Manifold/Headers Bolts

M8 x 1.25
Torque Value
18 ft-lbs (24 N·m)
Important Notes
Use new gasket and tighten in a star pattern.
3

Throttle Body Bolts

M6 x 1.0
Torque Value
8.75 ft-lbs (12 N·m)
Important Notes
Torque value is equal to 105 in-lbs. Tighten evenly.
4

EGR Valve Bolts

M6 x 1.0
Torque Value
8.75 ft-lbs (12 N·m)
Important Notes
Torque value is equal to 105 in-lbs. Tighten evenly.

Fuel System

Fasteners related to the fuel rail and injectors.

1

Fuel Rail Bolts

M6 x 1.0
Torque Value
8.75 ft-lbs (12 N·m)
Important Notes
Torque value is equal to 105 in-lbs. Tighten evenly.
2

Fuel Injector Bolts

M6 x 1.0
Torque Value
8.75 ft-lbs (12 N·m)
Important Notes
Torque value is equal to 105 in-lbs. Tighten evenly.

Ignition System

Fasteners related to the ignition coils.

1

Ignition Coil Bolts

M6 x 1.0
Torque Value
8.75 ft-lbs (12 N·m)
Important Notes
Torque value is equal to 105 in-lbs. Tighten evenly.

Cooling System

Fasteners related to the water pump, water pump pulley and thermostat housing.

1

Water Pump Bolts

M6 x 1.0
Torque Value
8.75 ft-lbs (12 N·m)
Important Notes
Torque value is equal to 105 in-lbs. Tighten evenly.
2

Water Pump Pulley Bolts

M6 x 1.0
Torque Value
8.75 ft-lbs (12 N·m)
Important Notes
Torque value is equal to 105 in-lbs. Tighten evenly.
3

Thermostat Housing Bolts

M6 x 1.0
Torque Value
8.75 ft-lbs (12 N·m)
Important Notes
Torque value is equal to 105 in-lbs. Tighten evenly.

Accessory Drive

Fasteners related to the serpentine/accessory drive belt tensioner.

1

Serpentine/Accessory Drive Belt Tensioner Bolt

M8 x 1.25
Torque Value
21 ft-lbs (28 N·m)
Important Notes
Tighten to specified torque.

Spark Plugs

Fasteners related to spark plugs.

1

Spark Plugs

M14 x 1.25
Torque Value
20 ft-lbs (27 N·m)
Important Notes
Tighten spark plugs to specified torque.

Troubleshooting Guide

Common issues, diagnostic steps, and prevention guidelines

Common Issues

Bolt stretching, stripped threads, uneven torque patterns

Loose Components

Symptoms:
  • Rattling or vibration noises
  • Visible movement in components
  • Uneven panel gaps
Solutions:
  • Clean threads and mounting surfaces
  • Replace damaged fasteners
  • Apply proper torque in sequence
  • Use thread locker if specified

Stripped Fasteners

Symptoms:
  • Unable to achieve proper torque
  • Fastener spins freely
  • Visible thread damage
Solutions:
  • Use thread repair kit if appropriate
  • Install thread insert (HeliCoil)
  • Replace component if threaded hole is damaged
  • Upgrade to higher grade fastener if recommended

Overtightened Components

Symptoms:
  • Cracked or deformed parts
  • Broken fasteners
  • Compressed gaskets or seals
Solutions:
  • Replace damaged components
  • Use new fasteners
  • Follow proper torque sequence
  • Verify correct torque specifications

Diagnostic Steps

Visual inspection, torque verification, thread assessment

1

Visual Inspection

Inspect the affected area for any visible signs of damage or wear

  • Check for cracks or deformation
  • Look for signs of excessive wear
  • Verify proper fastener installation
2

Torque Verification

Verify the torque applied to the fasteners

  • Check the torque wrench calibration
  • Verify the torque specification
  • Compare the applied torque to the specification
3

Thread Assessment

Assess the condition of the threads

  • Check for signs of thread damage
  • Verify the thread type and size
  • Check for proper thread engagement

Prevention Guidelines

Best practices, maintenance tips, tool care

Best Practices

  • Always follow the recommended torque specification
  • Use the correct type and size of fasteners
  • Verify the torque wrench calibration regularly

Maintenance Tips

  • Regularly inspect the affected area for signs of wear or damage
  • Replace damaged or worn-out components promptly
  • Keep the work area clean and organized

Tool Care

  • Regularly clean and maintain the torque wrench
  • Store the torque wrench in a dry and secure location
  • Verify the torque wrench calibration before each use

Frequently Asked Questions

Find answers to common questions about torque specifications

Q1

Why is it important to use the correct torque specifications?

