engine oil CHRYSLER VOYAGER 2002 Service Manual
[x] Cancel search | Manufacturer: CHRYSLER, Model Year: 2002, Model line: VOYAGER, Model: CHRYSLER VOYAGER 2002Pages: 2399, PDF Size: 57.96 MB
Page 1363 of 2399
INSTALLATION
INSTALLATION.......................47
INSTALLATION.......................48
OIL PRESSURE SENSOR/SWITCH
DESCRIPTION.........................48
REMOVAL.............................48
INSTALLATION.........................48
OIL TEMPERATURE SENSOR
DESCRIPTION.........................48
REMOVAL.............................48
INSTALLATION.........................48
OIL PRESSURE RELIEF VALVE
DESCRIPTION.........................49
REMOVAL.............................49
INSTALLATION.........................49
OIL COOLER & LINES
REMOVAL.............................50
INSTALLATION.........................50
OIL FILTER
DESCRIPTION.........................51
REMOVAL.............................51
INSTALLATION.........................51
OIL JET
DESCRIPTION.........................52
REMOVAL.............................52
INSTALLATION.........................52
INTAKE MANIFOLD
DESCRIPTION.........................52
REMOVAL.............................52INSTALLATION.........................52
VALVE TIMING
STANDARD PROCEDURE - LOCKING ENGINE
90É AFTER TDC.......................53
BALANCE SHAFT
DESCRIPTION.........................54
OPERATION...........................54
REMOVAL.............................55
INSTALLATION.........................55
TIMING BELT / CHAIN COVER(S)
REMOVAL
REMOVAL - TIMING BELT OUTER COVER . . 56
REMOVAL - TIMING BELT INNER COVER . . . 56
INSTALLATION
INSTALLATION - TIMING BELT OUTER
COVER.............................56
INSTALLATION - TIMING BELT INNER
COVER.............................57
TIMING BELT IDLER PULLEY
REMOVAL.............................58
INSTALLATION.........................58
TMNG BELT/CHAIN TENSIONER
REMOVAL.............................59
INSTALLATION.........................59
ADJUSTMENTS
ADJUSTMENT - TIMING BELT TENSIONER . 60
TIMING BELT/CHAIN AND SPROCKETS
REMOVAL.............................60
INSTALLATION.........................61
ENGINE 2.5L TURBO DIESEL
DESCRIPTION
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
DESCRIPTION SPECIFICATION
Thermostat Opening 80ÉC 2ÉC
Generator Rating Denso 12V-95A
Cooling System Capacity 13.8 Liters W/O Auxiliary
Heater
16.6 Liters With Auxiliary
Heater
Engine Oil Capacity 6.0L 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 ENGINERG
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Page 1365 of 2399
(9) Remove power steering reservoir hose from
power steering pump and drain power steering fluid
(Fig. 4).
(10) Disconnect high pressure line at pump (Fig.
4).
(11) Disconnect power steering pump return hose
clamp (Fig. 4).
(12) Remove power steering return line retaining
clamp (Fig. 4).
(13) Remove power steering line clamps from oil
pan (Fig. 4).
(14) Remove power steering pump reservoir and
bracket (Fig. 4).(15) Drain coolant system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(16) Remove coolant pressure tank (Fig. 5).
Fig. 4 RESERVOIR AND HOSES - 2.5L DIESEL
1 - POWER STEERING FLUID RESERVOIR
2 - RESERVOIR BRACKET
3 - SUPPLY HOSE BRACKET
4 - RETURN HOSE FROM GEAR
5 - ROUTING CLIP
6 - PRESSURE HOSE TO GEAR
7 - SUPPLY HOSE (PUMP END)
8 - PRESSURE HOSE (PUMP END)
9 - SUPPLY HOSE
10 - RETURN HOSE
Fig. 5 COOLANT RECOVERY PRESSURE
CONTAINER LOCATION
1 - PRESSURE/VENT CAP
2 - BRAKE MASTER CYLINDER
3 - BATTERY
4 - BATTERY SHIELD
5 - COOLANT RECOVERY PRESSURE CONTAINER RETAING
CLIP
6 - ENGINE COVER
7 - COOLANT RECOVERY PRESSURE CONTAINER
9a - 4 ENGINERG
ENGINE 2.5L TURBO DIESEL (Continued)
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Page 1366 of 2399
(17) Remove battery shield.
