engine CHRYSLER VOYAGER 2001 Service Manual

(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)

and cylinder bore taper is 0.100 mm (.0039 in.) max-
imum. If the cylinder walls are badly scuffed or
scored, new liners should be installed and honed, and
new pistons and rings fitted.
Measure the cylinder bore at three levels in direc-
tions A and B (Fig. 43). Top measurement should be
10 mm (3/8 in.) down and bottom measurement
should be 10 mm (3/8 in.) up from the bottom bore.
INSTALLATION
(1) Carefully clean residual LOCTITE from liner
and engine block, and degrease the engine block
where it comes into contact with the liners. Install
the liners in the engine block as shown, rotating
them back and forth by 45É in order to guarantee cor-
rect positioning (Fig. 44).
(2) Measure the liner recess relative to block deck
with a dial indicator mounted on a special tool
VM-1010 A.All the measurements must be taken
on camshaft side. Zero dial gauge on block deck.
(3) Move dial gauge to cylinder liner record read-
ing on dial gauge.
(4) Remove liner and special tool.
(5) Then select the correct shim thickness to give
proper protrusion (0.01 - 0.06 mm).
(6) Fit the shim and the O-rings onto the liner.
(7) Lubricate the lower liner location in the block.
Apply LOCTITE AVX to the corner of the liner seat.
Apply LOCTITE AVX uniformly to the upper part of
the liner at area.
Fig. 42 CYLINDER LINER REMOVAL
1 - SPECIAL TOOL VM.1001
2 - CYLINDER LINER
3 - ENGINE BLOCK
Fig. 43 LINER INSPECTION
Fig. 44 LINER INSTALLATION
1 - CYLINDER LINER
2 - SHIMS
3 - O-RINGS
4 - BLOCK LEDGE
5 - ENGINE BLOCK
RGENGINE 2.5L TURBO DIESEL9a-35
CYLINDER LINERS (Continued)

(8) Fit the liners in the crankcase making sure
that the shim is positioned correctly in the seat. Lock
the liners in position using special tool (VM.1076)
and bolts (Fig. 45). Clean the residual LOCTITE on
the upper surface of the block deck.
(9) Recheck the liner protrusion. It should be 0.01
- 0.06 mm.
NOTE: A period of six hours must elapse between
the liners being installed and engine start-up. If
engine assembly is not continued after liner instal-
lation, the liners need to be clamped for twelve
hours minimum.
(10) Reassemble engine.
(11) Install engine in vehicle.
INTERNAL VACUUM PUMP
DESCRIPTION
The diesel engine uses a internal vacuum pump.
This vacuum pump is mounted in the front of the
engine block under the engine front cover (Fig. 46).
The vacuum pump is driven by a sprocket on the
crankshaft.
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove air cleaner housing.
(3) Remove power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(4) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(5) Support engine and remove right engine mount
(Refer to 9 - ENGINE/ENGINE MOUNTING/RIGHT
MOUNT - REMOVAL).
(6) Remove vibration damper/crankshaft pulley
(Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL).
(7) Remove outer timing belt cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(8) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL).
(9) Remove timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
NOTE: Crankshaft hub has LHD thread.
(10) Remove crankshaft hub.
(11) Remove front engine cover (Refer to 9 -
ENGINE/ENGINE BLOCK/ENGINE COVER -
REMOVAL).
(12) Remove crankshaft sprocket (Fig. 47).
(13) Remove vacuum pump (Fig. 47).
INSTALLATION
(1) Lubricate vacuum pump components and
install in engine block (Fig. 47). Torque bolts to
10.8N´m.
(2) Install crankshaft sprocket (Fig. 47). Torque
bolts to 10.8N´m.
(3) Install front engine cover (Refer to 9 -
ENGINE/ENGINE BLOCK/ENGINE COVER -
INSTALLATION).
Fig. 45 LINER CLAMP LOCATION
1 - ENGINE BLOCK
2 - LINER RETAINER VM.1076
3 - CYLINDER LINER
Fig. 46 VACUUM PUMP
9a - 36 ENGINE 2.5L TURBO DIESELRG
CYLINDER LINERS (Continued)

