engine CHRYSLER VOYAGER 2001 Service Manual

(3) Install the remaining manifold attaching bolts.
Tighten all bolts to 23 N´m (200 in. lbs.).
(4) Position the power steering pump support strut
and install upper bolt (Fig. 142).
(5) Install heat shield and attaching screws (Fig.
144).
(6) Install and connect upstream oxygen sensor
(Fig. 144).
(7) Raise the vehicle.
(8) Attach catalytic converter pipe to exhaust man-
ifold using new gasket and tighten bolts to 37 N´m
(27 ft. lbs.) (Fig. 143).
(9) Connect downstream oxygen sensor connector.
(10) Tighten the power steering pump support
strut lower bolt (Fig. 142).
(11) Install the belt splash shield and lower the
vehicle.
(12) Install the wiper module. (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
INSTALLATION)
(13) Connect battery negative cable.
EXHAUST MANIFOLD - LEFT
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove bolts attaching crossover pipe to
exhaust manifold (Fig. 146).
(3) Disconnect left cylinder bank spark plug wires.
(4) Remove heat shield attaching bolts (Fig. 147).
(5) Remove bolts attaching exhaust manifold to
cylinder head (Fig. 147).
(6) Remove the exhaust manifold (Fig. 147).(7) Inspect and clean manifold. (Refer to 9 -
ENGINE/MANIFOLDS/EXHAUST MANIFOLD -
INSPECTION) (Refer to 9 - ENGINE/MANIFOLDS/
EXHAUST MANIFOLD - CLEANING)
CLEANING
(1) Discard gasket (if equipped) and clean all sur-
faces of manifold and cylinder head.
Fig. 145 Check Exhaust Manifold Mounting
1 - STRAIGHT EDGE
2 - CROSSOVER PIPE MOUNTING SURFACE
3 - FEELER GAUGE
Fig. 146 CROSS-OVER PIPE
1 - CROSS-OVER PIPE
2 - BOLT
3 - GASKET
4 - FLAG NUT
Fig. 147 EXHAUST MANIFOLD - LEFT
1 - EXHAUST MANIFOLD - LEFT BANK
2 - HEAT SHIELD
3 - NUT - HEAT SHIELD
4 - BOLT - EXHAUST MANIFOLD
9 - 152 ENGINE 3.3/3.8LRS
EXHAUST MANIFOLD - RIGHT (Continued)

