fuel CHRYSLER VOYAGER 2001 Service Manual

INSPECTION
Check manifold for:
²Damage and cracks.
²Mounting surface distortion by using a straight-
edge and thickness gauge.
INSTALLATION - 3.8L
(1) If the following components were removed from
manifold, install and tighten to specifications:
²MAP sensor - 3.4 N´m (30 in. lbs.)
²Throttle cable bracket - 12 N´m (105 in. lbs.)
(2) Remove covering on lower intake manifold and
clean surfaces.
(3) Position the new intake manifold gasket on
lower manifold.
(4) Position upper manifold on lower manifold (Fig.
133). Install and tighten bolts to 12 N´m (105 in. lbs.)
following torque sequence in (Fig. 134).
(5) Connect the MAP sensor electrical connector.
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
MAP SENSOR - COMPONENT LOCATION)
(6) Connect the brake booster and LDP vacuum
hose to intake manifold (Fig. 132).
(7) Connect the PCV hose (Fig. 130).
(8) Install the power steering reservoir (Fig. 131)
and torque fasteners to 12 N´m (105 in. lbs.).
(9) Connect the EGR transducer vacuum hose.
(10) Using new gaskets, install the EGR tube (Fig.
129) and torque bolts to 12 N´m (105 in. lbs.).
Fig. 132 BRAKE BOOSTER & LDP VACUUM HOSES
1 - LDP & SPEED CONTROL VACUUM HOSE
2 - BRAKE BOOSTER VACUUM HOSE
3 - MAP SENSOR
Fig. 133 INTAKE MANIFOLD - UPPER 3.8L
1 - BRACKET - THROTTLE CABLE
2 - BOLT
3 - SCREW
4 - MAP SENSOR
5 - MANIFOLD - UPPER
6 - WIRE HARNESS
7 - GASKET (1 PER CYL. BANK)
8 - BOLT
Fig. 134 UPPER MANIFOLD TIGHTENING
SEQUENCE
RSENGINE 3.3/3.8L9 - 147
INTAKE MANIFOLD - UPPER 3.8L (Continued)

(11) Install throttle and speed control cables.
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
THROTTLE CONTROL CABLE - INSTALLATION)
(12) Attach make up air hose clip into the hole in
the throttle cable bracket.
(13) Connect the vapor purge vacuum hose to
throttle body.
(14) Connect the wiring connectors to the throttle
position sensor (TPS) and Automatic Idle Speed (AIS)
motor. (Refer to 9 - ENGINE/MANIFOLDS/INTAKE
MANIFOLD - COMPONENT LOCATION)
(15) Install air cleaner and air inlet hose assembly.
(16) Connect the inlet air sensor electrical connec-
tor. (Refer to 14 - FUEL SYSTEM/FUEL INJEC-
TION/INLET AIR TEMPERATURE SENSOR -
COMPONENT LOCATION)
(17) Connect battery negative cable.
INTAKE MANIFOLD - LOWER
REMOVAL
(1) Perform fuel system pressure release procedure
(before attempting any repairs).(Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY - STANDARD
PROCEDURE)
(2) Drain the cooling system. (Refer to 7 - COOL-
ING - STANDARD PROCEDURE)
(3) Remove the upper intake manifold. (Refer to 9
- ENGINE/MANIFOLDS/INTAKE MANIFOLD -
REMOVAL)
(4) Remove the fuel line. (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/FUEL LINES - STANDARD
PROCEDURE) (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY/QUICK CONNECT FITTING - STAN-
DARD PROCEDURE)
(5) Remove ignition coil and bracket (Fig. 135).
(6) Disconnect heater supply hose and engine cool-
ant temperature sensor (Fig. 136).
(7) Disconnect the fuel injector wire harness.
(8) Remove the fuel injectors and rail assembly
(Fig. 135).
(9) Remove radiator upper hose.
(10) Remove the intake manifold bolts.
