2001 CHRYSLER VOYAGER engine diesel

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)

(10) Disconnect high pressure line at pump (Fig.
5).
(11) Disconnect power steering pump return hose
clamp (Fig. 5).
(12) Remove power steering return line retaining
clamp (Fig. 5).
(13) Remove power steering line clamps from oil
pan (Fig. 5).
(14) Remove power steering pump reservoir and
bracket (Fig. 5).
(15) Drain coolant system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(16) Remove coolant pressure tank (Fig. 6).
(17) Remove battery shield.
(18) Remove charge air cooler outlet hose.
(19) Remove charge air cooler inlet hose (Fig. 7).
(20) Disconnect upper radiator hose at engine (Fig.
8).
(21) Disconnect lower radiator hose at engine (Fig.
8).
(22) Disconnet brake booster vacuum supply hose.
(23) Disconnect heater core return hose at engine.
Fig. 4 MASS AIR FLOW (MAF) SENSOR LOCATION
1 - MAF SENSOR ELECTRICAL CONNECTOR
2 - RETAINING CLAMPS
3 - MASS AIR FLOW (MAF) SENSOR
4 - AIR CLEANER HOUSING
Fig. 5 RESERVOIR AND HOSES - 2.5L DIESEL
1 - 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. 6 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 ENGINE 2.5L TURBO DIESELRG
ENGINE 2.5L TURBO DIESEL (Continued)

(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. 9).
(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. 10).
(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/
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.
Fig. 7 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. 8 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
RGENGINE 2.5L TURBO DIESEL9a-5
ENGINE 2.5L TURBO DIESEL (Continued)

(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 the engine cover retaining bolts.
(2) Remove the engine cover from the engine.
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.
Fig. 9 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. 10 REAR ENGINE VIEW
1 - SUSPENSION CRADLE
2 - ENGINE BLOCK
3 - OIL PRESSURE SWITCH
4 - OIL TEMPERATURE SENSOR
5 - VEHICLE SPEED SENSOR
6 - TRANSMISSION
Fig. 11 Figure Caption Here
1 - ENGINE COVER MOUNTING BOLTS
2 - ENGINE COVER
9a - 6 ENGINE 2.5L TURBO DIESELRG
ENGINE 2.5L TURBO DIESEL (Continued)

(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. 9).
(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. 8).
(27) Install charger air cooler inlet hose (Fig. 7).
(28) Install charge air cooler outlet hose (Fig. 7).
(29) Connect upper radiator hose to engine (Fig.
8).
(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. 5).
(33) Raise vehicle
(34) Connect oil pressure sensor, oil temperature
sensor, engine speed sensor, and vehicle speed sensor
electrical connector (Fig. 10).(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. 5).
(38) Install the power steering line brackets on oil
pan (Fig. 5).
(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. 4).
(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. 3).
(47) Connect negative battery cable.
INSTALLATION - ENGINE COVER
(1) Install engine cover on engine.
(2) Install the engine cover mounting bolts (Fig.
11).
SPECIFICATIONS
SPECIFICATIONS - 2.5L COMMON RAIL
DIESEL ENGINE
ENGINE SPECIFICATIONS
DESCRIPTION SPECIFICATION
Type R2516C
Number of Cylinders 4
Bore 92 mm
Stroke 94 mm
Displacement 2499.5cc
Injection Order 1-3-4-2
Compression Ratio 17.5:1 (  0.5)
Maximum Power 103kW (140 HP) @ 4000
RPM
Peak Torque 340Nm (34.6 kgm) @
1800 RPM
RGENGINE 2.5L TURBO DIESEL9a-7
ENGINE 2.5L TURBO DIESEL (Continued)

DESCRIPTION SPECIFICATION
CRANKSHAFT
Front Journal Diameter
Nominal 62.985-63.005 mm
-0.25 62.735-62.755 mm
-0.125 62.860-62.880 mm
Front Bearing Diameter
Nominal 63.045-63.074 mm
-0.25 62.795-62.824 mm
-0.125 62.920-62.949 mm
Clearance Between
Journal and Bearing0.040-0.089 mm
Center Journal Diameter
Nominal 63.005-63.020 mm
-0.25 62.755-62.770 mm
-0.125 62.880-62.895 mm
Center Bearing Diameter
Nominal 63.969-63.997 mm
-0.25 62.719-62.747 mm
-0.125 62.844-62.872 mm
Clearance Between
Journal and Bearing0.008-0.051 mm
Rear Journal Diameter
Nominal 89.980-90.000 mm
-0.25 89.730-99.750 mm
-0.125 89.855-99.875 mm
Rear Bearing Diameter
Nominal 90.045-90.065 mm
-0.25 89.795-89.815 mm
-0.125 89.920-89.940 mm
Clearance Between
Journal and Bearing0.045-0.085 mm
Wear Limit 0.200 mm
Connecting Rod Journal
Nominal 53.977-54.016 mm
-0.25 53.690-53.705 mm
-0.125 53.815-53.830 mm
Connecting Rod Bearing
Nominal 53.977-54.016 mm
-0.25 53.727-53.766 mm
-0.125 53.852-53.891 mm
Clearance Between
Journal and Bearing0.022-0.076 mm
Wear Limit 0.200 mmDESCRIPTION SPECIFICATION
Crankshaft End Play
End Play 0.080-0.280 mm
Adjustment Thrust Washers
Thrust Washers Available 2.31-2.36 mm
2.41-2.46 mm
2.51-2.56mm
MAIN BEARING CARRIERS
Internal Diameter
Front 67.025-67.050 mm
Center 66.670-66.687 mm
Rear 85.985-86.005 mm
LINERS
Internal Diameter 91.997-92.015 mm
Protrusion 0.01-0.06 mm
Adjustment Shims
Available Shims 0.15 mm
0.17 mm
0.20 mm
0.23 mm
0.25 mm
CYLINDER HEAD
Minimum Thickness 89.95-90.05 mm
Gasket Thickness 1.32 mm   0.08, 0
notches
1.42 mm   0.08, 1 notch
1.52 mm   0.08, 2
notches
End Plates
Height 89.92-90.00 mm
CONNECTING RODS
Weight (without the
crankbearing)1129-1195 grams
Small End Bearing
Internal Diameter
Minimum 30.035 mm
Maximum 30.050 mm
Large End Internal
Diameter53.977-54.016 mm
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
9a - 8 ENGINE 2.5L TURBO DIESELRG
ENGINE 2.5L TURBO DIESEL (Continued)

DESCRIPTION SPECIFICATION
Top of Piston to Cylinder
Head0.69-0.92 mm
Piston Potrusion 0.40-0.60 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 0.080-0.130 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 38.980-39.000 mm
Bearing Clearance 0.100-0.150 mm
Journal Diameter±Center 38.980-39.000 mm
Bearing Clearance 0.100-0.150 mm
Journal Diameter±Rear 38.980-39.000 mm
Bearing Clearance 0.100-0.150 mm
TAPPETS
Outside Diameter 14.965-14.985 mm
ROCKER GEAR
Shaft Diameter 29.960-29.980 mm
Bushing Internal
Diameter30.020-30.060 mm
Assembly Clearance 0.040-0.100 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 14.5-15.0 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
Opens7.00 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
RGENGINE 2.5L TURBO DIESEL9a-9
ENGINE 2.5L TURBO DIESEL (Continued)