2002 CHRYSLER VOYAGER drive belt

(3) Install oil pump retaining bolts (Fig. 71).
Torque bolts to 10.8N´m.
(4) Install crankshaft sprocket (Fig. 71). Torque
bolts to 10.8N´m.
(5) Install front engine cover (Refer to 9 -
ENGINE/ENGINE BLOCK/ENGINE COVER -
INSTALLATION).
(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 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. 72). 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. 73).
REMOVAL
(1) Disconnect negative battery cable.
(2) Raise vehicle on hoist.
(3) Disconnect oil pressure switch electrical con-
nector (Fig. 73).
(4) Remove oil pressure switch from engine block.
INSTALLATION
(1) Apply MopartThread Sealant to the switch
threads.
(2) Install oil pressure switch in engine block.
(3) Connect oil pressure switch electrical connector
(Fig. 73).(4) Lower vehicle.
(5) Start engine and check for leaks.
(6) Check and adjust oil level as necessary.
OIL TEMPERATURE SENSOR
DESCRIPTION
The oil temperature sensor is located on the right
side of the engine block. The sensor screws into the
engines main oil gallery (Fig. 74).
REMOVAL
(1) Disconnect negative battery cable.
(2) Raise vehicle on hoist.
(3) Disconnect oil temperature sensor electrical
connector (Fig. 74).
(4) Remove oil temperature sensor from engine
block.
INSTALLATION
(1) Apply MopartThread Sealant to the sensor
threads.
(2) Install oil temperature sensor in engine block.
(3) Connect oil temperature sensor electrical con-
nector (Fig. 74)
Fig. 73 REAR ENGINE VIEW
1 - SUSPENSION CRADLE
2 - ENGINE BLOCK
3 - OIL PRESSURE SWITCH
4 - OIL TEMPERATURE SENSOR
5 - VEHICLE SPEED SENSOR
6 - TRANSMISSION
9a - 48 ENGINERG
OIL PUMP (Continued)
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(9) Remove plug in cylinder head cover/intake
manifold and insert VM.1052 to lock intake camshaft
in position (Fig. 87).
(10) At this point the timing belt can be removed
for service.
(11) After engine service is completed and timing
belt reinstalled, remove both camshaft locking pins
from cylinder head cover/intake manifold.
(12) Install both camshaft access plugs.
(13) Remove 90É after TDC engine locking pin.
(14) Install starter motor (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - INSTALLA-
TION).
(15) Install generator (Refer to 8 - ELECTRICAL/
CHARGING/GENERATOR - INSTALLATION).
(16) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
(17) Install front wiper unit (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
INSTALLATION).
(18) Connect negative battery cable.BALANCE SHAFT
DESCRIPTION
The 2.5L Common Rail Diesel engine is equipped
with two nodular cast iron balance shafts in a cast
aluminum carrier. The balance shaft assembly is
mounted to the engine block (Fig. 88).
OPERATION
The balance shaft is driven by the crankshaft. The
balance shafts are connected by heelical gears. The
dual-counter rotating shafts decrease second order
vertical shaking forces caused by component move-
ment.
Fig. 87 INTAKE CAMSHAFT LOCKING PIN VM.1052
1 - TIMING BELT INNER COVER
2 - GLOW PLUG ELECTRICAL CONNECTOR
3 - CYLINDER HEAD COVER/INTAKE MANIFOLD
4 - FUEL RAIL
5 - INTAKE CAMSHAFT LOCKING PIN VM.1052
Fig. 88 BALANCE SHAFT 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
9a - 54 ENGINERG
VALVE TIMING (Continued)
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(3) Install balance shaft assembly and retaining
bolts (Fig. 89). 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
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. 92).
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).
(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).(10) Remove timing belt idler pulleys (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT IDLER
PULLEY - REMOVAL).
(11) Using special tool VM.1055, remove camshaft
sprockets (Fig. 93).
(12) Remove timing belt tensioner (Refer to 9 -
ENGINE/VALVE TIMING/TMNG BELT/CHAIN
TENSIONER&PULLEY - REMOVAL) .
(13) Remove injection pump sprocket (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL INJEC-
TION PUMP - REMOVAL).
(14) Remove timing belt inner cover retaining bolts
and remove cover (Fig. 94).
INSTALLATION
INSTALLATION - TIMING BELT OUTER COVER
(1) Install timing belt outer cover seal and cover
(Fig. 92). Torque 3mm bolts to 10.8N´m and 8mm
bolts to 10.8N´m.
(2) Install vibration damper (Refer to 9 - ENGINE/
ENGINE BLOCK/VIBRATION DAMPER - INSTAL-
LATION).
Fig. 92 TIMING BELT COVER (OUTER)
1 - SEAL
2 - TIMING BELT OUTER COVER
3 - RETAINING BOLTS
9a - 56 ENGINERG
BALANCE SHAFT (Continued)
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(3) Install accessory drive belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(4) Install power steering belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(5) Install right engine mount.
(6) Install air cleaner housing.
(7) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
(8) Connect negative battery cable.
INSTALLATION - TIMING BELT INNER COVER
(1) Install timing belt inner cover to engine front
cover seal (Fig. 94).
(2) Install timing belt inner cover to cylinder head
cover gaskets (Fig. 94).
(3) Install timing belt inner cover and retaining
bolts (Fig. 94). 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. 93). 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).
Fig. 93 CAMSHAFT SPROCKET REMOVAL/
INSTALLATION
1 - TIMING BELT INNER COVER
2 - CAMSHAFT SPROCKET
3 - IDLER PULLEYS
4 - CAMSHAFT SPROCKET
5 - VM.1055
Fig. 94 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
RGENGINE9a-57
TIMING BELT / CHAIN COVER(S) (Continued)
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(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. 95).