(11) Remove lower intake manifold (Fig. 137).
WARNING: INTAKE MANIFOLD GASKET IS MADE
OF VERY THIN METAL AND MAY CAUSE PER-
SONAL INJURY, HANDLE WITH CARE.
(12) Remove intake manifold seal retainers screws
(Fig. 137). Remove intake manifold gasket.
(13) Inspect and clean manifold. (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSPECTION) (Refer to 9 - ENGINE/MANIFOLDS/
INTAKE MANIFOLD - CLEANING)
CLEANING
(1) Discard gasket(s).
(2) Clean all sealing surfaces.
INSPECTION
Check for:
²Damage and cracks of each section.
²Clogged water passages in end cross-overs (if
equipped).
²Check for cylinder head mounting surface distor-
tion using a straightedge and thickness gauge. (Refer
to 9 - ENGINE/CYLINDER HEAD - INSPECTION)
Fig. 135 FUEL RAIL AND IGNITION COIL &
BRACKET
1 - FUEL RAIL
2 - BOLT - FUEL RAIL
3 - NUT - IGNITION COIL
4 - BOLT - IGNITION COIL
5 - IGNITION COIL
6 - BRACKET - IGNITION COIL
7 - STUD - IGNITION COIL
8 - SEPARATOR - SPARK PLUG CABLE
9 - BRACKET - SPARK PLUG CABLE SEPARATOR
10 - BOLT - SEPARATOR BRACKET
11 - BRACKET - SPARK PLUG CABLE SEPARATOR
9 - 148 ENGINE 3.3/3.8LRS
INTAKE MANIFOLD - UPPER 3.8L (Continued)

INSTALLATION
(1) Place a bead (approximately 1/4 in. diameter)
of MopartEngine RTV GEN II onto each of thefour
manifold to cylinder head gasket corners (Fig. 138).
(2) Carefully install the new intake manifold gas-
ket (Fig. 139). Tighten end seal retainer screws to 12
N´m (105 in. lbs.).
(3) Install lower intake manifold (Fig. 139). Install
the bolts and torque to 1 N´m (10 in. lbs.). Then
torque bolts to 22 N´m (200 in. lbs.) in sequence
shown in (Fig. 140). Then torque again to 22 N´m
(200 in. lbs.). After intake manifold is in place,
inspect to make sure seals are in place.
(4) Install the fuel injectors and rail assembly.
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/
FUEL RAIL - INSTALLATION)
(5) Connect fuel injector electrical harness.
(6) Connect the engine coolant temperature sensor
(Fig. 136).
(7) Connect the heater supply (Fig. 136) and radi-
ator upper hoses to manifold.
(8) Connect the fuel line. (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/QUICK CONNECT FIT-
TING - STANDARD PROCEDURE)
(9) Install the upper intake manifold. (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSTALLATION)
(10) Connect negative battery cable.(11) Fill the cooling system. (Refer to 7 - COOL-
ING - STANDARD PROCEDURE)
Fig. 136 ECT SENSOR & HEATER SUPPLY
1 - ENGINE COOLANT TEMPERATURE SENSOR
2 - CONNECTOR - ENGINE COOLANT SENSOR
3 - FITTING - HEATER SUPPLY
Fig. 137 INTAKE MANIFOLD - LOWER
1 - INTAKE MANIFOLD - LOWER
2 - BOLT - GASKET END SEAL RETAINER
3 - GASKET
4 - BOLT - LOWER INTAKE MANIFOLD
Fig. 138 Intake Manifold Gasket Sealing
1 - SEALER LOCATIONS
RSENGINE 3.3/3.8L9 - 149
INTAKE MANIFOLD - LOWER (Continued)

OIL FILTER
DESCRIPTION...........................52
REMOVAL..............................53
INSTALLATION...........................53
OIL JET
DESCRIPTION...........................53
REMOVAL..............................53
INSTALLATION...........................53
INTAKE MANIFOLD
DESCRIPTION...........................54
REMOVAL..............................54
