wheel CHRYSLER VOYAGER 2001 Service Manual

VM.1069 CRANKSHAFT REM/INSTALL SLEEVE
VM.1070 FLYWHEEL LOCKING TOOL
VM.1072 COMPRESSION TESTER ADAPTER
VM.1073 CRANKSHAFT FRONT BEARING
REMOVER/INSTALLER
9a - 16 ENGINE 2.5L TURBO DIESELRG
ENGINE 2.5L TURBO DIESEL (Continued)

VM.1074 TIMING BELT RETAINER
VM.1075 FLYWHEEL ALIGNMENT PINS
VM.1077 POWER STEERING BELT REMOVER
VM.1078 POWER STEERING BELT INSTALLER
RGENGINE 2.5L TURBO DIESEL9a-17
ENGINE 2.5L TURBO DIESEL (Continued)

INSPECTION
Clean each lifter assembly in cleaning solvent to
remove all varnish and sludge deposits. Inspect for
indications of scuffing on the side and base of each
lifter body.
INSTALLATION
(1) Install rocker arm and lifter assemblies in
lifter bores.
(2) Install cylinder head cover/intake manifold
(Fig. 33) (Refer to 9 - ENGINE/CYLINDER HEAD/
CYLINDER HEAD COVER(S) - INSTALLATION).
(3) Install timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(4) Install timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION) .
(5) Install timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(6) Install right engine mount (Refer to 9 -
ENGINE/ENGINE MOUNTING/RIGHT MOUNT -
INSTALLATION).
(7) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
(8) Install front wiper unit (Refer to 8 - ELECTRI-
CAL/WIPERS/WASHERS/WIPER MODULE -
INSTALLATION).
(9) Connect negative battery cable.
ENGINE BLOCK
DESCRIPTION
The 2.5L CRD Diesel engine uses a cast iron
engine block with wet cast iron cylinder liners (Fig.
34).
CRANKSHAFT
DESCRIPTION
The crankshaft is a forged steel splayed type
design with five main bearing journals. The crank-
shaft is located at the bottom of the engine block and
is held in place with three main bearing supports
(Fig. 35).
OPERATION
The crankshaft transfers force generated by com-
bustion within the cylinder bores to the flywheel or
flexplate.
Fig. 34 ENGINE BLOCK
Fig. 35 CRANKSHAFT ASSEMBLY
1 - CRANKSHAFT SUPPORT HALVE
2 - MAIN BEARING HALVE
3 - CRANKSHAFT
4 - MAIN BEARING HALVE
5 - CRANKSHAFT SUPPORT HALVE
6 - MAIN BEARING SUPPORT BOLTS
7 - WASHERS
RGENGINE 2.5L TURBO DIESEL9a-31
HYDRAULIC LIFTERS (Continued)

STANDARD PROCEDURE - CHECKING
CRANKSHAFT END PLAY
(1) Mount a dial indicator to a stationary point at
rear of engine. Locate the probe perpendicular
against the flywheel (Fig. 36).
(2) Move the crankshaft all the way to the front of
its travel.
(3) Zero the dial indicator.
(4) Move the crankshaft all the way to the rear
and read dial indicator. For crankshaft end play
clearances (Refer to 9 - ENGINE - SPECIFICA-
TIONS).
REMOVAL
(1) Remove engine from vehicle (Refer to 9 -
ENGINE - REMOVAL).
(2) Mount engine on an engine stand.
(3) Drain engine oil and remove oil filter.
(4) Remove timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(5) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL).
(6) Remove timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(7) Remove cylinder head cover/intake manifold
(Refer to 9 - ENGINE/CYLINDER HEAD/CYLIN-
DER HEAD COVER(S) - REMOVAL).
(8) Remove cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
(9) Remove flywheel.
(10) Remove rear main bearing support/adapter
plate retaining bolts and remove adapter plate (Fig.
37).
(11) Remove rear main bearing support by thread-
ing two retaining bolts in holes provided. Tighten
bolts equally to push main bearing support out of
block (Fig. 38).
(12) Remove front engine cover (Refer to 9 -
ENGINE/ENGINE BLOCK/ENGINE COVER -
REMOVAL).
(13) Remove crankshaft sprocket.
Fig. 36 CHECKING CRANKSHAFT END PLAY
1 - DIAL INDICATOR
2 - ADAPTER PLATE
3 - REAR MAIN BEARING SUPPORT
4 - SEALING RING
5 - SEALING RING
6 - ALIGNMENT PIN
7 - CRANKSHAFT
8 - RELUCTOR WHEEL
9 - RELUCTOR WHEEL RETAINING BOLT
10 - REAR MAIN BEARING SUPPORT RETAINING BOLTS
11 - FLYWHEEL
12 - FLYWHEEL BOLTS
9a - 32 ENGINE 2.5L TURBO DIESELRG
CRANKSHAFT (Continued)

