2001 CHRYSLER VOYAGER lock

(19) Remove exhaust manifold heat shield (Fig.
18).
(20) Remove exhaust manifold retaining nuts (Fig.
18).
(21) Slide exhaust manifold and turbocharger off of
exhaust manifold studs (Fig. 18).
(22) Remove cylinder head bolts.
(23) Remove cylinder head assembly from engine
block (Fig. 19).CLEANING
Thoroughly clean the engine cylinder head and cyl-
inder block mating surfaces. Clean the intake and
exhaust manifold and engine cylinder head mating
surfaces. Remove all gasket material and carbon.
Check to ensure that no coolant or foreign material
has fallen into the tappet bore area.
Remove the carbon deposits from the combustion
chambers and top of the pistons.
Fig. 17 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. 18 EXHAUST MANIFOLD AND
TURBOCHARGER
1 - TURBOCHARGER OIL SUPPLY LINE BANJO FITTING
2 - WASHER
3 - EXHAUST MANIFOLD GASKET
4 - WASHER
5 - HEAT SHIELD RETAINING BOLTS
6 - TURBOCHARGER
7 - LIFT HOOK
8 - LIFT HOOK RETAINING BOLTS
9 - SPACERS
10 - EXHAUST MANIFOLD RETAINING NUTS
11 - TURBOCHARGER OIL RETURN HOSE
12 - CLAMPS
13 - EXHAUST MANIFOLD STUD
RGENGINE 2.5L TURBO DIESEL9a-21
CYLINDER HEAD (Continued)

INSPECTION
Use a straightedge and feeler gauge to check the
flatness of the engine cylinder head and block mating
surfaces.
The minimum cylinder head thickness is 89.95mm
(3.541 in.).
INSTALLATION
CAUTION: Piston protrusion must be measured to
determine cylinder head gasket thickness if one or
more cylinder liners have benn replaced (Refer to 9
- ENGINE/CYLINDER HEAD - STANDARD PROCE-
DURE).
NOTE: If cylinder liner(s) have not been removed,
the same thickness head gasket that was removed
can be used.(1) Clean and inspect gasket mating surfaces.
(2) Position correct head gasket on engine block.
(3) Place cylinder head on engine block (Fig. 19).
CAUTION: New cylinder head bolts must be uesd.
(4) Tighten cylinder head bolts following procedure
below.
Cylinder Head Bolt Torquing Procedure
(1) Lubricate cylinder head bolts with engine oil.
(2) Torque bolts to 30N´m in numerical starting
with bolt #1 (Fig. 20).
(3) Tighten all bolts an additional 50É, starting
with bolt #4 then 5-6-7-8-9-10-1-2-3-11-12-13-14-15-
16-17-18 (Fig. 20).
(4) Finally tighten all bolts an additional 75É in
numerical order starting with bolt #1 (Fig. 20).
(5) Slide exhaust manifold and turbocharger on
exhaust manifold studs (Fig. 18).
(6) Install exhaust manifold retaining nuts. Torque
nuts to 32.4N´m.
(7) Install exhaust manifold heat shield (Fig. 18).
Torque bolts to 27.5N´m.
(8) Install turbocharger outlet to charge air cooler
pipe (Fig. 17).
(9) Install thermostat housing to upper radiator
hose pipe (Fig. 17). Install retaining bolt and torque
to 47.1N´m.
(10) Install coolant recovery pressure container
(Refer to 7 - COOLING/ENGINE/COOLANT RECOV-
ERY PRESS CONTAINER - INSTALLATION).
Fig. 19 CYLINDER HEAD ASSEMBLY
1 - VALVE SPRING
2 - CYLINDER HEAD BOLT
3 - GLOW PLUG
4 - COOLANT TEMPERATURE SENSOR
5 - CYLINDER HEAD ALIGNMENT DOWEL
6 - CYLINDER BLOCK
7 - CYLINDER LINER
8 - ENGINE BLOCK DECK
9 - CYLINDER HEAD GASKET
10 - CYLINDER HEAD
11 - ROCKER ARM AND LIFTER ASSEMBLY
Fig. 20 CYLINDER HEAD TORQUE SEQUENCE
9a - 22 ENGINE 2.5L TURBO DIESELRG
CYLINDER HEAD (Continued)