INSTALLATION...........................54
VALVE TIMING
STANDARD PROCEDURE..................54
LOCKING ENGINE 90É AFTER TDC.........54
BALANCE SHAFT
DESCRIPTION...........................55OPERATION.............................56
REMOVAL..............................56
INSTALLATION...........................57
TIMING BELT / CHAIN COVER(S)
REMOVAL..............................57
INSTALLATION...........................58
TIMING BELT IDLER PULLEY
REMOVAL..............................59
INSTALLATION...........................60
TIMING BELT/CHAIN TENSIONER
REMOVAL..............................60
INSTALLATION...........................60
ADJUSTMENTS..........................61
TIMING BELT/CHAIN AND SPROCKETS
REMOVAL..............................62
INSTALLATION...........................63
ENGINE 2.5L TURBO DIESEL
DESCRIPTION - 2.5L COMMON RAIL DIESEL
ENGINE
This 2.5 Liter (2500cc) four-cylinder ªcommon railº
direct injection engine is an in-line overhead valve
diesel engine. This engine utilizes a cast iron cylin-
der block and an aluminum cylinder head. The
engine is turbocharged and intercooled. The engine
also has four valves per cylinder and dual overhead
camshafts (Fig. 1).
DESCRIPTION SPECIFICATION
Displacement 2.5L (2499 cc)
Bore 92.00
Stroke 94.00
Compression Ratio 17.5:1
Vacuum at Idle 685.8 mm/Hg (27.0
In/Hg)
Belt Tension Automatic Belt Tensioner
Thermostat Opening 80ÉC   2ÉC
Generator Rating Denso 12V-95A
DESCRIPTION SPECIFICATION
Cooling System Capacity 13.8 Liters W/O Auxiliary
Heater
16.6 Liters With Auxiliary
Heater
Engine Oil Capacity 5.22L W/Filter Change
Timing System Belt Driven Camshafts In
Cylinder Head Cover
Air Intake Dry Filter
Fuel Feed Vane Pump Incorporated
In Injection Pump
Fuel System Direct Fuel Injection
Combustion Cycle 4 Stroke
Cooling System Water Cooling
Injection Pump Rotary Pump and
Electronically Managed
Lubrication Pressure Lubricated By
Rotary Pump
Engine Rotation Clockwise Viewed From
Front Cover
9a - 2 ENGINE 2.5L TURBO DIESELRG

(24) Disconnect egr solenoid vacuum line at brake
booster check valve.
(25) Disconnect fuel injector, cam sensor, boost
pressure/intake air temp sensor, fuel rail high pres-
sure, and egr solenoid connectors (Fig. 9).
(26) Disconnect generator electrical connectors.
(27) Disconnect coolant temp sensor and glow plug
electrical connectors.
(28) Disconnect injection pump and A/C compres-
sor electrical connectors.
(29) Disconnect starter electrical connectors.
(30) Disconnect ground wires at engine block.
(31) Raise vehicle on hoist.
(32) Disconnect oil temp sensor, oil pressure sen-
sor, engine speed sensor, and vehicle speed sensor
electrical connector (Fig. 10).
(33) Remove front wheels.
(34) Remove the suspension cradle assembly (Refer
to 13 - FRAME & BUMPERS/FRAME/ENGINE
CRADLE CROSSMEMBER - REMOVAL).
(35) Remove both axle shaft assemblies (Refer to 3
- DIFFERENTIAL & DRIVELINE/HALF SHAFT -
REMOVAL).(36) Disconnect the clutch slave cylinder quick dis-
connect line (RHD only)(Refer to 6 - CLUTCH/SLAVE
CYLINDER - REMOVAL).
(37) Disconnect reverse lamp connector.
(38) Disconnect shifter cables at the tranmission
(Refer to 21 - TRANSMISSION/TRANSAXLE/MAN-
UAL/GEAR SHIFT CABLE - REMOVAL).
