2002 CHRYSLER VOYAGER Service Manual

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Page 1369 of 2399

CHRYSLER VOYAGER 2002 Service Manual 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

Page 1370 of 2399

CHRYSLER VOYAGER 2002 Service Manual DESCRIPTION SPECIFICATION
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
Top of Piston to Cylinder
Head0.69-0.83

DESCRIPTION SPECIFICATION
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
Top of Piston to Cylinder
Head0.69-0.83 mm
Piston Potrusion 0.49-0.60 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 0.078-0.137 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 29.960-29.980 mm
Bearing Clearance 0.03-0.08 mm
Journal Diameter±Center 39.250-39.270 mm
Bearing Clearance 0.03-0.08 mm
Journal Diameter±Rear 39.250-39.270 mm
Bearing Clearance 0.03-0.08 mm
HYDRAULIC LIFTER
Outside Diameter 11.994 0.006 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
Intake 14.5-15.0 mm
Exhaust 16.5-17.0 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
Opens6.50 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
RGENGINE9a-9
ENGINE 2.5L TURBO DIESEL (Continued)
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Page 1371 of 2399

CHRYSLER VOYAGER 2002 Service Manual SPECIFICATIONS - TORQUE
2.5L DIESEL TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Oil Pump Bolts 10.8 8 96
Vacuum Pump Bolts 10.8 8 96
Crankshaft Gear Bolts 10.8 8 96
Crankshaft Position
Se

Page 1372 of 2399

CHRYSLER VOYAGER 2002 Service Manual DESCRIPTION N´m Ft. Lbs. In. Lbs.
8mm 10.8 8 96
10mm 47.1 35 Ð
Outer Timing Belt Cover
Bolts
3mm 6 Ð 54
8mm 10.8 8 96
Engine Mount Bracket to
Cylinder Head Bolts47.1 35 Ð
Intake Inlet Tube Bolts 1

Page 1373 of 2399

CHRYSLER VOYAGER 2002 Service Manual SPECIAL TOOLS
VM.1001 CYLINDER LINER PULLER
VM.1005 TORQUE ANGLE GAUGE
VM.1010 CYLINDER LINER PROTRUSION TOOL
VM.1013 DIAL INDICATOR
VM.1016 CYLINDER RETAINER
9a - 12 ENGINERG
ENGINE 2.5L TURBO DIESEL

Page 1374 of 2399

CHRYSLER VOYAGER 2002 Service Manual VM.1050 CRANKSHAFT REAR SEAL INSTALLER
VM.1051 TDC ALIGNMENT PIN
VM.1052 INTAKE CAMSHAFT ALIGNMENT PIN
VM.1053 EXHAUST CAMSHAFT ALIGNMENT PIN
VM.1054 RELIEF VALVE REMOVER/CENTRAL
CARRIER PIN REMOVER/I

Page 1375 of 2399

CHRYSLER VOYAGER 2002 Service Manual VM.1056 BALANCE SHAFT LOCKING PIN
VM.1059 OIL PRESSURE RELIEF VALVE INSTALLER
VM.1060 OIL JET REMOVER /INSTALLER
VM.1061 FRONT OIL SEAL INSTALLER
VM.1062 POWER STEERING PUMP INSTALLER
VM.1063 FUEL INJ

Page 1376 of 2399

CHRYSLER VOYAGER 2002 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
VM.1069 CRANKSHAFT REM/INSTALL SLEEVE
VM.1

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