INSPECTION
Inspect exhaust manifolds for damage or cracks
and check distortion of the cylinder head mounting
surface and exhaust crossover mounting surface with
a straightedge and thickness gauge (Fig. 148).
Manifold surface flatness limits should not exceed
1.0 mm (0.039 in.).
INSTALLATION
(1) Position exhaust manifold on cylinder head
(Fig. 147). Install bolts to center runner (cylinder #4)
and initial tighten to 2.8 N´m (25 in. lbs.).
(2) Using a new gasket, attach crossover pipe to
exhaust manifold and tighten bolts to 41 N´m (30 ft.
lbs.) (Fig. 146).
NOTE: Inspect crossover pipe fasteners for damage
from heat and corrosion. The cross-over bolts are
made of a special stainless steel alloy. If replace-
ment is required, OEM bolts are highly recom-
mended.
(3) Position heat shield on manifold (Fig. 147).
(4) Install the remaining manifold attaching bolts.
Tighten all bolts to 23 N´m (200 in. lbs.).
(5) Install and tighten heat shield attaching nut to
12 N´m (105 in. lbs.) (Fig. 147).
(6) Connect battery negative cable.
VALVE TIMING
VALVE TIMING VERIFICATION
(1) Remove front cylinder head cover and all 6
spark plugs.(2) Rotate engine until the #2 piston is at TDC of
the compression stroke.
(3) Install a degree wheel on the crankshaft pulley.
(4) With proper adaptor, install a dial indicator
into #2 spark plug hole. Using the indicator find TDC
on the compression stroke.
(5) Position the degree wheel to zero.
(6) Remove dial indicator from spark plug hole.
(7) Place a 5.08 mm (0.200 in.) spacer between the
valve stem tip of #2 intake valve and rocker arm pad.
Allow tappet to bleed down to give a solid tappet
effect.
(8) Install a dial indicator so plunger contacts the
#2 intake valve spring retainer as nearly perpendic-
ular as possible. Zero the indicator.
(9) Rotate the engine clockwise until the intake
valve has lifted .254 mm (0.010 in.).
CAUTION: Do not turn crankshaft any further clock-
wise as intake valve might bottom and result in
serious damage.
(10) Degree wheel should read 6 degrees BTDC to
6 degrees ATDC.
TIMING CHAIN COVER
REMOVAL
(1) Disconnect negative cable from battery.
(2) Drain cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(3) Raise vehicle on hoist.
(4) Drain engine oil.
(5) Remove right wheel and inner splash shield.
(6) Remove oil pan. (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - REMOVAL)
(7) Remove oil pick-up tube (Fig. 149).
(8) Remove accessory drive belt. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)
(9) Remove A/C compressor and set aside.
(10) Remove crankshaft vibration damper. (Refer
to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL)
(11) Remove radiator lower hose.
(12) Remove heater hose from timing chain cover
housing (Fig. 150) or water pump inlet tube (if
engine oil cooler equipped) (Fig. 151).
(13) Remove the right side engine mount. (Refer to
9 - ENGINE/ENGINE MOUNTING/RIGHT MOUNT
- REMOVAL)
(14) Remove idler pulley from engine bracket (Fig.
152).
(15) Remove the engine mount bracket (Fig. 152).
(16) Remove cam sensor from timing chain cover
(Fig. 152).
Fig. 148 Check Exhaust Manifold Mounting
1 - STRAIGHT EDGE
2 - CROSSOVER PIPE MOUNTING SURFACE
3 - FEELER GAUGE
RSENGINE 3.3/3.8L9 - 153
EXHAUST MANIFOLD - LEFT (Continued)

(17) Remove the water pump for cover removal
clearance. (Refer to 7 - COOLING/ENGINE/WATER
PUMP - REMOVAL)
(18) Remove the bolt attaching the power steering
pump support strut to the front cover (Fig. 153).
(19) Remove the timing chain cover (Fig. 154).
INSTALLATION
(1) Be sure mating surfaces of chain case cover
and cylinder block are clean and free from burrs.
Crankshaft oil seal must be removed to insure cor-
rect oil pump engagement.
NOTE: DO NOT USE SEALER ON COVER GASKET
(2) Position new gasket on timing cover (Fig. 154).
Adhere new gasket to chain case cover, making sure
that the lower edge of the gasket is flush to 0.5 mm
(0.020 in.) passed the lower edge of the cover.
(3) Rotate crankshaft so that the oil pump drive
flats are in the vertical position.
(4) Position oil pump inner rotor so the mating
flats are in the same position as the crankshaft drive
flats (Fig. 154).
CAUTION: Make sure the oil pump is engaged on
the crankshaft correctly or severe damage may
result.
Fig. 149 OIL PICKUP TUBE
1 - BOLT
2 - OIL PICK-UP TUBE
3 - O-RING
Fig. 150 HEATER RETURN HOSE (Without Engine
Oil Cooler)
1 - CAP AND CLAMP (OIL COOLER EQUIPPED ONLY)
2 - HOSE ASSEMBLY - HEATER RETURN
3 - BOLT - HEATER TUBE ATTACHING
4 - BOLT - HEATER TUBE ATTACHING
Fig. 151 HEATER HOSES 3.3/3.8L (With Engine Oil
Cooler)
1 - HOSE - HEATER SUPPLY
2 - HOSE - HEATER RETURN
3 - TUBE ASSEMBLY - HEATER RETURN
4 - BOLT - TUBE ASSEMBLY
5 - BOLT - TUBE ASSEMBLY
6 - HOSE - HEATER RETURN/OIL COOLER OUTLET
9 - 154 ENGINE 3.3/3.8LRS
TIMING CHAIN COVER (Continued)

