Chrysler RG Voyager. Manual - part 469

(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. 3).

(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) Fill engine crankcase to proper level, with cor-

rect viscosity engine oil.

(46) Connect negative battery cable.
(47) Recharge A/C system (Refer to 24 - HEATING

AIR

CONDITIONING/PLUMBING/REFRIGER-

ANT - STANDARD PROCEDURE).

Perform fuel system air purge procedure (Refer to

14 - FUEL SYSTEM - STANDARD PROCEDURE).

(48) Install engine cover (Refer to 9 - ENGINE -

INSTALLATION) (Fig. 2).

INSTALLATION - ENGINE COVER

(1) Install engine cover on engine.
(2) Install the engine cover mounting bolts (Fig.

10).

SPECIFICATIONS

SPECIFICATIONS - 2.5L COMMON RAIL
DIESEL ENGINE

GENERAL DESCRIPTION

DESCRIPTION

SPECIFICATION

Engine Type

R2516C5

Transmission

MTX

Number of Cylinders

Bore

92 mm

Stroke

94 mm

Displacement

2499.5cc

Injection Order

1-3-4-2

Compression Ratio

17.5:1 (± 0.5)

Maximum Power

105kW (143 HP) @ 4000

RPM

Peak Torque

340N·m @ 2000 RPM

Cylinder Compression

(Max. Difference Between

Cylinders

5 Bar

Minimum Oil Pressure

(Warm)

.7 Bar @ Idle

2 Bar @ 3800 RPM

CRANKSHAFT

DESCRIPTION

SPECIFICATION

Metric

Standard

Front Journal

Diameter-

Nominal

62.985-63.005

2.479-2.480 in

Front Journal

Diameter- minus

0.25

62.735-63.074

2.469-2.471 in.

Front Bearing

Diameter-

Nominal

63.005-63.034

2.480-2.481 in.

Front Bearing

Diameter-minus

0.25

62.775-62.784

2.470-2.471 in

Clearance

Between the

Journal and

Bearing

0.000-0.049

0.000-0.001 in.

Center Journal

Diameter-

Nominal

63.005-63.020

0.001-0.003 in.

Center Journal

Diameter-minus

0.25

62.775-62.770

2.470-2.471

Center Bearing

Diameter-

Nominal

63.005-63.020

2.480-2.481 in.

Center Bearing

Diameter-minus

0.25

62.775-62.770

2.470-2.471 in.

Clearance

Between

Journal and

Bearing

0.008-0.051

0.0003-0.0002

Rear Journal

Diameter-

Nominal

89.980-90.000

3.542-3.543 in

Rear Journal

Diameter- minus

0.25

89.730-99.750

3.532-3.927 in.

Rear Bearing

Diameter-

Nominal

90.045-90.065

3.545-3.546 in.

Rear Bearing

Diameter- minus

0.25

89.795-89.815

3.535-3.536 in.

9 - 8

ENGINE

ENGINE 2.5L/2.8 TURBO DIESEL (Continued)

DESCRIPTION

SPECIFICATION

Metric

Standard

Clearance

Between

Journal and

Bearing

0.045-0.080

0.001-0.003 in.

Connecting Rod

Journal-Nominal

53.940-53.955

2.123-2.124 in.

Connecting Rod

Journal- minus

0.25

53.690-53.705

2.113-2.114 in.

Connecting Rod

Bearing-

Nominal

53.997-54.016

2.125-2.126 in.

Connecting Rod

Bearing- minus

0.25

53.727-53.766

2.115-2.116 in.

Clearance

Between

Journal and

Bearing

0.022-0.076

0.0008-0.0029

in.

Crankshaft End

Play

0.080-0.280

0.003-0.011 in.

Adjustment

Thrust Washers

Available

2.31-2.36 mm

0.090-0.092 in.

2.41-2.46 mm

0.094-0.096 in.

2.51-2.56 mm

0.098-0.100

Carrier with

Thrush Washers

Installed

27.670-27.820

1.089-1.095 in.