(39) Disconnect exhaust pipe from the turbo-
charger downpipe and reposition to right side of vehi-
cle.
(40) Disconnect cabin heater coolant line (Refer to
24 - HEATING & AIR CONDITIONING/CABIN
HEATER/HEATER UNIT - REMOVAL).
(41) Remove front engine mount bracket retaining
bolts from lower radiator support
(42) Lower vehicle. Evacuate the A/C system
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/REFRIGERANT - STANDARD PROCE-
DURE).
(43) Disconnect the A/C lines at the A/C compres-
sor.
(44) Disconnect the fuel supply and return lines.
(45) Position engine cradle under engine and lower
vehicle over cradle.
(46) Remove right engine mount bolts.
Fig. 7 CHARGE AIR COOLER HOSES
1 - COOLING MODULE
2 - BYPASS HOSE
3 - UPPER RADIATOR HOSE
4 - CHARGE AIR COOLER OULET HOSE
5 - CHARGE AIR COOLER INLET HOSE
6 - LOWER RADIATOR HOSE
7 - CHARGE AIR COOLER
Fig. 8 UPPER AND LOWER RADIATOR HOSES
1 - COOLANT BYPASS HOSE
2 - RADIATOR ASSEMBLY
3 - UPPER RADIATOR HOSE
4 - COOLING FAN
5 - LOWER RADIATOR HOSE
6 - CHARGE AIR COOLER
7 - RADIATOR BRACKET
RGENGINE 2.5L TURBO DIESEL9a-5
ENGINE 2.5L TURBO DIESEL (Continued)

(47) Remove left engine mount through bolt.
(48) Raise vehicle, leaving engine and transmis-
sion on engine cradle.
(49) Lift engine from engine cradle and diassemble
as necessary.
REMOVAL - ENGINE COVER
(1) Remove the engine cover retaining bolts.
(2) Remove the engine cover from the engine.
INSTALLATION - 2.5L TURBO DIESEL ENGINE
(1) Reassembly engine and transmission assembly
and install on engine cradle.
(2) Position engine and cradle assembly under
vehicle.
(3) Slowly lower the vehicle down over the engine
and cradle assembly.
(4) Install right engine mount bolts. Torque to
54N´m (40 ft. lbs.)
(5) Install left engine mount through bolt. Torque
to 75N´m (55 ft. lbs.)
(6) Raise vehicle and engine from engine cradle.
Fig. 9 ENGINE COMPONENT LOCATIONS
1 - FUEL INJECTOR RETURN LINE
2 - FUEL INJECTOR SUPPLY LINE
3 - OIL SEPARATOR
4 - FUEL INJECTOR
5 - CAMSHAFT POSITION SENSOR
6 - BOOST PRESSURE/INTAKE AIR TEMPERATURE SENSOR
7 - EGR SOLENOID
8 - FUEL PRESSURE SENSOR
9 - CYLINDER HEAD COVER/INTAKE MANIFOL
10 - FUEL RAIL
11 - WIRING HARNESS RETAINING CLIPS
Fig. 10 REAR ENGINE VIEW
1 - SUSPENSION CRADLE
2 - ENGINE BLOCK
3 - OIL PRESSURE SWITCH
4 - OIL TEMPERATURE SENSOR
5 - VEHICLE SPEED SENSOR
6 - TRANSMISSION
Fig. 11 Figure Caption Here
1 - ENGINE COVER MOUNTING BOLTS
2 - ENGINE COVER
9a - 6 ENGINE 2.5L TURBO DIESELRG
ENGINE 2.5L TURBO DIESEL (Continued)

(7) Attach front engine mount bracket to lower
radiator support. Torque to 54N´m (40 ft. lbs.)
(8) Connect cabin heater coolant hose.
(9) Connect exhaust pipe to the turbocharger
downpipe flange. Torque to 28 N´m (250 in. lbs.)
(10) Connect reverse lamp electrical connector at
transmission.