(5) Install timing cover (Fig. 154).
(6) Install timing chain cover bolts. Tighten M8
bolts to 27 N´m (20 ft. lbs.) and M10 bolts to 54 N´m
(40 ft. lbs.) (Fig. 155).
(7) Install crankshaft front oil seal. (Refer to 9 -
ENGINE/ENGINE BLOCK/CRANKSHAFT OIL
SEAL - FRONT - INSTALLATION)(8) Install water pump and pulley. (Refer to 7 -
COOLING/ENGINE/WATER PUMP - INSTALLA-
TION)
(9) Install crankshaft vibration damper. (Refer to 9
- ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
INSTALLATION)
(10) Install engine mount bracket (Fig. 152) and
tighten M10 to 54 N´m (40 ft. lbs.), M8 bolt to 28
N´m (21 ft. lb. lbs.).
(11) Install idler pulley on engine mount bracket
(Fig. 152).
(12) Install right side engine mount. (Refer to 9 -
ENGINE/ENGINE MOUNTING/RIGHT MOUNT -
INSTALLATION)
(13) Install camshaft sensor. Refer to IGNITION
SYSTEM for procedure.
(14) Connect the heater return hose at rear of tim-
ing chain cover (Fig. 150) or at water pump inlet
tube (if engine oil cooler equipped) (Fig. 151).
(15) Connect the radiator lower hose.
(16) Install A/C compressor.
(17) Install accessory drive belt. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION)
(18) Install oil pump pick-up tube with new
O-ring. Tighten attaching bolt to 28 N´m (250 in.
lbs.).
(19) Install oil pan. (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION)
(20) Install inner splash shield and right front
wheel.
(21) Fill crankcase with engine oil to proper level.
(22) Fill cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(23) Connect negative cable to battery.
Fig. 152 Engine Mount Bracket
1 - CAMSHAFT SENSOR
2 - BOLT - CAMSHAFT SENSOR
3 - BOLT - MOUNT BRACKET (VERTICAL)
4 - BRACKET - ENGINE MOUNT
5 - BOLT - MOUNT BRACKET (HORIZONTAL)
6 - PULLEY - IDLER
7 - BOLT - IDLER PULLEY
8 - SPACER - IDLER PULLEY BOLT
9 - BOLT - MOUNT BRACKET (HORIZONTAL)
Fig. 153 Power Steering Pump Strut
1 - BOLT - LOWER
2 - STRUT - P/S PUMP
3 - BOLT - UPPER
Fig. 154 Timing Chain Cover and Gasket
1 - GASKET
2 - TIMING CHAIN COVER
RSENGINE 3.3/3.8L9 - 155
TIMING CHAIN COVER (Continued)

TIMING CHAIN AND
SPROCKETS
REMOVAL - TIMING CHAIN AND CAMSHAFT
SPROCKET
(1) Disconnect negative cable from battery.
(2) Remove the timing chain cover. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL)
(3) Rotate engine by turning crankshaft until the
timing marks are aligned as shown in (Fig. 156).
(4) Remove camshaft sprocket attaching bolt.
(5) Remove the timing chain with camshaft
sprocket.
(6) Remove the crankshaft sprocket. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - REMOVAL)
REMOVAL - CRANKSHAFT SPROCKET
(1) Remove the timing chain. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - REMOVAL)
(2) Using Special Tools 8539, 5048-6, and 5048-1,
remove the crankshaft sprocket while holding the
crankshaft from turning (Fig. 157). Be careful not to
damage the crankshaft surfaces.
INSPECTION
(1) Position a scale next to timing chain so that
any movement of chain may be measured.
(2) Position a torque wrench and socket on the
camshaft sprocket attaching bolt. Apply force in the
direction of crankshaft rotation to take up slack to
the following torque:
²41 N´m (30 ft. lb.) with cylinder heads installed
²20 N´m (15 ft. lb.) with cylinder heads removed
Fig. 155 TIMING CHAIN COVER BOLT LOCATIONS
1 - BOLT - M8 x 1.25 x 95 4 - BOLT - M8 x 1.25 x 80
2 - BOLT - M10 x 1.5 x 100 5 - BOLT - M8 x 1.25 x 45
3 - BOLT - M10 x 1.5 x 85
9 - 156 ENGINE 3.3/3.8LRS
TIMING CHAIN COVER (Continued)