(5) Install front engine cover (Refer to 9 -
ENGINE/ENGINE BLOCK/ENGINE COVER -
INSTALLATION).
(6) Install rear main bearing support in engine
block.Be sure to align oil hole in rear main
bearing support with hole in block.
(7) Install adapter plate and retaining bolts (Fig.
37). Torque bolts to 27.5N´m.
(8) Install flywheel.
(9) Install piston and connecting rod assemblies
(Refer to 9 - ENGINE/ENGINE BLOCK/PISTON &
CONNECTING ROD - INSTALLATION).
(10) Install oil jets (Refer to 9 - ENGINE/LUBRI-
CATION/OIL JET - INSTALLATION).
(11) Install balance shaft assembly (Refer to 9 -
ENGINE/VALVE TIMING/BALANCE SHAFT -
INSTALLATION).
(12) Install oil pump pickup tube (Refer to 9 -
ENGINE/LUBRICATION/OIL PUMP - INSTALLA-
TION).
(13) Install oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION).
(14) Install cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - INSTALLATION).
(15) Install cylinder head cover/intake manifold
(Refer to 9 - ENGINE/CYLINDER HEAD/CYLIN-
DER HEAD COVER(S) - INSTALLATION).
(16) Install timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(17) Install timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION) .(18) Install timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(19) Install engine in vehicle.
(20) Fill engine oil with proper oil to correct level.
CYLINDER LINERS
DESCRIPTION
The cylinder wall liner used on this engine is of
the wet design. O-rings are used to seal the liner to
the engine block.
REMOVAL
(1) Remove engine from vehicle.
(2) With engine completely disassembled, use spe-
cial tool VM.1001 to remove liner assembly (Fig. 41).
(3) Tighten bolt on VM.1001 to remove liner from
block (Fig. 42).
(4) Remove shims from cylinder liner or cylinder
block recess. Keep shims with each cylinder liner.
INSPECTION
The cylinder walls should be checked for out-of-
round and taper with a dial bore gauge. The cylinder
bore out-of-round is 0.100 mm (.0039 in.) maximum
Fig. 40 CRANKSHAFT SUPPORT RETAINERS
1 - CRANKSHAFT SUPPORT RETAINERS
2 - ENGINE BLOCK
Fig. 41 CYLINDER LINER REMOVER
9a - 34 ENGINE 2.5L TURBO DIESELRG
CRANKSHAFT (Continued)

INSTALLATION
CRANKSHAFT MAIN BEARINGS
(1) Install bearing halves in crankshaft supports.
(2) Lubricate crankshaft and main bearings with
clean engine oil.
(3) Install crankshaft supports on crankshaft (Fig.
65). Torque bolts to 44.1N´m.
FRONT CRANKSHAFT MAIN BEARING
(1) Using special tool VM.1073, push front crank-
shaft main bearing in engine block (Fig. 66).
(2) Be sure oil hole in bearing lines up with oil gal-
lery in engine block (Fig. 67).
(3) Reassemble engine and install in vehicle.
CRANKSHAFT OIL SEAL -
REAR
REMOVAL
This must be done with either the engine or trans-
mission removed from vehicle.
(1) Remove flywheel assembly.
(2) Pry out old crankshaft oil seal.
INSTALLATION
(1) Using special tool VM.1050, install rear crank-
shaft oil seal in rear main bearing support (Fig. 68).
(2) Install engine or tranmission in vehicle.
OIL PAN
REMOVAL
(1) Disconnect negative battery cable.
(2) Raise vehicle on hoist.
(3) Drain engine oil from engine.
(4) Remove all oil pan retaining bolts and oil pan
(Fig. 69).
Fig. 64 FRONT MAIN BEARING REMOVAL
1 - VM.1073
2 - FRONT CRANKSHAFT MAIN BEARING
3 - ENGINE BLOCK
Fig. 65 CRANKSHAFT ASSEMBLY
1 - CRANKSHAFT SUPPORT HALVE
2 - MAIN BEARING HALVE
3 - CRANKSHAFT
4 - MAIN BEARING HALVE
5 - CRANKSHAFT SUPPORT HALVE
6 - MAIN BEARING SUPPORT BOLTS
7 - WASHERS
9a - 46 ENGINE 2.5L TURBO DIESELRG
CRANKSHAFT MAIN BEARINGS (Continued)