INSTALLATION
(1) Install timing belt idler pulleys (Fig. 95).
Torque bolts to 47.1N´m.
(2) Install timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION) .
(3) Install timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(4) Install vibration damper (Refer to 9 - ENGINE/
ENGINE BLOCK/VIBRATION DAMPER - INSTAL-
LATION).(5) Install accessory drive belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(6) Install power steering belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(7) Install right engine mount.
(8) Install air cleaner housing.
(9) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
(10) Connect negative battery cable.
Fig. 95 TIMING BELT AND SPROCKETS
1 -CAMSHAFT SPROCKETS
2 - INJECTION PUMP SPROCKET
3 - INJECTION PUMP SPROCKET RETAINING NUT
4 - TIMING BELT
5 - TIMING BELT TENSIONER RETAINING BOLT
6 - TIMING BELT TENSIONER
7 - TENSIONER ALIGNMENT PIN
8 - IDLER PULLEY
9 - CAMSHAFT SPROCKET RETAINING BOLT
9a - 58 ENGINERG
TIMING BELT / CHAIN COVER(S) (Continued)
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TMNG BELT/CHAIN
TENSIONER
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) Loosen and remove timing belt tensioner (Fig.
96).
INSTALLATION
(1) Install timing belt tensioner and retaining bolt
(Fig. 96).
(2) Adjust timing belt tensioner (Refer to 9 -
ENGINE/VALVE TIMING/TMNG BELT/CHAIN
TENSIONER&PULLEY - ADJUSTMENTS) .
(3) Install timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(4) Install vibration damper (Refer to 9 - ENGINE/
ENGINE BLOCK/VIBRATION DAMPER - INSTAL-
LATION).
(5) Install accessory drive belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).(6) Install power steering belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(7) Install right engine mount.
(8) Install air cleaner housing.
(9) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
(10) Connect negative battery cable.Fig. 96 TIMING BELT AND SPROCKETS
1 -CAMSHAFT SPROCKETS
2 - INJECTION PUMP SPROCKET
3 - INJECTION PUMP SPROCKET RETAINING NUT
4 - TIMING BELT
5 - TIMING BELT TENSIONER RETAINING BOLT
6 - TIMING BELT TENSIONER
7 - TENSIONER ALIGNMENT PIN
8 - IDLER PULLEY
9 - CAMSHAFT SPROCKET RETAINING BOLT
RGENGINE9a-59
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ADJUSTMENTS
ADJUSTMENT - TIMING BELT TENSIONER
(1) With timing belt outer cover removed and tim-
ing belt installed.
(2) Loosen timing belt tensioner (Fig. 97).
(3) Align timing belt tensioner spring stop with
tensioner as shown (Fig. 98) and torque timing belt
tensioner retaining bolt to 34.7N´m.
(4) Rotate engine 2 complete revolution and then
recheck tensioner alignment. Readjust tensioner
alignment as necessary.
TIMING BELT/CHAIN AND
SPROCKETS
REMOVAL
CAUTION: Before removing 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)
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(3) Remove air cleaner housing assembly.
(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).
Fig. 97 TIMING BELT TENSIONER ADJUSTMENT
1 - TIMING BELT IDLER PULLEY
2 - ENGINE FRONT COVER
3 - CRANKSHAFT HUB
4 - TIMING BELT TENSIONER
5 - TIMING BELT
Fig. 98 TIMING BELT TENSIONER ALIGNMENT
1 - TENSIONER SPRING STOP
2 - TIMING BELT TENSIONER
3 - TIMING BELT TENSIONER
4 - TIMING BELT
5 - TIMING BELT INNER COVER
9a - 60 ENGINERG
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(8) Remove timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(9) Loosen timing belt tensioner and remove tim-
ing belt (Fig. 99).
INSTALLATION
(1) With both camshaft alignment pins still
installed and the engine locked at 90É after TDC.
(2) Align timing mark on injection pump sprocket
with timing mark on timing belt (Fig. 100).(3) Install timing belt.
(4) Adjust the timing belt tensioner (Refer to 9 -
ENGINE/VALVE TIMING/TMNG BELT/CHAIN
TENSIONER&PULLEY - ADJUSTMENTS) .
(5) Remove both camshaft alignment pins from cyl-
inder head cover/intake manifold and engine locking
pin from engine block (Refer to 9 - ENGINE/VALVE
TIMING - STANDARD PROCEDURE).
(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 accessory drive belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(9) Install power steering belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(10) Install right engine mount.
(11) Install air cleaner housing.
(12) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
(13) Connect negative battery cable.
Fig. 99 TIMING BELT AND SPROCKETS
1 -CAMSHAFT SPROCKETS
2 - INJECTION PUMP SPROCKET
3 - INJECTION PUMP SPROCKET RETAINING NUT
4 - TIMING BELT
5 - TIMING BELT TENSIONER RETAINING BOLT
6 - TIMING BELT TENSIONER
7 - TENSIONER ALIGNMENT PIN
8 - IDLER PULLEY
9 - CAMSHAFT SPROCKET RETAINING BOLT
Fig. 100 INJECTION PUMP GEAR TIMING MARKS
1 - TIMING MARK ON COVER
2 - TIMING MARK ON INJECTION PUMP SPROCKET
3 - INJECTION PUMP SPROCKET
RGENGINE9a-61
TIMING BELT/CHAIN AND SPROCKETS (Continued)
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