(11) Connect glow plug and coolant temperature
sensor electrical connectors.
(12) Install new cylinder head cover/intake mani-
fold gasket.
(13) Install rocker arm and lifter assemblies.Be
sure to put rocker arm and lifter assemblies in
same location as removed.
(14) Install cylinder head cover/intake manifold
(Fig. 16)(Refer to 9 - ENGINE/CYLINDER HEAD/
CYLINDER HEAD COVER(S) - INSTALLATION).
(15) Install timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(16) Install timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION) .
(17) Install timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(18)Remove crankshaft and both camshaft
locking pins at this time(Refer to 9 - ENGINE/
VALVE TIMING - STANDARD PROCEDURE).
(19) Install generator (Refer to 8 - ELECTRICAL/
CHARGING/GENERATOR - INSTALLATION).
(20) Install accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(21) Install power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(22) Install right engine mount (Refer to 9 -
ENGINE/ENGINE MOUNTING/RIGHT MOUNT -
INSTALLATION).
(23) Install air cleaner housing assembly.
(24) Refill cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(25) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
(26) Install front wiper unit (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
INSTALLATION).
(27) Connect negative battery cable.
CAMSHAFT(S)
DESCRIPTION
The camshafts are made of gray cast iron with
eight machined lobes and four bearing journals (Fig.
21).
OPERATION
When the camshaft rotates the lobes actuate the
hydraulic lifters and rocker arms, forcing downward
on the rocker arms which opens the valves.
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove front wiper unit (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
REMOVAL).
(3) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(4) Drain cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(5) Remove air cleaner housing.
(6) Remove power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(7) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(8) Remove generator (Refer to 8 - ELECTRICAL/
CHARGING/GENERATOR - REMOVAL).
(9) Support engine and remove right engine mount
(Refer to 9 - ENGINE/ENGINE MOUNTING/RIGHT
MOUNT - 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)
(10) Remove timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(11) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL).
(12) Remove timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
Fig. 21 CAMSHAFTS
1 - INTAKE CAMSHAFT
2 - EXHAUST CAMSHAFT
RGENGINE 2.5L TURBO DIESEL9a-23
CYLINDER HEAD (Continued)

(13) Remove cylinder head cover/intake manifold
(Refer to 9 - ENGINE/CYLINDER HEAD/CYLIN-
DER HEAD COVER(S) - REMOVAL).
(14) With cylinder head cover/intake manifold on
work bench, remove plugs at rear of cylinder head
cover/intake manifold.
(15) Remove camshaft oil seals (Fig. 22).
(16) Remove snapring and thrust washer from
camshaft (Fig. 22).
(17) Slide camshaft through access hole at rear of
cylinder head cover/intake manifold.
INSTALLATION
(1) Lubricate the camshafts with MopartEngine
Oil Supplement, or equivalent.
(2) Carefully install camshafts into access holes in
rear of cylinder head cover/intake manifold.
(3) Install thrust washer, snapring, and camshaft
oil seal (Fig. 22).
(4) Install access hole plugs and gaskets at rear of
cylinder head cover/intake manifold. Torque plugs to
80N´m.
(5) Install cylinder head cover/intake manifold on
engine block (Refer to 9 - ENGINE/CYLINDER
HEAD/CYLINDER HEAD COVER(S) - INSTALLA-
TION).(6) Install timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(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 right engine mount (Refer to 9 -
ENGINE/ENGINE MOUNTING/RIGHT MOUNT -
INSTALLATION).
(10) Install generator (Refer to 8 - ELECTRICAL/
CHARGING/GENERATOR - INSTALLATION).
(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 air cleaner housing.
(14) Refill cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(15) Install front wiper unit (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
INSTALLATION).
(16) Connect negative battery cable.
CYLINDER HEAD COVER(S)
DESCRIPTION
The cylinder head cover is made of cast aluminum
and is also the intake manifold on this engine (Fig.
23).
REMOVAL
CAUTION: Before removing the cylinder head cover/
intake manifold 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)
(1) Disconnect negative battery cable.
(2) Remove front wiper unit (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
REMOVAL).
(3) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(4) Drain cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(5) Rotate engine until 90É after TDC is reached.
Install both camshaft locking pins and the crankshaft
locking pin. (Refer to 9 - ENGINE/VALVE TIMING -
STANDARD PROCEDURE)
(6) Remove air cleaner housing assembly.
Fig. 22 CAMSHAFT ASSEMBLY
1 - INTAKE CAMSHAFT
2 - SNAPRING
3 - CAMSHAFT OIL SEAL
4 - THRUST WASHER
5 - CYLINDER HEAD COVER/INTAKE MANIFOLD
6 - EXHAUST MANIFOLD
9a - 24 ENGINE 2.5L TURBO DIESELRG
CAMSHAFT(S) (Continued)

(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)