NOTE: With torque applied to the camshaft
sprocket bolt, crankshaft should not be permitted to
move. It may be necessary to block crankshaft to
prevent rotation.
(3) Holding a measuring scale along edge of chain
links (Fig. 158).
(4) Apply force in the reverse direction to the fol-
lowing torque:
²41 N´m (30 ft. lb.) with cylinder heads installed
²20 N´m (15 ft. lb.) with cylinder heads removed
(5) Measure amount of sprocket/chain movement.
(6) Install a new timing chain and sprockets if
movement exceeds 3.175 mm (1/8 in.). (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - REMOVAL)
INSTALLATION - TIMING CHAIN AND
CAMSHAFT SPROCKET
(1) Rotate crankshaft so the timing arrow is to the
12 o'clock position (Fig. 156).
NOTE: Lubricate timing chain and sprockets with
clean engine oil before installation.
(2) While holding camshaft sprocket and chain in
hand, place timing chain around the sprocket, align-
ing the plated link with the dot on the sprocket. Posi-
tion the timing arrow to the 6 o'clock position (Fig.
156).
(3) Place timing chain around crankshaft sprocket
with the plated link lined up with the dot on the
sprocket. Install camshaft sprocket into position.
(4) Use a straight edge to check alignment of tim-
ing marks.
(5) Install camshaft sprocket bolt and washer.
Tighten bolt to 54 N´m (40 ft. lbs.).
Fig. 156 Timing Mark Alignment
1 - CAMSHAFT SPROCKET TIMING MARK (DOT)
2 - PLATED LINK
3 - CRANKSHAFT SPROCKET TIMING MARK (DOT)
4 - ARROWS
Fig. 157 CRANKSHAFT SPROCKET - REMOVAL
1 - SPECIAL TOOL 5048-6
2 - SPECIAL TOOL 5048-1
3 - SPECIAL TOOL 8450
4 - CRANKSHAFT SPROCKET
5 - SPECIAL TOOL 8539
Fig. 158 Measuring Timing Chain Wear
1 - TORQUE WRENCH
RSENGINE 3.3/3.8L9 - 157
TIMING CHAIN AND SPROCKETS (Continued)

(6) Rotate crankshaft 2 revolutions and check tim-
ing mark alignment (Fig. 156). If timing marks do
not line up, remove camshaft sprocket and realign.
(7) Install the timing chain cover. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION)
(8) Connect negative cable to battery.
INSTALLATION - CRANKSHAFT SPROCKET
(1) Position the sprocket on the crankshaft (timing
mark out) with the timing slot aligned with the tim-
ing pin.
(2) Install sprocket using Special Tools 8451 and
8452 (Fig. 159). Install sprocket until it is fully seats
on the crankshaft.
(3) Install the timing chain and camshaft sprocket.
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT/CHAIN AND SPROCKETS - INSTALLATION)
Fig. 159 CRANKSHAFT SPROCKET - INSTALLATION
1 - SPECIAL TOOL 8451
2 - SPECIAL TOOL 8452
3 - CRANKSHAFT SPROCKET
4 - BEARING AND WASHER
9 - 158 ENGINE 3.3/3.8LRS
TIMING CHAIN AND SPROCKETS (Continued)