Using the correct torque specifications ensures that bolts are tightened enough to properly clamp components together, preventing leaks, vibrations, and potential component failure. Over-tightening can damage threads or deform parts, while under-tightening can lead to loosening over time, causing engine issues or even component separation. For example, overtightening a cylinder head bolt can warp the head, causing a blown head gasket. Correct torque also ensures even pressure distribution.

Q2

What happens if I over-tighten or under-tighten bolts on my 2.4L engine?

Over-tightening can stretch or break bolts, strip threads in aluminum engine blocks, or damage gaskets and components. Under-tightening can cause parts to vibrate loose, leading to leaks, increased wear, and potentially catastrophic failure, especially with critical components like the connecting rods or crankshaft. For example, if a connecting rod bolt is under-torqued, it can lead to a rod knock and eventually engine seizure.

Q3

Do I need to use new bolts when working on my 2.4L engine?

It's generally recommended to use new bolts, especially for critical components like cylinder head bolts, connecting rod bolts, and main bearing cap bolts. These bolts often stretch during initial use and may not provide the correct clamping force if reused. Additionally, some bolts are torque-to-yield (TTY), designed to stretch when properly torqued and must NEVER be reused. Consult your specific repair manual for the 2.4L engine in your 2001-2003 Voyager for specific guidance. For example, head bolts on this engine are often recommended for replacement with each head removal.

Q4

What is 'torque-to-yield' (TTY) and how does it affect my 2.4L engine?

Torque-to-yield bolts are designed to stretch slightly when torqued, achieving a specific clamping force. These bolts must not be reused as they're stretched to their yield point upon initial tightening. The 2.4L engine in the Voyager may utilize TTY bolts for certain applications, specifically cylinder head bolts. Refer to the repair manual for clarification on which bolts are TTY. Always replace TTY bolts with new ones. Attempting to re-use them will likely lead to improper torque and engine failure.

Q5

What tools do I need to properly torque the bolts on my 2.4L engine?

You will need a calibrated torque wrench, sockets of the appropriate sizes for the fasteners, and potentially a torque angle gauge if some bolts require torque-angle tightening (TTY). It is critical to ensure your torque wrench is accurate. Always follow the manufacturer's specified torque sequence. Failure to do so can result in improper component sealing and damage. For example, using an impact wrench instead of a hand torque wrench for sensitive engine components can lead to overtightening and component failure.

Environmental Considerations

Temperature, humidity, and seasonal effects on torque specifications

Temperature Effects

Includes: High Heat, Cold Weather, Thermal Cycling

Temperature can significantly impact torque values and fastener behavior

Cold Weather

Effects:
  • Increased material brittleness
  • Higher torque required due to thread contraction
  • Reduced thread lubricant effectiveness
Recommendations:
  • Allow components to warm to room temperature when possible
  • Consider using winter-grade thread lubricants
  • Check torque values more frequently during winter months

Hot Weather

Effects:
  • Thermal expansion of components
  • Decreased friction in threads
  • Accelerated lubricant breakdown
Recommendations:
  • Check torque when components are at normal operating temperature
  • Use temperature-resistant thread lockers
  • Consider re-torquing after heat cycles

Humidity and Corrosion

Covers: Rust Prevention, Salt Exposure, Moisture Control

Moisture and corrosion can affect fastener integrity and torque values

High Humidity

Effects:
  • Accelerated corrosion formation
  • Reduced friction coefficient
  • Potential thread seizing
Prevention:
  • Use corrosion-resistant fasteners
  • Apply appropriate anti-seize compounds
  • Maintain proper protective coatings

Salt Exposure

Effects:
  • Rapid corrosion development
  • Thread damage
  • Seized fasteners
Prevention:
  • Regular underbody washing
  • Use of sacrificial anodes where appropriate
  • Application of protective coatings

Seasonal Maintenance

Spring, Summer, Fall, and Winter maintenance schedules

Spring

  • Inspect for winter damage
  • Clean and protect exposed fasteners
  • Check torque on critical components

Summer

  • Monitor heat-affected components
  • Check expansion-related loosening
  • Inspect cooling system mounts

Fall

  • Prepare for winter conditions
  • Apply corrosion protection
  • Verify all fasteners are properly torqued

Winter

  • More frequent inspection of critical fasteners
  • Check for salt damage
  • Monitor suspension component torque

Related Resources

Tools, service procedures, and technical bulletins

Recommended Tools

Torque Wrench (1/2-inch drive)

A calibrated torque wrench is essential for achieving precise bolt torque specifications.

  • Measures torque in foot-pounds (ft-lb) or Newton-meters (Nm)
  • Click-type or digital readout for accurate settings
Learn more

Torque Wrench (3/8-inch drive)

A smaller torque wrench is useful for lower torque applications.

  • Measures torque in inch-pounds (in-lb) or Newton-meters (Nm)
  • Click-type or digital readout for accurate settings
Learn more

Socket Set (Standard and Metric)

A comprehensive socket set is needed to fit various bolt head sizes found on the 2.4L engine.