(4) Install oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION).
(5) Refill engine oil to proper level.
(6) Connect negative battery cable.
INTAKE MANIFOLD
DESCRIPTION
(Refer to 9 - ENGINE/CYLINDER HEAD/CYLIN-
DER HEAD COVER(S) - DESCRIPTION)
REMOVAL
(1) (Refer to 9 - ENGINE/CYLINDER HEAD/CYL-
INDER HEAD COVER(S) - REMOVAL)
INSTALLATION
(1) (Refer to 9 - ENGINE/CYLINDER HEAD/CYL-
INDER HEAD COVER(S) - INSTALLATION)
VALVE TIMING
STANDARD PROCEDURE - LOCKING ENGINE
90É AFTER TDC
(1) Disconnect negative battery cable.
(2) Remove starter motor (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - REMOVAL).
(3) Rotate engine by hand until special tool
VM.1068 can be install in engine block as shown
(Fig. 83). This will lock the engine at 90É after TDC.
(4) Remove front wiper unit (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
REMOVAL).
(5) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
Fig. 82 OIL JET REMOVAL/INSTALLATION
1 - SPECIAL TOOL VM.1060
2 - OIL JET
3 - CONNECTING ROD
4 - CRANKSHAFT
Fig. 83 TDC AND 90 DEGREES AFTER TDC
ALIGNMENT PIN LOCATION
1 - ENGINE BLOCK
2 - VM.1051 TDC PIN OR VM.1068 90 DEGREES ATDC PIN
3 - FLYWHEEL
9a - 54 ENGINE 2.5L TURBO DIESELRG
OIL JET (Continued)

INSTALLATION
(1) Before installation of the balance shaft assem-
bly, the # 1 cylinder must be brought to TDC. Using
special tool VM.1051, roll engine over by hand until
tool can be inserted into engine block locking fly-
wheel from turning (Fig. 88). Once the # 1 cylinder is
brought to TDC, the balance shaft assembly can be
installed.
(2) With balance shaft assembly on work bench.
Insert special tool VM.1056 into balance shaft assem-
bly (Fig. 89). This will ensure proper balance shaft
and crankshaft timing after assembly.
(3) Install balance shaft assembly and retaining
bolts (Fig. 87). Torque bolts to 32.4N´m.
(4) Install oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION).
(5) Refill engine oil to proper level.
(6) Connect negative battery cable.
TIMING BELT / CHAIN
COVER(S)
REMOVAL - TIMING BELT OUTER COVER
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).(3) Remove air cleaner housing.
(4) Support engine and remove right engine mount
and bracket.
(5) Remove power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(6) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(7) Remove vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(8) Remove timing belt outer cover retaining bolts
and remove cover (Fig. 90).
REMOVAL - TIMING BELT INNER COVER
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(3) Remove air cleaner housing.
(4) Support engine and remove right engine mount
and bracket.
(5) Remove power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(6) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
Fig. 88 TDC AND 90 DEGREES AFTER TDC
ALIGNMENT PIN LOCATION
1 - ENGINE BLOCK
2 - VM.1051 TDC PIN OR VM.1068 90 DEGREES ATDC PIN
3 - FLYWHEEL
Fig. 89 BALANCE SHAFT ALIGNMENT PIN VM.1056
1 - VM.1056
2 - BALANCE SHAFT ASSEMBLY
RGENGINE 2.5L TURBO DIESEL9a-57
BALANCE SHAFT (Continued)