MAIL BEARING CARRIERS

DESCRIPTION

SPECIFICATION

Metric

Standard

Internal

Diameter-Front

67.025-67.050

2.638-2.639 in.

Internal

Diameter-Center

66.670-66.690

2.624-2.624 in.

Internal

Diameter-Rear

85.985-86.005

3.385-3.386 in.

LINERS

DESCRIPTION

SPECIFICATION

Metric

Standard

Internal

Diameter

091.997-92.015

mm.

3.621-3.622 in.

Protrusion

0.00-0.05 mm

0.00-0.001 in.

DESCRIPTION

SPECIFICATION

Metric

Standard

Available

Adjustment

Shims

0.15 mm

0.005 in.

0.17 mm

0.006 in.

0.20 mm

0.007 in.

0.23 mm

0.009

0.25 mm

0.0098

CYLINDER HEAD

DESCRIPTION

SPECIFICATION

Metric

Standard

Minimum

Thickness

94.95-95.05

mm.

3.738-3.742 in.

Gasket
Thickness

1.32 mm ±

0.08, 0 notches

0.0051 in. ±

0.003, 0

notches

1.42 mm ±

0.08, 1 notch

0.051 in. ±

0.003, 1 notch

1.52 mm ±

0.08, 2 notches

0.059 in. ±

0.003, 1

notches

CONNECTING RODS

DESCRIPTION

SPECIFICATION

Metric

Standard

Small end

Bearing Internal

Diameter

32.035-32.050

1.2612-1.2618

in.

Large End

Internal

Diameter

53.997-54.016

2.125-2.126 in.

PISTONS

DESCRIPTION

SPECIFICATION

Metric

Standard

Skirt Diameter

(measured at

approximately

10 mm above

the bottom of

the skirt)

91.912-91.928

mm.

3.618-3.619 in.

Piston

Clearance

0.065-0.83 mm

0.002-0.003 in.

Top of Piston to

Cylinder Head

0.69-0.83 mm

0.027-0.032 in.

ENGINE

9 - 9

ENGINE 2.5L/2.8 TURBO DIESEL (Continued)

DESCRIPTION

SPECIFICATION

Metric

Standard

Piston
Protrusion

0.460-0.609

mm Fit Gasket,

Number

(1.32mm), 0

notches or

holes

0.018-0.023 in.

Fit Gasket,

Number (0.051

in.), 0 notches

0.610-0.709

mm Fit Gasket,

Number (1.42

mm) 1 notch or

hole

0.024-0.027 in.

Fit Gasket,

Number (0.055

in.) 1 notch or

hole

0.710-0.810

mm Fit Gasket,

Number (1.52

mm), 2 notches

or holes

0.027-0.031 in.
Number (0.059

in) 2 notches or

holes

PISTON PINS

DESCRIPTION

SPECIFICATION

Metric

Standard

Type

Full Floating

Pin Diameter

32.004-32.008

32.004-32.010

1.2599-1.2601

in.

1.2599-1.2602

in.

Clearance

0.010-0.020

0.004-0.012

0.0001-0.0004

in.

0.0001-0.0004

in.

PISTON RINGS

DESCRIPTION

SPECIFICATION

Metric

Standard

Clearance in
Groove

Top

Compression

Ring

0.078-0.137

0.003-0.005 in.

Second

Compression

Ring

0.070-0.110

0.002-0.004 in.

Oil Control

(Steel Rails)

0.40-0.080 mm

0.001 - 0.003 in.

Fitted Gap

DESCRIPTION

SPECIFICATION

Metric

Standard

Top

Compression

Ring

.030-0.45 mm

0.011-0.017 in.

Second

Compression

Ring

0.035 - 0.050

0.0013 - 0.0019

in.

Oil Ring (Steel

Ring)

.025 - 0.50 mm

.0009 - .0019 in.

CAMSHAFT

DESCRIPTION

SPECIFICATION

Metric

Standard

Journal

Diameter-Front

29.960-29.980

1.179-1.180 in.

Bearing

Clearance

0.03-0.08 mm

0.0011-0.0031

in.

Journal

Diameter-Center

39.250-39.270

1.545-1.546 in.

