2001 CHRYSLER VOYAGER steering

(4) Install turbo inlet tube retaining bolt at intake
manifold. Torque bolt to 27.5 N´m.
(5) Connect oil separator outlet hose at separator.
(6) Install oil dipstick tube retaining bolt at intake
manifold inlet. Torque bolt to 10 N´m.
(7) Install power steering pump reservoir in
bracket.
(8) Install fuel rail (Refer to 14 - FUEL SYSTEM/
FUEL DELIVERY/FUEL RAIL - INSTALLATION).
(9) Install fuel injectors and fuel injector supply
lines (Refer to 14 - FUEL SYSTEM/FUEL INJEC-
TION/FUEL INJECTOR - INSTALLATION).
(10) Connect vacuum lines at EGR solenoid.
(11) Clip wiring harness retainers on studs on fuel
rail (Fig. 24).
(12) Connect camshaft position sensor, boost pres-
sure/intake air temperature sensor, EGR solenoid,
and fuel pressure sensor electrical connectors (Fig.
24).
(13) Install inner timing belt cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(14) Install timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION) .
(15) Install outer timing belt cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(16) Install right engine mount (Refer to 9 -
ENGINE/ENGINE MOUNTING/RIGHT MOUNT -
INSTALLATION).
(17) Install generator (Refer to 8 - ELECTRICAL/
CHARGING/GENERATOR - INSTALLATION).
(18) Install accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(19) Install power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(20) Install air cleaner housing assembly.
(21) Remove crankshaft and both camshaft locking
pins (Refer to 9 - ENGINE/VALVE TIMING - STAN-
DARD PROCEDURE).
(22) Refill cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(23) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
(24) Install front wiper unit (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
INSTALLATION).
(25) Connect negative battery cable.
Fig. 27 CYLINDER HEAD COVER/INTAKE
MANIFOLD ALIGNMENT STUDS VM.1066
1 - CYLINDER HEAD COVER/INTAKE MANIFOLD ALIGNMENT
STUDS VM.1066
2 - CYLINDER HEAD
Fig. 28 CYLINDER HEAD COVER/INTAKE
MANIFOLD TIGHTENING SEQUENCE
RGENGINE 2.5L TURBO DIESEL9a-27
CYLINDER HEAD COVER(S) (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)

(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)

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)