Chrysler RG Voyager. Manual - part 470

CRANKSHAFT

DESCRIPTION

SPECIFICATION

Metric

Standard

Front Journal

Diameter-

Nominal

62.985-63.005

mm

2.479-2.480 in

Front Journal

Diameter- minus

0.25

62.735-62.755

mm

2.469-2.470 in.

Front Bearing

Diameter-

Nominal

63.005-63.034

mm

2.480-2.481 in.

Front Bearing

Diameter-minus

0.25

62.755-62.784

mm

2.471-2.478 in

Clearance

Between the

Journal and

Bearing

0.00-0.049 mm

0.000-0.001 in.

Center Journal

Diameter-

Nominal

63.005-63.020

mm

0.001-0.003 in.

Center Journal

Diameter-minus

0.25

62.775-62.770

mm

2.470-2.471

Center Bearing

Diameter-

Nominal

63.005-63.020

mm

2.480-2.481 in.

Center Bearing

Diameter-minus

0.25

62.775-62.770

mm

2.470-2.471 in.

Clearance

Between

Journal and

Bearing

0.008-0.051

mm

0.0003-0.0002

in

Rear Journal

Diameter-

Nominal

89.980-90.000

mm

3.542-3.543 in

Rear Journal

Diameter- minus

0.25

89.730-99.750

mm

3.532-3.927 in.

Rear Bearing

Diameter-

Nominal

90.045-90.065

mm

3.545-3.546 in.

Rear Bearing

Diameter- minus

0.25

89.795-89.815

mm

3.535-3.536 in.

Clearance

Between

Journal and

Bearing

0.045-0.080

mm

0.001-0.003 in.

Connecting Rod

Journal-Nominal

53.940-53.955

mm

2.123-2.124 in.

Connecting Rod

Journal- minus

0.25

53.690-53.705

mm

2.113-2.114 in.

Connecting Rod

Bearing-

Nominal

53.997-54.016

mm

2.125-2.126 in.

Connecting Rod

Bearing- minus

0.25

53.727-53.766

mm

2.115-2.116 in.

Clearance

Between

Journal and

Bearing

0.022-0.076

mm

0.0008-0.0029

in.

Crankshaft End

Play

0.080-0.280

mm

0.003-0.011 in.

Adjustment

Thrust Washers

Thrust Washers

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

mm

1.089-1.095 in.

MAIL BEARING CARRIERS

DESCRIPTION

SPECIFICATION

Metric

Standard

Internal

Diameter-Front

67.025-67.050

mm

2.638-2.639 in.

Internal

Diameter-Center

66.670-66.690

mm

2.624-2.624 in.

Internal

Diameter-Rear

85.985-86.005

mm

3.385-3.386 in.

9 - 12

ENGINE

RG

ENGINE 2.5L/2.8 TURBO DIESEL (Continued)

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.

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

mm

1.2612-1.2618

in.

Large End

Internal

Diameter

53.997-54.016

mm

2.125-2.126 in.

PISTONS

DESCRIPTION

SPECIFICATION

Metric

Standard

Skirt Diameter

(measured at

approximately

10 mm above

the bottom of

the skirt)

93.912-93.928

mm.

3.6973-3.6979

in.

Piston

Clearance

0.010-0.22 mm

0.0003-0.0008

in.

Top of Piston to

Cylinder Head

0.69-0.83 mm

0.027-0.032 in.

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 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 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

32.004-32.010

mm

1.259-1.260 in.

Clearance

0.010-0.020

mm

0.0003-0.0007

in.

RG

ENGINE

9 - 13

ENGINE 2.5L/2.8 TURBO DIESEL (Continued)

PISTON RINGS

DESCRIPTION

SPECIFICATION

Metric

Standard

Clearance in
Groove

Top

Compression

Ring

0.078-0.137

mm

0.003-0.005 in.

Second

Compression

Ring

0.070-0.110

mm

0.002-0.004 in.

Oil Control

(Steel Rails)

0.40-0.080 mm

0.001 - 0.003 in.

Fitted Gap

Top

Compression

Ring

.030-0.45 mm

0.011-0.017 in.

Second

Compression

Ring

0.030 - 0.050

mm

0.0011 - 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

mm

1.179-1.180 in.

Bearing

Clearance

0.03-0.08 mm

0.001-0.003 in.

Journal

Diameter-Center

39.250-39.270

mm

1.545-1.546 in.

Bearing

Clearance

0.03-0.08 mm

0.001-0.003 in

Journal

Diameter-Rear

39.250-39.270

mm

1.545-1.546 in.

Bearing

Clearance

0.03-0.08 mm

0.001-0.003 in.

Camshaft End

Play

0.10-0.55mm

0.004-0.021 in.

HYDRAULIC LIFTER

DESCRIPTION

SPECIFICATION

Metric

Standard

Outside

Diameter

11.994 ± 0.006

mm

0.472 ± 0.0002

in.

VALVES

DESCRIPTION

SPECIFICATION

Metric

Standard

Face Angle-

Intake

45° 25’-55° 35’

mm

-

Face Angle-

Exhaust

45° 25’-45° 35’

mm

-

Intake Valve

Opens

15.6° ± 2°

A.T.D.C.

-

Intake Valve

Closes

64.4° ± 2°

A.B.D.C.

-

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

mm

1.271-1.279 in.

Head Diameter-

Exhaust

30.80-31.00

mm

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

mm

0.234-0.235 in.

Stem Diameter-

Exhaust

5.942-5.960

mm

0.233-0.234 in.

Clearance in

Guide-Intake

0.030-0.060

mm

0.001-0.002 in.

Clearance in

Guide-Exhaust

0.040-0.070

mm

0.001-0.002 in.

9 - 14

ENGINE

RG

ENGINE 2.5L/2.8 TURBO DIESEL (Continued)

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%

Kg

-

Load at Top of

Lift

395 ± 5% Kg

-

Number of Coils

8

-

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

mm

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

mm

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 - TORQUE

2.5L/2.8L 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 Sensor Bolts

10.8

8

96

Flywheel Bolts - 2.5L, Refer to the Service Procedure

Flex Plate Bolts - 2.8L, Refer to the Service Procedure

Cylinder Head Bolts - Refer to the Service Procedure

Reluctor Wheel Bolts

14.6

11

130

Rear Main Bearing Support Bolts

27.5

21

240

Oil Cooler to Engine Block Bolt

38

28

—

Water Pump Housing Nuts

24.4

18

212

Connecting Rod Bolts - Refer to the Service Procedure

Balance Shaft Bolts

32.4

24

—

Oil Jet Bolts

10.8

8

96

Oil Pan Bolts

11.8

8

96

Crankshaft Hub Bolt

275

202

—

RG

ENGINE

9 - 15

ENGINE 2.5L/2.8 TURBO DIESEL (Continued)