(18) Remove charge air cooler outlet hose.
(19) Remove charge air cooler inlet hose (Fig. 6).
(20) Disconnect upper radiator hose at engine (Fig.
7).
(21) Disconnect lower radiator hose at engine (Fig.
7).
(22) Disconnet brake booster vacuum supply hose.
(23) Disconnect heater core return hose at engine.
(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. 8).
(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. 9).(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/
Fig. 6 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. 7 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
RGENGINE9a-5
ENGINE 2.5L TURBO DIESEL (Continued)
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Page 1367 of 2399
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.
(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 engine cover retaining bolts.
(2) Remove engine cover from engine (Fig. 10).
Fig. 8 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. 9 REAR ENGINE VIEW
1 - SUSPENSION CRADLE
2 - ENGINE BLOCK
3 - OIL PRESSURE SWITCH
4 - OIL TEMPERATURE SENSOR
5 - VEHICLE SPEED SENSOR
6 - TRANSMISSION
Fig. 10 ENGINE COVER
1 - ENGINE COVER MOUNTING BOLTS
2 - ENGINE COVER
9a - 6 ENGINERG
ENGINE 2.5L TURBO DIESEL (Continued)
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Page 1368 of 2399
INSTALLATION
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.
(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. 8).
(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. 7).
(27) Install charger air cooler inlet hose (Fig. 6).
(28) Install charge air cooler outlet hose (Fig. 6).
(29) Connect upper radiator hose to engine (Fig.
7).
(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. 4).
(33) Raise vehicle
(34) Connect oil pressure sensor, oil temperature
sensor, engine speed sensor, and vehicle speed sensor
electrical connector (Fig. 9).
(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. 4).
(38) Install the power steering line brackets on oil
pan (Fig. 4).
(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. 3).
(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. 2).
(47) Connect negative battery cable.
INSTALLATION - ENGINE COVER
(1) Install engine cover on engine.
(2) Install the engine cover mounting bolts (Fig.
10).
RGENGINE9a-7
ENGINE 2.5L TURBO DIESEL (Continued)
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Page 1370 of 2399
DESCRIPTION SPECIFICATION
PISTONS
Skirt Diameter (measured
at approximately 10 mm
above the bottom of the
skirt)91.912-91.928 mm
Piston Clearance 0.065-0.083 mm
Top of Piston to Cylinder
Head0.69-0.83 mm
Piston Potrusion 0.49-0.60 Fit Gasket
Number (1.32), 0 notches
or holes
0.61-0.70 Fit Gasket
Number (1.42), 1 notch
or hole
0.71-0.83 Fit Gasket
Number (1.52), 2 notches
or holes
PISTON PINS
Type Full Floating
Pin Diameter 29.992-29.996 mm
Clearance 0.004-0.012 mm
PISTON RINGS
Clearance in Groove
Top 0.078-0.137 mm
Second 0.070-0.110 mm
Oil Control 0.040-0.080 mm
Fitted Gap
Top 0.30-0.45 mm
Second 0.30-0.45 mm
Oil Control 0.25-0.50 mm
CAMSHAFT
Journal Diameter±Front 29.960-29.980 mm
Bearing Clearance 0.03-0.08 mm
Journal Diameter±Center 39.250-39.270 mm
Bearing Clearance 0.03-0.08 mm
Journal Diameter±Rear 39.250-39.270 mm
Bearing Clearance 0.03-0.08 mm
HYDRAULIC LIFTER
Outside Diameter 11.994 0.006 mm
VA LV E S
Intake Valve
Opens 16É B.T.D.C.
Closes 58É A.B.D.C.
Exhaust ValveDESCRIPTION SPECIFICATION
Opens 65É B.B.D.C.
Closes 29É A.T.D.C.