(11) Connect both shifter cables (Refer to 21 -
TRANSMISSION/TRANSAXLE/MANUAL/GEAR
SHIFT CABLE - INSTALLATION).
(12) Connect the clutch slave cylinder quick dis-
connect connector (RHD only)(Refer to 6 - CLUTCH/
SLAVE CYLINDER - INSTALLATION).
(13) Install engine harness into bracket on trans-
mission.
(14) Lower vehicle.
(15) Connect fuel supply and return lines.
(16) Connect A/C lines to A/C compressor. Torque
to 23N´m (17 ft. lbs.)
(17) Route engine wiring harnes to proper location.
(18) Connect engine harness ground cables to
engine block
(19) Connect starter solenoid electrical connector
and battery feed wire to starter. Torque to 10N´m (90
in. lbs.)
(20) Connect A/C compressor, injection pump, glow
plugs, and coolant temperature sensor electrical con-
nectors.
(21) Connect generator electrical connector. Torque
to 9N´m (75 in. lbs.)
(22) Connect the fuel injector, fuel pressure sensor,
boost pressure/intake air temp sensor, cam sensor,
and egr solenoid electrical connectors (Fig. 9).
(23) Connect egr solenoid vacuum supply line to
brake boost vacuum supply line.
(24) Connect brake booster vacuum supply line.
(25) Connect heater core return hose to coolant
pipe.
(26) Connect lower radiator hose to engine (Fig. 8).
(27) Install charger air cooler inlet hose (Fig. 7).
(28) Install charge air cooler outlet hose (Fig. 7).
(29) Connect upper radiator hose to engine (Fig.
8).
(30) Install battery shield.
(31) Install coolant reserve pressure container
(Refer to 7 - COOLING/ENGINE/COOLANT RECOV-
ERY PRESS CONTAINER - INSTALLATION).
(32) Install power steering reservoir and bracket
(Fig. 5).
(33) Raise vehicle
(34) Connect oil pressure sensor, oil temperature
sensor, engine speed sensor, and vehicle speed sensor
electrical connector (Fig. 10).(35) Install suspension cradle in vehicle (Refer to
13 - FRAME & BUMPERS/FRAME/ENGINE CRA-
DLE CROSSMEMBER - INSTALLATION).
(36) Install both axle shaft assemblies (Refer to 3 -
DIFFERENTIAL & DRIVELINE/HALF SHAFT -
INSTALLATION).
(37) Connect the power steering supply, pressure,
and return lines to power steering pump (Fig. 5).
(38) Install the power steering line brackets on oil
pan (Fig. 5).
(39) Install lower splash shield and side panels.
(40) Install both front wheel and tire assemblies.
(41) Lower vehicle.
(42) Install air cleaner housing, MAF sensor, and
air intake tube assembly (Fig. 4).
(43) Refill transmission to proper level (Refer to 21
- TRANSMISSION/TRANSAXLE/MANUAL/FLUID -
STANDARD PROCEDURE).
(44) Refill engine coolant (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(45) Recharge A/C system (Refer to 24 - HEATING
& AIR CONDITIONING/PLUMBING/REFRIGER-
ANT - STANDARD PROCEDURE) .
(46) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION) (Fig. 3).
(47) Connect negative battery cable.
INSTALLATION - ENGINE COVER
(1) Install engine cover on engine.
(2) Install the engine cover mounting bolts (Fig.
11).