INSTALLATION
(1) Clean and inspect gasket sealing surfaces.
(2) Install new gasket on cylinder head.
(3) Lubricate lifter ball end of lifter(s), valve(s),
and rocker arm roller(s) with MopartEngine Oil
Supplement or equivlalent.
(4) Connect rocker arm(s) to lifter and reposition
on valve(s) (Fig. 31).
(5) Install cylinder head cover/intake manifold
(Refer to 9 - ENGINE/CYLINDER HEAD/CYLIN-
DER HEAD COVER(S) - INSTALLATION).(6) Install inner timing belt cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(7) Install timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION) .
(8) Install outer timing belt cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(9) Install right engine mount (Refer to 9 -
ENGINE/ENGINE MOUNTING/RIGHT MOUNT -
INSTALLATION).
(10) Install air cleaner housing assembly.
(11) Install front wiper unit (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
INSTALLATION).
(12) Connect negative battery cable.
Fig. 30 CYLINDER HEAD ASSEMBLY
1 - VALVE SPRING
2 - CYLINDER HEAD BOLT
3 - GLOW PLUG
4 - COOLANT TEMPERATURE SENSOR
5 - CYLINDER HEAD ALIGNMENT DOWEL
6 - CYLINDER BLOCK
7 - CYLINDER LINER
8 - ENGINE BLOCK DECK
9 - CYLINDER HEAD GASKET
10 - CYLINDER HEAD
11 - ROCKER ARM AND LIFTER ASSEMBLY
Fig. 31 ROCKER ARM ASSEMBLY
1 - ROCKER ARM ASSEMBLY
2 - CYLINDER HEAD COVER/INTAKE MANIFOLD
3 - HYDRAULIC LIFTER
4 - CYLINDER HEAD
5 - VALVE
RGENGINE 2.5L TURBO DIESEL9a-29
ROCKER ARMS (Continued)

HYDRAULIC LIFTERS
DESCRIPTION
Valve lash is controlled by hydraulic tappets
located inside the cylinder head, in tappet bores
below the camshafts (Fig. 32).
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove front wiper unit (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
REMOVAL).
(3) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(4) Support engine and remove right engine mount
(Refer to 9 - ENGINE/ENGINE MOUNTING/RIGHT
MOUNT - REMOVAL).(5) Remove outer timing belt cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
CAUTION: Before removing the cylinder head cover/
intake manifold or the 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)
(6) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL).
(7) Remove inner timing belt cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(8) Remove cylinder head cover/intake manifold
(Fig. 33)(Refer to 9 - ENGINE/CYLINDER HEAD/
CYLINDER HEAD COVER(S) - REMOVAL).
(9) Remove rocker arm and lifter assemblies from
lifter bores.
Fig. 32 CYLINDER HEAD ASSEMBLY
1 - VALVE SPRING
2 - CYLINDER HEAD BOLT
3 - GLOW PLUG
4 - COOLANT TEMPERATURE SENSOR
5 - CYLINDER HEAD ALIGNMENT DOWEL
6 - CYLINDER BLOCK
7 - CYLINDER LINER
8 - ENGINE BLOCK DECK
9 - CYLINDER HEAD GASKET
10 - CYLINDER HEAD
11 - ROCKER ARM AND LIFTER ASSEMBLY
Fig. 33 CYLINDER HEAD COVER/INTAKE
MANIFOLD
1 - CYLINDER HEAD COVER/INTAKE MANIFOLD BOLTS(LONG)
2 - CYLINDER HEAD COVER/INTAKE MANIFOLD
3 - CYLINDER HEAD
4 - CYLINDER HEAD COVER/INTAKE MANIFOLD GASKET
5 - CYLINDER HEAD COVER/INTAKE MANIFOLD
BOLTS(SHORT)
9a - 30 ENGINE 2.5L TURBO DIESELRG

INSPECTION
Clean each lifter assembly in cleaning solvent to
remove all varnish and sludge deposits. Inspect for
indications of scuffing on the side and base of each
lifter body.
INSTALLATION
(1) Install rocker arm and lifter assemblies in
lifter bores.
(2) Install cylinder head cover/intake manifold
(Fig. 33) (Refer to 9 - ENGINE/CYLINDER HEAD/
CYLINDER HEAD COVER(S) - INSTALLATION).
(3) Install timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(4) Install timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION) .
(5) Install timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(6) Install right engine mount (Refer to 9 -
ENGINE/ENGINE MOUNTING/RIGHT MOUNT -
INSTALLATION).
(7) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
(8) Install front wiper unit (Refer to 8 - ELECTRI-
CAL/WIPERS/WASHERS/WIPER MODULE -
INSTALLATION).
(9) Connect negative battery cable.
ENGINE BLOCK
DESCRIPTION
The 2.5L CRD Diesel engine uses a cast iron
engine block with wet cast iron cylinder liners (Fig.
34).
CRANKSHAFT
DESCRIPTION
The crankshaft is a forged steel splayed type
design with five main bearing journals. The crank-
shaft is located at the bottom of the engine block and
is held in place with three main bearing supports
(Fig. 35).
OPERATION
The crankshaft transfers force generated by com-
bustion within the cylinder bores to the flywheel or
flexplate.
Fig. 34 ENGINE BLOCK
Fig. 35 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-31
HYDRAULIC LIFTERS (Continued)