Face Angle
Intake 45É 25'-55É 35'
Exhaust 45É 25'-45É 35'
Head Diameter
Intake 32.30-32.50 mm
Exhaust 30.80-31.00 mm
Head Stand Down
Intake 1.08-1.34 mm
Exhaust 0.99-1.25 mm
Stem Diameter
Intake 5.952-5.970 mm
Exhaust 5.942-5.960 mm
Clearance in Guide
Intake 0.030-0.060 mm
Exhaust 0.040-0.070 mm
VALVE GUIDE
Inside Diameter 6.00-6.012 mm
Fitted Height
Intake 14.5-15.0 mm
Exhaust 16.5-17.0 mm
VALVE SPRINGS
Free Length 45.26 mm
Fitted Length 38.00 mm
Load at Fitted Length 182 5-10% Kg
Load at Top of Lift 395 5% Kg
Number of Coils 8
LUBRICATION
System Pressure at 4000
RPM4.5-5.0 bar (oil at
90-100ÉC)
Pressure Relief Valve
Opens6.50 bar
Pressure Relief Valve
Spring-Free Length51.5 mm
OIL PUMP
Outer Rotor End Float 0.060-0.160 mm
Inner Rotor End Float 0.060-0.160 mm
Outer Rotor to Body
Diameter Clearance0.130-0.240 mm
Rotor Body to Drive Gear
Clearance (pump not
fitted)0.90-1.50 mm
RGENGINE9a-9
ENGINE 2.5L TURBO DIESEL (Continued)
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Page 1371 of 2399
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
9a - 10 ENGINERG
ENGINE 2.5L TURBO DIESEL (Continued)
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Page 1372 of 2399
DESCRIPTION N´m Ft. Lbs. In. Lbs.
8mm 10.8 8 96
10mm 47.1 35 Ð
Outer Timing Belt Cover
Bolts
3mm 6 Ð 54
8mm 10.8 8 96
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
RGENGINE9a-11
ENGINE 2.5L TURBO DIESEL (Continued)
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Page 1375 of 2399
VM.1056 BALANCE SHAFT LOCKING PIN
VM.1059 OIL PRESSURE RELIEF VALVE INSTALLER
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 ENGINERG
ENGINE 2.5L TURBO DIESEL (Continued)
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Page 1381 of 2399
(13) Remove rocker arm and lifter assemblies from
cylinder head.
(14) Remove cylinder head cover/intake manifold
gasket from cylinder head.
(15) Disconnect glow plug and engine coolant tem-
perture electrical connectors.
(16) Remove coolant recovery pressure container
(Refer to 7 - COOLING/ENGINE/COOLANT RECOV-
ERY PRESS CONTAINER - REMOVAL).
(17) Remove thermostat housing to upper radiator
hose pipe (Fig. 16).
(18) Remove turbocharger outlet to charge air
cooler pipe (Fig. 16).(19) Remove exhaust manifold heat shield (Fig.
17).
(20) Remove exhaust manifold retaining nuts (Fig.
17).
(21) Slide exhaust manifold and turbocharger off of
exhaust manifold studs (Fig. 17).
(22) Remove cylinder head bolts.
Fig. 16 TURBOCHARGER AND COOLANT PIPES
1 - TURBOCHARGER OUTLET PIPE RETAINING BOLT
2 - TURBOCHARGER OUTLET PIPE
3 - ADAPTER HOSE
4 - HEAT SHIELD
5 - HOSE CLAMPS
6 - TURBOCHARGER INLET PIPE RETAINING BOLT
7 - TURBOCHARGER INLET PIPE
8 - ADAPTER HOSE
9 - HOSE CLAMPS
10 - CLAMP
11 - EGR VALVE TO INTAKE AIR INLET PIPE
12 - CLAMP
13 - THERMOSTAT HOUSING TO UPPER RADIATOR HOSE
PIPE
Fig. 17 EXHAUST MANIFOLD AND
TURBOCHARGER
1 - TURBOCHARGER OIL SUPPLY BANJO BOLT
2 - COPPER WASHER
3 - EXHAUST MANIFOLD GASKET
4 - COPPER WASHER
5 - EXHAUST MANIFOLD HEAT SHIELD RETAINING BOLT
6 - TURBOCHARGER
7 - ENGINE LIFT HOOK
8 - ENGINE LIFT HOOK RETAINING BOLT
9 - SPACER
10 - EXHAUST MANIFOLD RETAINING NUT
11 - TURBOCHARGER OIL RETURN HOSE
12 - HOSE CLAMPS
13 - EXHAUST MANIFOLD STUDS
9a - 20 ENGINERG
CYLINDER HEAD (Continued)
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