(4) Install front crankshaft hub. Torque bolt to
304N´m.
(5) Install timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(6) Install timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION) .
(7) Install timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(8) Install vibration damper/crankshaft pulley.
(9) Install right engine mount (Refer to 9 -
ENGINE/ENGINE MOUNTING/RIGHT MOUNT -
INSTALLATION).
(10) Install accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(11) Install power steering belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(12) Install air cleaner housing.
(13) Connect negative battery cable.
PISTON & CONNECTING ROD
DESCRIPTION
The pistons are of a free floating design. Oil jets in
the engine block lubricate and cool the piston and pin
assembly. The connecting rods have a pressed in
place wrist pin bushing which is lubricated by the oil
jets (Fig. 48).
STANDARD PROCEDURE - PISTON RING
FITTING
(1) Wipe cylinder bore clean. Insert ring and push
down with piston to ensure it is square in bore. The
ring gap measurement must be made with the ring
positioning at least 12 mm (0.50 in.) from bottom of
Fig. 47 OIL PUMP AND VACUUM PUMP
1 - VACUUM PUMP
2 - CRANKSHAFT SPROCKET
3 - OIL PUMP
4 - ENGINE BLOCK
5 - CRANKSHAFT
Fig. 48 PISTON AND CONNECTING ROD ASSEMBLY
1 - PISTON PIN
2 - PISTON
3 - SNAP RING
4 - CONNECTING ROD ALIGNMENT NUMBERS
5 - CONNECTING ROD BOLT
6 - CONNECTING ROD BEARING
7 - CONNECTING ROD
8 - SNAP RING
RGENGINE 2.5L TURBO DIESEL9a-37
INTERNAL VACUUM PUMP (Continued)

cylinder bore. Check gap with feeler gauge (Fig. 49).
Top compression ring gap .30 to .45mm (.0118 to
.0177 in.). Second compression ring gap .30 to .45mm
(.0118 to .0177 in.). Oil control ring gap .25 to .50mm
(.0098 to .0196 in.).
(2) If ring gaps exceed dimension given, new rings
or cylinder liners must be fitted. Keep piston rings in
piston sets.
(3) Check piston ring to groove clearance (Fig. 50).
Top compression ring gap .080 to .130mm (.0031 to
.0051 in.). Second compression ring gap .070 to
.110mm (.0027 to .0043 in.). Oil control ring gap .040
to .080mm (.0015 to .0031 in.).REMOVAL
(1) Disconnect negative battery cable.
(2) Remove cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
(3) Raise vehicle on hoist.
(4) Remove oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - REMOVAL).
(5) Remove oil pump pickup tube.(Refer to 9 -
ENGINE/LUBRICATION/OIL PUMP - REMOVAL)
(6) Remove balance shaft assembly (Refer to 9 -
ENGINE/VALVE TIMING/BALANCE SHAFT -
REMOVAL).
(7) Remove top ridge of cylinder bores with a ridge
reamer before removing pistons from cylinder block.
Be sure to keep top of pistons covered during
this operation.
(8) Piston and connecting rods must be removed
from top of cylinder block. Rotate crankshaft so that
each connecting rod is centered in cylinder bore.
NOTE: Be careful not to nick or scratch crankshaft
journals
(9) After removal, install bearing cap on the mat-
ing rod and mark pistons with matching cylinder
number when removed from engine block.
PISTON PIN - REMOVAL
(1) Secure connecting rods in a soft jawed vice.
(2) Remove 2 snap rings securing piston pin (Fig.
51).
(3) Push piston pin out of piston and connecting
rod (Fig. 51).
PISTON RING - REMOVAL
(1) ID mark on face of top and second piston rings
must point toward piston crown.
(2) Using a suitable ring expander, remove top and
second piston rings (Fig. 52).
(3) Remove upper oil ring side rail, lower oil ring
side rail and then the oil expander from piston.
(4) Carefully clean carbon from piston crowns,
skirts and ring grooves ensuring the 4 oil holes in
the oil control ring groove are clear.
INSPECTION
PISTONS
(1) Piston Diameter: Size: 91.912-91.928mm
(3.6185-3.6192 in.) Maximum wear limit .05mm
(.0019 in.).
(2) Check piston pin bores in piston for roundness.
Make 3 checks at 120É intervals. Maximum out of
roundness .05mm (.0019in.).
(3) The piston diameter should be measured
approximately 15 mm (.590 in.) up from the base.
Fig. 49 RING END GAP MEASUREMENT
1 - FEELER GAUGE
Fig. 50 PISTON RING TO GROOVE CLEARANCE
9a - 38 ENGINE 2.5L TURBO DIESELRG
PISTON & CONNECTING ROD (Continued)