SPECIFICATIONS
SPECIFICATIONS - 2.5L COMMON RAIL
DIESEL ENGINE
ENGINE SPECIFICATIONS
DESCRIPTION SPECIFICATION
Type R2516C
Number of Cylinders 4
Bore 92 mm
Stroke 94 mm
Displacement 2499.5cc
Injection Order 1-3-4-2
Compression Ratio 17.5:1 (  0.5)
Maximum Power 103kW (140 HP) @ 4000
RPM
Peak Torque 340Nm (34.6 kgm) @
1800 RPM
RGENGINE 2.5L TURBO DIESEL9a-7
ENGINE 2.5L TURBO DIESEL (Continued)

SPECIFICATIONS - TORQUE
2.5L DIESEL TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Oil Pump Bolts 10.8 8 96
Vacuum Pump Bolts 10.8 8 96
Crankshaft Gear Bolts 10.8 8 96
Crankshaft Position
Sensor Bolts10.8 8 96
Flywheel Bolts - Refer to the Service Procedure
Cylinder Head Bolts - Refer to the Service Procedure
Reluctor Wheel Bolts 14.6 11 130
Rear Main Bearing
Support Bolts27.5 21 240
Oil Cooler to Engine Block
Bolt47.1 35 Ð
Oil Cooler Mounting Stud 50 37 Ð
Water Pump Housing Nuts 24.4 18 212
Connecting Rod Bolts - Refer to the Service Procedure
Balance Shaft Bolts 32.4 24 Ð
Oil Jet Bolts 10.8 8 96
Oil Pan Bolts 11.8 8 96
Crankshaft Hub Bolt 304 225 Ð
Front Engine Cover Bolts 11.8 8 96
Transmission to Engine
Bolts83.4 62 Ð
Cylinder Head Cover /
Intake Manifold Bolts27.5 20 Ð
Camshaft Access Plugs 80 59 Ð
Oil Separator Bolts 10.8 8 96
Camshaft Position Sensor
Bolt10.8 8 96
Boost Pressure / Intake
Air Temp. Sensor Bolts5.4 Ð 48
Accessory Drive Bracket
Bolts47.1 35 Ð
Vacuum Line Fitting Bolt 56.9 42 Ð
Fuel Pump Nuts 27.5 21 Ð
Fuel Line Fittings at Pump 27.5 21 Ð
Inner Timing Belt Cover Bolts
8mm 10.8 8 96
10mm 47.1 35 Ð
Outer Timing Belt Cover Bolts
3mm 6 Ð 54
8mm 10.8 8 96
9a - 10 ENGINE 2.5L TURBO DIESELRG
ENGINE 2.5L TURBO DIESEL (Continued)

DESCRIPTION N´m Ft. Lbs. In. Lbs.
Engine Mount Bracket to
Cylinder Head Bolts47.1 35 Ð
Intake Inlet Tube Bolts 10.1 8 89
Camshaft Sprocket Bolts 108 80 Ð
Timing Belt Idler Pulley
Bolt47.1 35 Ð
Timing Belt Tensioner Bolt 34.7 26 Ð
Fuel Pump Nut 88.3 65 Ð
Engine Lift Hook Bolts 32.4 24 Ð
Thermostat Housing Bolts 27.5 21 Ð
Turbocharger Oil Feed
Line Fitting24.5 18 217
Exhaust Manifold Nuts 32.4 24 Ð
Exhaust Manifold
Heatshield Bolts27.5 21 Ð
EGR Valve Nuts 32.4 24 Ð
EGR Cooler to EGR Bolts 32.4 24 Ð
Turbocharger Downpipe
Nuts32.4 24 Ð
Turbocharger Bracket
Bolts47.1 35 Ð
Vibration Damper to
Crankshaft Hub Bolts27.5 21 Ð
Crankshaft Support Bolts 44.1 33 Ð
Turbocharger to Exhaust
Manifold Nuts32.4 24 Ð
RGENGINE 2.5L TURBO DIESEL9a-11
ENGINE 2.5L TURBO DIESEL (Continued)

VM.1060 OIL JET REMOVER /INSTALLER
VM.1061 FRONT OIL SEAL INSTALLER
VM.1062 POWER STEERING PUMP INSTALLER
VM.1063 FUEL INJECTOR REMOVER
9a - 14 ENGINE 2.5L TURBO DIESELRG
ENGINE 2.5L TURBO DIESEL (Continued)