  • Standard (SAE) and metric sizes
  • Variety of depths and drive sizes
Learn more

Socket Extensions

Extensions provide extra reach for bolts in recessed or hard-to-access areas.

  • Various lengths for different applications
  • Helps reach difficult bolts
Learn more

Universal Joint

A universal joint allows the socket to be used at an angle, helpful in tight spaces.

  • Enables socket access at angles
  • Assists in reaching hard to access fasteners
Learn more

Thread Lubricant (Engine Assembly Lube/Anti-Seize)

Engine assembly lube or anti-seize compound ensures proper torque readings and prevents seizing.

  • Reduces friction
  • Prevents galling and seizing
Learn more
Service Procedures

Cylinder Head Bolt Torque Procedure

This procedure details how to properly torque the cylinder head bolts on the 2.4L engine.

  • Clean all bolt threads and cylinder head bolt holes.
  • Apply a light coat of engine assembly lube or anti-seize to the threads of the bolts.
  • Install all cylinder head bolts by hand, tightening them finger tight.
  • Torque the bolts in the specified sequence, in three stages. Stage 1: Torque all bolts to 22 ft-lb, Stage 2: Torque all bolts to 45 ft-lb. Stage 3: Tighten all bolts an additional 90 degrees.
  • Verify all bolts are tightened to specification.
  • Recheck all bolts after running the engine to operating temperature and allowing it to cool down.
View full procedure

Intake Manifold Bolt Torque Procedure

This procedure details how to properly torque the intake manifold bolts on the 2.4L engine.

  • Clean all bolt threads and intake manifold bolt holes.
  • Apply a light coat of engine assembly lube or anti-seize to the threads of the bolts.
  • Install all intake manifold bolts by hand, tightening them finger tight.
  • Torque all bolts to 15 ft-lb in the specified sequence.
  • Verify all bolts are tightened to specification.
View full procedure

Exhaust Manifold Bolt Torque Procedure

This procedure details how to properly torque the exhaust manifold bolts on the 2.4L engine.

  • Clean all bolt threads and exhaust manifold bolt holes.
  • Apply a light coat of anti-seize to the threads of the bolts.
  • Install all exhaust manifold bolts by hand, tightening them finger tight.
  • Torque all bolts to 23 ft-lb in the specified sequence.
  • Verify all bolts are tightened to specification.
View full procedure

Connecting Rod Bolt Torque Procedure

This procedure details how to properly torque the connecting rod bolts on the 2.4L engine.

  • Clean all bolt threads and connecting rod bolt holes.
  • Apply a light coat of engine assembly lube or anti-seize to the threads of the bolts.
  • Install all connecting rod bolts by hand, tightening them finger tight.
  • Torque all bolts to 20 ft-lb, then an additional 60 degrees in the specified sequence.
  • Verify all bolts are tightened to specification.
View full procedure

Main Bearing Cap Bolt Torque Procedure

This procedure details how to properly torque the main bearing cap bolts on the 2.4L engine.

  • Clean all bolt threads and main bearing cap bolt holes.
  • Apply a light coat of engine assembly lube or anti-seize to the threads of the bolts.
  • Install all main bearing cap bolts by hand, tightening them finger tight.
  • Torque the bolts in the specified sequence. Stage 1: Torque all bolts to 25 ft-lb. Stage 2: Torque the bolts an additional 45 degrees.
  • Verify all bolts are tightened to specification.
View full procedure
Technical Service Bulletins

Engine Oil Leakage from Cylinder Head Area

2002-05-15

Some 2001-2003 2.4L engines may experience oil leakage from the cylinder head gasket area due to improper bolt torque or gasket material issues.

2001-2003

Resolution: Verify the cylinder head bolts are torqued to the correct specifications. Replace the cylinder head gasket if necessary and retorque according to the service manual's torque sequence.

Excessive Engine Noise Due to Loose Exhaust Manifold Bolts

2003-01-10

Reports of excessive engine noise due to loose exhaust manifold bolts on 2.4L equipped vehicles have been noted. This can lead to exhaust leaks and noise.

2001-2003

Resolution: Inspect and tighten the exhaust manifold bolts to the specified torque. Replace the exhaust manifold gasket if it is damaged.

Connecting Rod Bolt Failure/Loosening

2002-11-20

Some 2.4L engines have experienced connecting rod bolt failure or loosening, leading to engine damage. This may be due to over-tightening or improper installation.

2001-2002

Resolution: When servicing the connecting rod bolts, ensure that the correct torque and angle specifications are followed exactly. Replace the bolts if any damage is detected.

About the Author

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Alan Montanye - Automotive Technical Specialist
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Alan Montanye

Automotive Technical Specialist

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