(4) Skirt wear should not exceed 0.1 mm (.00039
in.).
(5) The clearance between the cylinder liner and
piston should not exceed 0.065-0.083 mm
(.0025-.0032 in.).
(6) Make sure the weight of the pistons does not
differ by more than 5 g.
CONNECTING RODS
(1) Assemble bearing shells and bearing caps to
their respective connecting rods ensuring that the
serrations on the cap and reference marks are
aligned.
(2) Tighten bearing cap bolts to 29 N´m (21 ft. lbs.)
plus 60É.
(3) Check and record internal diameter of crank
end of connecting rod.
NOTE: When changing connecting rods, all four
must have the same weight and be stamped with
the same number. Replacement connecting rods
will only be supplied in sets of four.
Connecting rods are supplied in sets of four since
they all must be of the same weight category. Max
allowable weight difference is 18 gr.
NOTE: On one side of the big end of the con-rod
there is a two-digit number which refers to the
weight category. On the other side of the big end
there is a four digit number on both the rod and the
cap. These numbers must both face the injection
pump side of the block. Lightly heat the piston in
oven. Insert piston pin in position and secure it
with provided snap rings.
The Four digit numbers marked on con rod
big end and rod cap must be on the same side
as the injection pump.After having coated threads
with Molyguard, tighten con rod bolts to 29 N´m (21
ft. lbs.) plus 60É.
Fig. 51 PISTON AND CONNECTING ROD ASSEMBLY
1 - PISTON PIN
2 - PISTON
3 - SNAP RING
4 - CONNECTING ROD ALIGNMENT NUMBERS
5 - CONNECTING ROD BOLT
6 - CONNECTING ROD BEARING
7 - CONNECTING ROD
8 - SNAP RING
Fig. 52 PISTON RINGS - REMOVAL/INSTALLATION
RGENGINE 2.5L TURBO DIESEL9a-39
PISTON & CONNECTING ROD (Continued)

PISTON PINS
(1) Measure the diameter of piston pin in the cen-
ter and both ends.
(2) Piston pin diameter is 29.992 to 29.996mm
(1.1807 to 1.1809 in.).
INSTALLATION
PISTON PIN INSTALLATION
(1) Secure connecting rod in soft jawed vice.
(2) Lubricate piston pin and piston with clean
engine oil.
(3) Position piston on connecting rod (Fig. 53).
CAUTION: Ensure arrow on piston crown and the
bearing cap numbers on the connecting rod are on
the opposite side.
(4) Install piston pin (Fig. 53).
(5) Install clips in piston to retain piston pin (Fig.
53).
(6) Remove connecting rod from vice.
PISTON RINGS - INSTALLATION
(1) Install rings on the pistons using a suitable
ring expander (Fig. 54).
(2) Top compression ring is tapered and chromium
plated. The second ring is of the scraper type and
must be installed with scraping edge facing bottom of
the piston. The third is an oil control ring. Ring gaps
must be positioned, before inserting piston into the
liners, as follows.
(3) Top ring gap must be positioned at the #3 posi-
tion (looking at the piston crown from above) (Fig.
55).
(4) Second piston ring gap should be positioned at
the #1 position (Fig. 55).
(5) Oil control ring gap should be positioned at the
#2 position (Fig. 55).
(6) When assembling pistons check that compo-
nents are installed in the same position as before dis-
assembly, determined by the numbers stamped on
the crown of individual pistons. Engine cylinders are
numbered starting from gear train end of the engine.
Face arrow on top of piston toward front of
engine. Therefore, the numbers stamped on connect-
ing rod big end should face toward the injection
pump side of engine. To insert piston into cylinder
use a ring compressor as shown in (Fig. 56).
INSTALLATION
(1) Before installing pistons, and connecting rod
assemblies into the bore, be sure that compression
ring gaps are staggered so that neither is in line with
oil ring rail gap (Fig. 55).
Fig. 53 PISTON AND CONNECTING ROD ASSEMBLY
1 - PISTON PIN
2 - PISTON
3 - SNAP RING
4 - CONNECTING ROD ALIGNMENT NUMBERS
5 - CONNECTING ROD BOLT
6 - CONNECTING ROD BEARING
7 - CONNECTING ROD
8 - SNAP RING
9a - 40 ENGINE 2.5L TURBO DIESELRG
PISTON & CONNECTING ROD (Continued)