ENGINE 2.5L TURBO DIESEL
TABLE OF CONTENTS
page page
ENGINE 2.5L TURBO DIESEL
DESCRIPTION............................2
REMOVAL...............................3
INSTALLATION............................6
SPECIFICATIONS.........................7
SPECIAL TOOLS.........................12
CYLINDER HEAD
STANDARD PROCEDURE..................18
VALVE SERVICE.......................18
MEASURING PISTON PROTRUSION........19
REMOVAL..............................20
CLEANING..............................21
INSPECTION............................22
INSTALLATION...........................22
CAMSHAFT(S)
DESCRIPTION...........................23
OPERATION.............................23
REMOVAL..............................23
INSTALLATION...........................24
CYLINDER HEAD COVER(S)
DESCRIPTION...........................24
REMOVAL..............................24
INSTALLATION...........................26
CAMSHAFT OIL SEAL(S)
REMOVAL..............................28
INSTALLATION...........................28
ROCKER ARMS
DESCRIPTION...........................28
OPERATION.............................28
REMOVAL..............................28
INSTALLATION...........................29
HYDRAULIC LIFTERS
DESCRIPTION...........................30
REMOVAL..............................30
INSPECTION............................31
INSTALLATION...........................31
ENGINE BLOCK
DESCRIPTION...........................31
CRANKSHAFT
DESCRIPTION...........................31
OPERATION.............................31
STANDARD PROCEDURE..................32
CHECKING CRANKSHAFT END PLAY.......32
REMOVAL..............................32
INSTALLATION...........................33
CYLINDER LINERS
DESCRIPTION...........................34
REMOVAL..............................34
INSPECTION............................34INSTALLATION...........................35
INTERNAL VACUUM PUMP
DESCRIPTION...........................36
REMOVAL..............................36
INSTALLATION...........................36
PISTON & CONNECTING ROD
DESCRIPTION...........................37
STANDARD PROCEDURE..................37
PISTON RING FITTING..................37
REMOVAL..............................38
INSPECTION............................38
INSTALLATION...........................40
CRANKSHAFT OIL SEAL - FRONT
REMOVAL..............................42
INSTALLATION...........................42
VIBRATION DAMPER
REMOVAL..............................43
INSTALLATION...........................44
ENGINE COVER - FRONT
DESCRIPTION...........................44
REMOVAL..............................44
INSTALLATION...........................45
CRANKSHAFT MAIN BEARINGS
REMOVAL..............................45
INSTALLATION...........................46
CRANKSHAFT OIL SEAL - REAR
REMOVAL..............................46
INSTALLATION...........................46
OIL PAN
REMOVAL..............................46
INSTALLATION...........................47
OIL PUMP
REMOVAL..............................47
INSTALLATION...........................48
OIL PRESSURE SENSOR/SWITCH
DESCRIPTION...........................49
REMOVAL..............................49
INSTALLATION...........................50
OIL TEMPERATURE SENSOR
DESCRIPTION...........................50
REMOVAL..............................50
INSTALLATION...........................50
OIL PRESSURE RELIEF VALVE
DESCRIPTION...........................50
REMOVAL..............................51
INSTALLATION...........................51
OIL COOLER & LINES
REMOVAL..............................51
INSTALLATION...........................52
RGENGINE 2.5L TURBO DIESEL9a-1

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

DESCRIPTION - ENGINE COVER
The engine cover is a black plastic cover used to
cover the top of the engine. It is used to isolate
engine noises (Fig. 2).
REMOVAL - 2.5L DIESEL ENGINE
(1) Disconnect negative battery cable.
(2) Remove engine cover (Fig. 3). (Refer to 9 -
ENGINE - REMOVAL)
(3) Drain cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(4) Remove air cleaner housing, MAF sensor, and
air intake tube assembly (Fig. 4).
(5) Remove coolant pressure tank pressure cap.
(6) Raise vehicle on hoist.
(7) Remove lower splash shield.
(8) Remove splash shield side panels.
(9) Remove power steering reservoir hose from
power steering pump and drain power steering fluid
(Fig. 5).
Fig. 1 2.5L COMMON RAIL DIESEL ENGINE
Fig. 2 ENGINE COVER
1 - ENGINE COVER MOUNTING BOLTS
2 - ENGINE COVER
Fig. 3 ENGINE COVER
1 - ENGINE COVER MOUNTING BOLTS
2 - ENGINE COVER
RGENGINE 2.5L TURBO DIESEL9a-3
ENGINE 2.5L TURBO DIESEL (Continued)