Content .. 474 475 476 477 ..

Chrysler RG Voyager. Manual - part 476

(27) Install air cleaner housing assembly.
(28) Remove crankshaft and both camshaft locking

pins (Refer to 9 - ENGINE/VALVE TIMING - STAN-
DARD PROCEDURE).

(29) Refill cooling system (Refer to 7 - COOLING/

ENGINE/COOLANT - STANDARD PROCEDURE).

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

INSTALLATION).

(31) Install front wiper unit (Refer to 8 - ELEC-

TRICAL/WIPERS/WASHERS/WIPER

MODULE

INSTALLATION).

(32) Connect negative battery cable.

INSTALLATION

NOTE: Using compressed air, blow out the oil
return passage in the cylinder head cover/ intake
manifold assembly. If the cylinder head cover/intake
manifold has been removed, be sure to clean the oil
drain back tube as well.

(1) Lubricate the O-rings with clean engine oil and

position in the cover (Fig. 29).

(2) Seat the oil separator, being careful not to

damage the O-rings (Fig. 29).

(3) Install the retaining fastener and torque the

bolt to 10.8 N·m (8 lbs. ft.).

(4) Install the engine cover (Refer to 9 - ENGINE -

INSTALLATION).

(5) Connect the negative battery cable.

CAMSHAFT OIL SEAL(S)

REMOVAL

(1) Disconnect negative battery cable.
(2) Remove air cleaner housing assembly.
(3) Support engine and remove right engine mount

(Refer to 9 - ENGINE/ENGINE MOUNTING/RIGHT
MOUNT - REMOVAL).

(4) Remove outer timing belt cover (Refer to 9 -

ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).

WARNING: Before removing the timing belt the
engine must put at 90° after TDC. Failure to do so
could result in valve and/or piston damage during
reassembly. (Refer to 9 - ENGINE/VALVE TIMING -
STANDARD PROCEDURE)

(5) Remove timing belt (Refer to 9 - ENGINE/

VALVE

TIMING/TIMING

BELT/CHAIN

AND

SPROCKETS - REMOVAL).

(6) Using VM.1055, remove both camshaft gears

(Fig. 32).

(7) Remove both camshaft oil seals.

INSTALLATION

(1) Install new camshaft oil seal using VM.1057

(Fig. 33).

Fig. 32 CAMSHAFT GEAR REMOVAL/INSTALLATION

1 - TIMING BELT INNER COVER
2 - CAMSHAFT SPROCKET
3 - IDLER PULLEYS
4 - CAMSHAFT SPROCKET
5 - VM.1055

Fig. 33 CAMSHAFT OIL SEAL INSTALLER

1 - VM.1057
2 - CAMSHAFT SEAL
3 - CYLINDER HEAD COVER/INTAKE MANIFOLD

9 - 36

ENGINE

CYLINDER HEAD COVER(S) (Continued)

(2) Install camshaft sprockets and tighten retain-

ing bolts finger tight.

(3) Install timing belt (Refer to 9 - ENGINE/

VALVE

TIMING/TIMING

BELT/CHAIN

AND

SPROCKETS - INSTALLATION).

(4) Torque camshaft sprockets to 108 N·m using

VM.1055 (Fig. 32).

(5) Install outer timing belt 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 air cleaner housing assembly.
(8) Connect negative battery cable.

ROCKER ARMS

DESCRIPTION

The rocker arms are made of stamped steel (Fig.

34).

OPERATION

The rocker arms are used as a link between the

camshaft and valves. As the camshaft rotates the
lobes of the camshafts apply downward pressure on
the rocker arms. This pressure is then transmitted to
the valves which causes the valves to open.

REMOVAL

(1) Disconnect negative battery cable.
(2) Remove front wiper unit (Refer to 8 - ELEC-

TRICAL/WIPERS/WASHERS/WIPER

MODULE

REMOVAL).

(3) Remove air cleaner housing assembly.
(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).

(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

(Refer to 9 - ENGINE/CYLINDER HEAD/CYLIN-
DER HEAD COVER(S) - REMOVAL).

(9) Remove rocker arm abd lifter (Fig. 35).

Fig. 34 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. 35 ROCKER ARM ASSEMBLY

1 - ROCKER ARM ASSEMBLY
2 - CYLINDER HEAD COVER/INTAKE MANIFOLD
3 - HYDRAULIC LIFTER
4 - CYLINDER HEAD
5 - VALVE

ENGINE

9 - 37

CAMSHAFT OIL SEAL(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 Mopar

t Engine Oil

Supplement or equivlalent.

(4) Connect rocker arm(s) to lifter and reposition

on valve(s) (Fig. 35).

(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.

HYDRAULIC LIFTERS

DESCRIPTION

Valve lash is controlled by hydraulic tappets

located inside the cylinder head, in tappet bores
below the camshafts (Fig. 36).

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 90° 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. 37)(Refer to 9 - ENGINE/CYLINDER HEAD/
CYLINDER HEAD COVER(S) - REMOVAL).

(9) Remove rocker arm and lifter assemblies from

lifter bores.

Fig. 36 CYLINDER HEAD ASSEMBLY

9 - 38

ENGINE

ROCKER ARMS (Continued)

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. 37) (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/2.8L CRD Diesel engine uses a cast iron

engine block with wet cast iron cylinder liners (Fig.
38), (Fig. 39).

Fig. 37 CYLINDER HEADCOVER/INTAKE MANIFOLD

ASSEMBLY

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)

Fig. 38 ENGINE BLOCK 2.5L

Fig. 39 ENGINE BLOCK 2.8L

ENGINE

9 - 39

HYDRAULIC LIFTERS (Continued)

Content .. 474 475 476 477 ..