2001 CHRYSLER VOYAGER engine cooling

INSTALLATION
(1) Install vibration damper and retaining bolts
(Fig. 61). Torque bolts to 27.5N´m.
(2) Install accessory drive belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(3) Install power steering belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
ENGINE COVER - FRONT
DESCRIPTION
The front engine cover on this engine is a stamped
steel cover which covers the oil pump and vacuum
pump.
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 (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(7) Remove timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
CAUTION: Before removing the cylinder head cover/
intake manifold or timing belt the engine must put
at 90É after TDC. Failure to do so could result in
valve and/or piston damage during reassembly.
(Refer to 9 - ENGINE/VALVE TIMING - STANDARD
PROCEDURE)(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 (Fig. 62).
Fig. 62 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 - 44 ENGINE 2.5L TURBO DIESELRG
VIBRATION DAMPER (Continued)

INSTALLATION
(1) Clean engine block and front engine cover seal-
ing surfaces.
(2) Apply a continous 3mm bead of Silicone Sealer
to cover, install within 10 minutes (Fig. 62). Torque
bolts to 11.8N´m.
(3) Install crankshaft hub (Fig. 62). Torque bolt to
304N´m.
(4) Install timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(5) Install timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION) .
(6) Install timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(7) Install vibration damper (Refer to 9 - ENGINE/
ENGINE BLOCK/VIBRATION DAMPER - INSTAL-
LATION).
(8) Install right engine mount (Refer to 9 -
ENGINE/ENGINE MOUNTING/RIGHT MOUNT -
INSTALLATION).
(9) Install accessory drive belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(10) Install power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(11) Install air cleaner housing.
(12) Connect negative battery cable.
CRANKSHAFT MAIN
BEARINGS
REMOVAL
The engine must be removed from vehicle and com-
pletely disassembled to replace the front main bear-
ing.
CRANKSHAFT MAIN BEARINGS
(1) With crankshaft assembly removed from
engine.
(2) Remove crankshaft supports from crankshaft
and remove bearing halves from supports (Fig. 63).
CRANKSHAFT FRONT MAIN BEARING
(1) Using special tool VM.1073 push front main
bearing out of front of engine block (Fig. 64).
Fig. 63 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-45
ENGINE COVER - FRONT (Continued)

INSTALLATION
(1) Clean oil pan and sealing surfaces. Inspect oil
pan and engine block.
(2) Install oil pan, gasket, and retaining bolts (Fig.
69).
(3) Be sure power steering line brackets are in
proper location (Fig. 69).
(4) Torque oil pan bolts to 11.8N´m.
(5) Lower vehicle.
(6) Refill engine oil to proper level.
(7) Connect negative battery cable.
OIL PUMP
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(3) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
Fig. 66 FRONT MAIN BEARING INSTALLATION
1 - FRONT CRANKSHAFT MAIN BEARING
2 - ENGINE BLOCK
3 - SPECIAL TOOL VM.1073
Fig. 67 FRONT MAIN BEARING ALIGNMENT
1 - ENGINE BLOCK
2 - OIL HOLE IN BEARING
3 - FRONT CRANKSHAFT MAIN BEARING
Fig. 68 REAR CRANKSHAFT OIL SEAL
INSTALLATION USING VM.1050
1 - SPECIAL TOOL VM.1050
2 - REAR MAIN BEARING SUPPORT
3 - OIL PAN
4 - ENGINE TO TRANSMISSION ADAPTER PLATE
RGENGINE 2.5L TURBO DIESEL9a-47
OIL PAN (Continued)

(7) Install timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION) .
(8) Install timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(9) Install accessory drive belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(10) Install power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(11) Connect negative battery cable.
INSTALLATION
(1) Lubricate o-ring on oil pump pickup tube with
engine oil.
(2) Install pickup tube in engine block and install
retaining bolt (Fig. 71). Torque bolt to 32.4N´m.
(3) Install oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION).
(4) Refill engine oil to proper level.
(5) Connect negative battery cable.
OIL PRESSURE SENSOR/
SWITCH
DESCRIPTION
The oil pressure switch is located on the right side
of the engine block. The switch screws into the
engines main oil gallery (Fig. 72).
REMOVAL
(1) Disconnect negative battery cable.
(2) Raise vehicle on hoist.
(3) Disconnect oil pressure switch electrical con-
nector (Fig. 72).
(4) Remove oil pressure switch from engine block.
Fig. 71 OIL PUMP PICKUP TUBE ASSEMBLY
1 - BALANCE SHAFT
2 - OIL JET RETAINING BOLT
3 - OIL JET
4 - ENGINE BLOCK
5 - CRANKSHAFT
6 - BALANCE SHAFT RETAINING BOLTS
7 - OIL DIPSTICK TUBE RETAINER
8 - RUBBER BUSHING
9 - RETAINING BOLT
Fig. 72 REAR ENGINE VIEW
1 - SUSPENSION CRADLE
2 - ENGINE BLOCK
3 - OIL PRESSURE SWITCH
4 - OIL TEMPERATURE SENSOR
5 - VEHICLE SPEED SENSOR
6 - TRANSMISSION
RGENGINE 2.5L TURBO DIESEL9a-49
OIL PUMP (Continued)