(2) Before installing the ring compressor, make
sure the oil ring expander ends are butted together.
(3) Immerse the piston head and rings in clean
engine oil, slide the ring compressor, over the piston
and tighten (Fig. 56).Ensure position of rings
does not change during this operation.
(4) Face arrow on piston towards front of engine.
NOTE: Be careful not to nick crankshaft journals.
(5) Rotate crankshaft so that the connecting rod
journal is on the center of the cylinder bore. Insert
rod and piston into cylinder bore and guide rod over
the crankshaft journal.
(6) Tap the piston down in cylinder bore, using a
hammer handle. At the same time, guide connecting
rod into position on connecting rod journal.
(7) Install connecting rod caps (Fig. 57). Install rod
bolts and tighten to 30N´m (22 ft.lb.) plus 60É. Then
torque to 88N´m (65 ft.lb).
Fig. 54 PISTON RINGS-INSTALLATION
Fig. 55 PISTON RING GAP LOCATION
3 - TOP COMPRESSION RING GAP POSITION
1 - SECOND COMPRESSION RING GAP POSITION
2 - OIL CONTROL RING GAP POSITION
Fig. 56 PISTON INSTALLATION USING VM.1065
1 - PISTON
2 - VM.1065
3 - ENGINE BLOCK
Fig. 57PISTON AND CONNECTING ROD INSTALLATION
1 - PISTON AND CONNECTING ROD ASSEMBLY
2 - FOUR DIGIT NUMBER
3 - CONNECTING ROD BOLT
4 - FOUR DIGIT NUMBER
RGENGINE 2.5L TURBO DIESEL9a-41
PISTON & CONNECTING ROD (Continued)

(8) Install cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - INSTALLATION).
(9) Install balance shaft assembly (Refer to 9 -
ENGINE/VALVE TIMING/BALANCE SHAFT -
INSTALLATION).
(10) Install oil pump pickup tube (Refer to 9 -
ENGINE/LUBRICATION/OIL PUMP - INSTALLA-
TION).
(11) Install oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION).
(12) Connect negative battery cable.
CRANKSHAFT OIL SEAL -
FRONT
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove air cleaner housing.
(3) Support engine and remove right engine mount
(Refer to 9 - ENGINE/ENGINE MOUNTING/RIGHT
MOUNT - REMOVAL).
(4) Remove power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(5) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(6) Remove vibration damper/crankshaft pulley
(Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL).
(7) Remove outer timing belt cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(8) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL).
(9) Remove timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
NOTE: Crankshaft hub retaining bolt has LHD
thread.
(10) Remove crankshaft hub.
(11) Remove front engine cover (Fig. 58) (Refer to
9 - ENGINE/ENGINE BLOCK/ENGINE COVER -
REMOVAL).
(12) With cover on work bench, pry out old seal.
INSTALLATION
(1) Clean engine block and front engine cover seal-
ing surfaces.
(2) Install crankshaft oil seal on VM.1061 (Fig.
59).(3) Place sleeve for VM.1061 on workbench as
shown (Fig. 59).
(4) Using hammer, install new seal into front
engine cover (Fig. 60).
(5) Install front engine cover (Refer to 9 -
ENGINE/ENGINE BLOCK/ENGINE COVER -
INSTALLATION).
(6) Install crankshaft hub and retaining bolt.
Torque bolt to 304N´m.
(7) Install timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(8) Install timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION) .
(9) Install timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(10) Install vibration damper/crankshaft pulley
(Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - INSTALLATION).
Fig. 58 ENGINE COVER - FRONT
1 - CRANKSHAFT HUB RETAINING BOLT
2 - FRONT ENGINE COVER RETAINING BOLTS
3 - ENGINE BLOCK
4 - FRONT ENGINE COVER ALIGNMENT DOWELS
5 - FRONT ENGINE COVER
6 - CRANKSHAFT HUB
9a - 42 ENGINE 2.5L TURBO DIESELRG
PISTON & CONNECTING ROD (Continued)

(11) Install accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(12) Install power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(13) Install right engine mount (Refer to 9 -
ENGINE/ENGINE MOUNTING/RIGHT MOUNT -
INSTALLATION).
(14) Install air cleaner housing.
(15) Connect negative battery cable.
VIBRATION DAMPER
REMOVAL
(1) Remove power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(2) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(3) Remove vibration damper retaining bolts and
damper (Fig. 61).
Fig. 59 VM.1061 PLACEMENT
1 - VM.1061
2 - FRONT ENGINE COVER
3 - WORK BENCH
4 - SLEEVE FROM VM.1061
Fig. 60 CRANKSHAFT OIL SEAL INSTALLATION
WITH VM.1061
1 - VM.1061
2 - FRONT ENGINE COVER
3 - WORK BENCH
Fig. 61 VIBRATION DAMPER
1 - BELT TENSIONER RETAINING BOLT
2 - BELT TENSIONER
3 - IDLER PULLEY
4 - VIBRATION DAMPER/CRANKSHAFT PULLEY
5 - VIBRATION DAMPER/CRANKSHAFT PULLEY RETAINING
BOLTS
RGENGINE 2.5L TURBO DIESEL9a-43
CRANKSHAFT OIL SEAL - FRONT (Continued)