CROSS-OVER PIPE
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove the fasteners attaching the left bank
manifold connection to cross-over pipe (Fig. 6).
(3) Raise vehicle and remove the left front wheel.
(4) Access the lower right bank pipe connection
fastener through the left front wheel opening using a
long ratchet extension. Loosen and remove the lower
fastener.
(5) Remove the upper right bank pipe connection
fastener by accessing though the catalytic converter
floor pan tunnel.
(6) Lower the vehicle.
(7) Remove the cross-over pipe (Fig. 6).
(8) Remove gaskets and discard (Fig. 6).
INSTALLATION
(1) Position cross-over pipe to the manifold connec-
tions (Fig. 6).
(2) Position new gasket on left bank (front) pipe
connection and loosely install fasteners (Fig. 6).
(3) Raise the vehicle.
(4) Position new gasket on the right bank pipe con-
nection and install fasteners.
(5) Tighten right bank upper fastener to 41 N´m
(30 ft. lbs.).
(6) Tighten right bank lower fastener to 41 N´m
(30 ft. lbs.) using a long ratchet extension accessing
through the left wheel opening.
(7) Install the left front wheel and lower vehicle.
(8) Tighten the left bank pipe connection fasteners
to 41 N´m (30 ft. lbs.) (Fig. 6).
HEAT SHIELDS
DESCRIPTION
The exhaust system heat shields (Fig. 7), (Fig. 8),
or (Fig. 9) are attached to the under body of the vehi-
cle. On vehicles equipped with All Wheel Dive
(AWD), an additional heat shield is mounted to the
catalytic converter.
OPERATION
Heat shields are needed to protect both the vehicle
and the environment from the high temperatures
developed near the catalytic converter.
Fig. 6 CROSS-OVER PIPE
1 - CROSS-OVER PIPE
2 - BOLT
3 - GASKET
4 - FLAG NUT
Fig. 7 CATALYTIC CONVERTER HEAT SHIELD
1 - HEAT SHIELD - CATALYTIC CONVERTER
2 - SCREW (QTY. 4)
Fig. 8 MUFFLER HEAT SHIELD
1 - HEAT SHIELD - MUFFLER
2 - SCREW (QTY. 6)
11 - 6 EXHAUST SYSTEMRS

TURBOCHARGER SYSTEM
DESCRIPTION
CAUTION: The turbocharger is a performance part
and must not be tampered with. The wastegate
bracket is an integral part of the turbocharger. Tam-
pering with the wastegate components can reduce
durability by increasing cylinder pressure and ther-
mal loading due to incorrect inlet and exhaust man-
ifold pressure. Poor fuel economy and failure to
meet regulatory emissions laws may result. Increas-
ing the turbocharger boost WILL NOT increase
engine power.
The turbocharger is an exhaust-driven super-
charger which increases the pressure and density of
the air entering the engine. With the increase of air
entering the engine, more fuel can be injected into
the cylinders, which creates more power during com-
bustion.
The turbocharger assembly consists of four (4)
major component systems (Fig. 1) (Fig. 2):
²Turbine section
²Compressor section
²Bearing housing
²Wastegate
OPERATION
Exhaust gas pressure and energy drive the tur-
bine, which in turn drives a centrifugal compressor
that compresses the inlet air, and forces the air into
the engine through the charge air cooler and plumb-
ing. Since heat is a by-product of this compression,
the air must pass through a charge air cooler to cool
the incoming air and maintain power and efficiency.
Increasing air flow to the engine provides:
²Improved engine performance
²Lower exhaust smoke density
²Improved operating economy
²Altitude compensation
²Noise reduction.
The turbocharger also uses a wastegate (Fig. 3),
which regulates intake manifold air pressure and
prevents over boosting at high engine speeds. When
the wastegate valve is closed, all of the exhaust gases
flow through the turbine wheel. As the intake mani-
fold pressure increases, the wastegate actuator opens
the valve, diverting some of the exhaust gases away
from the turbine wheel. This limits turbine shaft
speed and air output from the impeller.
Fig. 1 Turbocharger Operation
1 - TURBINE SECTION
2 - EXHAUST GAS
3 - BEARING HOUSING
4 - COMPRESSOR SECTION
5 - INLET AIR
6 - COMPRESSED AIR TO ENGINE
7 - EXHAUST GAS
8 - EXHAUST GAS TO EXHAUST PIPE
Fig. 2 Turbocharger Wastegate Actuator
1 - TURBOCHARGER
2 - DIAPHRAGM
3 - WASTE GATE ACTUATOR
11a - 2 EXHAUST SYSTEM AND TURBOCHARGERRG