REMOVAL
(1) Remove engine oil pan (Refer to 9 - ENGINE/
LUBRICATION/OIL PAN - REMOVAL).
(2) Using special tool VM.1054, remove oil pres-
sure relief valve from engine block (Fig. 75).
INSTALLATION
(1) Thoroughly clean all components and relief
valve pocket in cylinder block.
(2) Lubricate all oil pressure relief valve compo-
nents with engine oil.
(3) Install oil pressure relief valve plunger, spring,
and cap.(4) Using special tool VM.1059, push oil pressure
relief valve cap in untill flush with engine block (Fig.
76).
(5) Install oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION).
OIL COOLER & LINES
REMOVAL
(1) Drain cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(2) Raise vehicle on hoist.
(3) Remove oil filter cap and filter (Refer to 9 -
ENGINE/LUBRICATION/OIL FILTER - REMOVAL).
(4) Remove oil filter housing retaining nut and
housing (Fig. 77).
(5) Disconnect coolant hoses at cooler (Fig. 78).
(6) Remove oil cooler retaining bolt at engine block
(Fig. 78).
Fig. 75 OIL PRESSURE RELIEF VALVE REMOVAL
1 - VM.1054
2 - OIL PRESSURE RELIEF VALVE
3 - ENGINE BLOCK
4 - OIL PUMP
Fig. 76 OIL PRESSURE RELIEF VALVE
INSTALLATION
1 - VM.1059
2 - OIL PRESSURE RELIEF VALVE
3 - ENGINE BLOCK
4 - OIL PUMP
RGENGINE 2.5L TURBO DIESEL9a-51
OIL PRESSURE RELIEF VALVE (Continued)

(7) Remove oil cooler retaining stud and remove oil
cooler from engine block (Fig. 78).
INSTALLATION
(1) Clean oil cooler and engine block sealing sur-
faces.
(2) Install oil cooler, retaining bolt, and stud (Fig.
78). Torque retaining bolt to 47.1N´m and stud to
50N´m.
(3) Connect coolant hoses at cooler (Fig. 78).
(4) Install oil filter housing and retaining nut (Fig.
77).
(5) Install oil filter cartridge and oil filter cap
(Refer to 9 - ENGINE/LUBRICATION/OIL FILTER -
INSTALLATION).
(6) Lower vehicle.
(7) Refill cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(8) Start engine and check for leaks.
(9) Check and adjust oil level as necessary.
OIL FILTER
DESCRIPTION
The oil filter used on this engine is a cartridge
style filter (Fig. 79).
Fig. 77 OIL FILTER HOUSING RETAINING NUT
1 - OIL FILTER HOUSING
2 - OIL FILTER HOUSING RETAINING NUT
3 - OIL COOLER
Fig. 78 WATER PUMP AND OIL COOLER
ASSEMBLIES
1 - WATER PUMP HOUSING STUDS
2 - WATER PUMP
3 - RETAINING NUTS
4 - OIL COOLER RETAINING STUD
5 - OIL COOLER TO ENGINE BLOCK RETAINING BOLT
6 - OIL COOLER COOLANT HOSE
7 - ENGINE BLOCK
Fig. 79 OIL FILTER ASSEMBLY
1 - OIL FILTER CAP
2 - DRAIN PLUG
3 - OIL FILTER CARTRIDGE
9a - 52 ENGINE 2.5L TURBO DIESELRG
OIL COOLER & LINES (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)

INSTALLATION - TIMING BELT INNER COVER
(1) Install timing belt inner cover to engine front
cover seal (Fig. 92).
(2) Install timing belt inner cover to cylinder head
cover gaskets (Fig. 92).
(3) Install timing belt inner cover and retaining
bolts (Fig. 92). Torque 10mm bolts to 47.1N´m and
8mm bolts to 10.8N´m.
(4) Install injection pump sprocket (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL INJEC-
TION PUMP - INSTALLATION).
(5) Install camshaft sprockets (Fig. 91). Torque
bolts to 108N´m.(6) Install timing belt idler pulleys (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT IDLER
PULLEY - INSTALLATION).
(7) Install timing belt and tensioner (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - INSTALLATION) .
(8) Install timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(9) Install vibration damper (Refer to 9 - ENGINE/
ENGINE BLOCK/VIBRATION DAMPER - INSTAL-
LATION).
(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 right engine mount assembly.
(13) Install air cleaner housing.
(14) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
(15) Connect negative battery cable.
TIMING BELT IDLER PULLEY
REMOVAL
(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.
(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 (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(9) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL).
NOTE: Idler pulley retaining bolts are LHD thread.
(10) Remove timing belt idler pulleys (Fig. 93).Fig. 92 TIMING BELT COVER - INNER
1 - TIMING BELT COVER TO CYLINDER HEAD COVER GASKET
2 - TIMING BELT COVER TO FRONT ENGINE COVER SEAL
3 - RUBBER GROMMET
4 - BUSHING
5 - TIMING BELT COVER - INNER
6 - RETAINING BOLT
7 - RETAINING BOLT
8 - RETAINING BOLT
9 - BUSHING
10 - RUBBER GROMMET
RGENGINE 2.5L TURBO DIESEL9a-59
TIMING BELT / CHAIN COVER(S) (Continued)