2001 CHRYSLER VOYAGER Service Manual

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Page 2793 of 4284

CHRYSLER VOYAGER 2001 Service Manual DESCRIPTION N´m Ft. Lbs. In. Lbs.
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
Tim

Page 2794 of 4284

CHRYSLER VOYAGER 2001 Service Manual SPECIAL TOOLS
SPECIAL TOOLS
VM.1050 CRANKSHAFT REAR SEAL INSTALLER
VM.1051 TDC ALIGNMENT PIN
VM.1052 INTAKE CAMSHAFT ALIGNMENT PIN
VM.1053 EXHAUST CAMSHAFT ALIGNMENT PIN
9a - 12 ENGINE 2.5L TURBO DIES

Page 2795 of 4284

CHRYSLER VOYAGER 2001 Service Manual VM.1054 RELIEF VALVE REMOVER/CENTRAL
CARRIER PIN REMOVER/INSTALLER
VM.1055 CAMSHAFT/INJECTION PUMP GEAR
HOLDER
VM.1056 BALANCE SHAFT LOCKING PIN
VM.1059 OIL PRESSURE RELIEF VALVE INSTALLER
RGENGINE 2.

Page 2796 of 4284

CHRYSLER VOYAGER 2001 Service Manual 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 ENGINE 2.5L TURBO DIESELRG
ENGINE 2.5L TURBO DIESEL (Con

Page 2797 of 4284

CHRYSLER VOYAGER 2001 Service Manual VM.1064 POWER STEERING PUMP GEAR
REMOVER
VM.1065 PISTON RING COMPRESSOR
VM.1066 CYLINDER HEAD COVER ALIGNMENT
PINS
VM.1068 90 DEGREES AFTER TDC ALIGNMENT PIN
RGENGINE 2.5L TURBO DIESEL9a-15
ENGINE 2.5

Page 2798 of 4284

CHRYSLER VOYAGER 2001 Service Manual VM.1069 CRANKSHAFT REM/INSTALL SLEEVE
VM.1070 FLYWHEEL LOCKING TOOL
VM.1072 COMPRESSION TESTER ADAPTER
VM.1073 CRANKSHAFT FRONT BEARING
REMOVER/INSTALLER
9a - 16 ENGINE 2.5L TURBO DIESELRG
ENGINE 2.5L

Page 2799 of 4284

CHRYSLER VOYAGER 2001 Service Manual VM.1074 TIMING BELT RETAINER
VM.1075 FLYWHEEL ALIGNMENT PINS
VM.1077 POWER STEERING BELT REMOVER
VM.1078 POWER STEERING BELT INSTALLER
RGENGINE 2.5L TURBO DIESEL9a-17
ENGINE 2.5L TURBO DIESEL (Continu

Page 2800 of 4284

CHRYSLER VOYAGER 2001 Service Manual CYLINDER HEAD
STANDARD PROCEDURE - VALVE SERVICE
This procedure is done with the engine cylinder
head removed from the block.
DISASSEMBLY
(1) Remove the engine cylinder head from the cyl-
inder block.

CYLINDER HEAD
STANDARD PROCEDURE - VALVE SERVICE
This procedure is done with the engine cylinder
head removed from the block.
DISASSEMBLY
(1) Remove the engine cylinder head from the cyl-
inder block. Refer to cylinder head removal and
installation in this section.
(2) Use Valve Spring Compressor Tool and com-
press each valve spring.
(3) Remove the valve locks, retainers, and springs.
(4) Use an Arkansas smooth stone or a jewelers
file to remove any burrs on the top of the valve stem,
especially around the groove for the locks.
(5) Remove the valves, and place them in a rack in
the same order as removed.
VALVE CLEANING
(1) Clean all carbon deposits from the combustion
chambers, valve ports, valve stems, valve stem
guides and head.
(2) Clean all grime and gasket material from the
engine cylinder head machined gasket surface.
INSPECTION
(1) Inspect for cracks in the combustion chambers
and valve ports.
(2) Inspect for cracks on the exhaust seat.
(3) Inspect for cracks in the gasket surface at each
coolant passage.
(4) Inspect valves for burned, cracked or warped
heads.
(5) Inspect for scuffed or bent valve stems.
(6) Replace valves displaying any damage.
(7) Check valve spring height (Fig. 12).
VALVE REFACING
(1) Use a valve refacing machine to reface the
intake and exhaust valves to the specified angle.
(2) After refacing, a margin of at least 4.52-4.49
mm (.178-.177 inch) must remain (Fig. 13). If the
margin is less than 4.49 mm (.177 inch), the valve
must be replaced.
VALVE SEAT REFACING
(1) Install a pilot of the correct size in the valve
guide bore. Reface the valve seat to the specified
angle with a good dressing stone. Remove only
enough metal to provide a smooth finish.
(2) Use tapered stones to obtain the specified seat
width when required.
VALVE STAND DOWN
Valve stand down is to maintain the adequate com-
pression ratio.
(1) Invert cylinder head.
(2) Fit each valve to its respective valve guide.
(3) Using a straight edge and feeler gauge, check
valve head stand down: Inlet valve head stand down
1.08 to 1.34 mm (.042 to .052 ins.) and exhaust valve
stand down .99 to 1.25 mm (.035 to .049 ins.).
(4) If valve head stand down is not in accordance
with above, discard original valves, check stand down
with new valves and recut valve seat inserts to
obtain correct stand down.
VALVE GUIDES
(1) Valve Guides height requirement.
(2) Measurement A (Fig. 14): 13.50 - 14.00 mm.
VALVE STEM-TO-GUIDE CLEARANCE
MEASUREMENT
(1) Measure and record internal diameter of valve
guides. Valve guide internal diameter is 8.0 to 8.015
mm (.3149 to .3155 ins.).
(2) Measure valve stems and record diameters.
Intake valve stem diameter 7.94 to 7.96 mm (.3125 to
.3133 in). Exhaust valve stem diameter 7.92 to 7.94
mm (.3118 to .31215 in).
Fig. 12 VALVE SPRING CHART
LOAD Kg HEIGHT mm STATE
P1 0.00 H1 45.26 FREE LENGTH
P2 182 5 -
10%H2 38.00 VALVE CLOSED
P3 395 5% H3 28.20 VALVE OPEN
9a - 18 ENGINE 2.5L TURBO DIESELRG

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