Bearing

Clearance

0.03-0.08 mm

0.001-0.003 in

Journal

Diameter-Rear

39.250-39.270

1.545-1.546 in.

Bearing

Clearance

0.03-0.08 mm

0.001-0.003 in.

HYDRAULIC LIFTER

DESCRIPTION

SPECIFICATION

Metric

Standard

Outside

Diameter

11.994 ± 0.006

0.472 ± 0.0002

in.

VALVES

DESCRIPTION

SPECIFICATION

Metric

Standard

Face Angle-

Intake

45° 25’-55° 35’

Face Angle-

Exhaust

45° 25’-45° 35’

Intake Valve

Opens

15.6° ± 2°

A.T.D.C.

Intake Valve

Closes

64.4° ± 2°

A.B.D.C.

9 - 10

ENGINE

ENGINE 2.5L/2.8 TURBO DIESEL (Continued)

DESCRIPTION

SPECIFICATION

Metric

Standard

Exhaust Valve

Opens

66° ± 2°

B.B.D.C.

Exhaust Valve

Closes

32° ± 2°
A.T.D.C.

Head Diameter-

Intake

32.30-32.50

1.271-1.279 in.

Head Diameter-

Exhaust

30.80-31.00

1.212-1.220 in.

Head Stand

Down-Intake

1.08-1.34 mm

0.042-0.052 in.

Head Stand

Down-Exhaust

0.99-1.25 mm

0.038-0.049 in.

Stem Diameter-

Intake

5.952-5.970

0.234-0.235 in.

Stem Diameter-

Exhaust

5.942-5.960

0.233-0.234 in.

Clearance in

Guide-Intake

0.030-0.060

0.001-0.002 in.

Clearance in

Guide-Exhaust

0.040-0.070

0.001-0.002 in.

VALVE GUIDE

DESCRIPTION

SPECIFICATION

Metric

Standard

Inside Diameter

6.00-6.012 mm

0.2362-0.2366

in.

Fitted

Height-Intake

14.5-15.0 mm

0.570-0.590 in.

Fitted

Height-Exhaust

16.5-17.0 mm

0.649-0.669 in.

VALVE SPRING

DESCRIPTION

SPECIFICATION

Metric

Standard

Free Length

45.26 mm

1.781 in.

Fitted Length

38.0 mm

1.496 in.

Load at Fitted

Length

182 ± 5-10%

Load at Top of

Lift

395 ± 5% Kg

Number of Coils

LUBRICATION

DESCRIPTION

SPECIFICATION

Metric

Standard

Pressure Relief

Valve Opens

6.50 bar

94 psi

Pressure Relief

Valve Spring-

Free Length

51.5 mm

2.02 in.

OIL PUMP

DESCRIPTION

SPECIFICATION

Metric

Standard

Outer Rotor End

Float

0.060-0.160

0.002-0.006 in.

Inner Rotor End

Float

0.060-0.160

0.002-0.006 in.

Outer Rotor to

Body Diameter

Clearance

0.130-0.240

0.005-0.009 in.

Rotor Body to

Drive Gear

Clearance

(pump not fitted)

0.90-1.50 mm

0.035-0.059 in.

SPECIFICATIONS - 2.8L COMMON RAIL
DIESEL ENGINE

GENERAL DESCRIPTION

DESCRIPTION

SPECIFICATION

Engine Type

R2816C5.05A

Transmission

ATX

Number of Cylinders

Bore

94 mm

Stroke

100 mm

Displacement

2776cc

Injection Order

1-3-4-2

Compression Ratio

17.5:1 (± 0.5)

Maximum Power

110kW (150 CV) @ 3800

RPM

Peak Torque

360 N·m @ 1800 RPM

Cylinder Compression

(Max. Difference Between

Cylinders

5 Bar

Minimum Oil Pressure

(Warm)

.7 Bar @ Idle

2 Bar @ 3800 RPM

ENGINE

9 - 11

ENGINE 2.5L/2.8 TURBO DIESEL (Continued)

Content .. 467 468 469 470 ..