Content .. 476 477 478 479 ..

Chrysler RG Voyager. Manual - part 478

(11) Install flywheel (2.5L), Install flex plate (2.8L).
(12) Install piston and connecting rod assemblies

(Refer to 9 - ENGINE/ENGINE BLOCK/PISTON &
CONNECTING ROD - INSTALLATION).

(13) Install oil jets (Refer to 9 - ENGINE/LUBRI-

CATION/OIL JET - INSTALLATION).

(14) Install balance shaft assembly (Refer to 9 -

ENGINE/VALVE

TIMING/BALANCE

SHAFT

INSTALLATION).

(15) Install oil pump pickup tube (Refer to 9 -

ENGINE/LUBRICATION/OIL PUMP - INSTALLA-
TION).

(16) Install oil pan (Refer to 9 - ENGINE/LUBRI-

CATION/OIL PAN - INSTALLATION).

(17) Install cylinder head (Refer to 9 - ENGINE/

CYLINDER HEAD - INSTALLATION).

(18) Install cylinder head cover/intake manifold

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

(19) Install timing belt inner cover (Refer to 9 -

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

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

VALVE

TIMING/TIMING

BELT/CHAIN

AND

SPROCKETS - INSTALLATION).

(21) Install timing belt outer cover (Refer to 9 -

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

(22) Install engine in vehicle.
(23) Fill engine oil with proper oil to correct level.

FLEX PLATE

REMOVAL

(1) Remove

the

transmission

(Refer

TRANSMISSION/TRANSAXLE/MANUAL

REMOVAL).

(2) Paint mark the flex plate to crankshaft rela-

tionship.

(3) Remove the flex plate fasteners and fly wheel

(Fig. 50).

INSTALLATION

NOTE: Do Not Lubricate new bolts because they are
already coated with an anti scuff treatment.

(1) Position the flex plate and install the fasteners

hand tight (Fig. 50).

(2) Tighten each fastener to 50 N·m (37 lbs. ft.) fol-

lowing a clockwise cross sequence.

(3) At this point, loosen only one fastener at a time

and with a torque wrench set to 25 N·m (19 lbs. ft.)
tighten the bolt, then with a torque angle gauge
tighten that bolt an additional 60 degrees.

(4) Perform the above procedure for each fastener

in a cross sequence.

Fig. 49 CRANKSHAFT SUPPORT RETAINERS/

BALANCE SHAFT OIL SUPPLY ALIGNMENT PINS

1 - ENGINE BLOCK
2 - ALIGNMENT PINS VM 1079

Fig. 50 2.8L REAR MAIN BEARING SUPPORT

REMOVAL

1 - ENGINE BLOCK
2 - PLATE
3 - REAR MAIN BEARING SUPPORT
4 - CRANKSHAFT
5 - FLEX PLATE
6 - BACKING PLATE
7 - BOLTS

9 - 44

ENGINE

CRANKSHAFT (Continued)

FLY WHEEL

REMOVAL

(1) Remove

the

transmission

(Refer

TRANSMISSION/TRANSAXLE/MANUAL

REMOVAL).

(2) Paint mark the fly wheel to crankshaft rela-

tionship.

(3) Remove the fly wheel fasteners and fly wheel

(Fig. 51).

INSTALLATION

NOTE: Do Not Lubricate new bolts because they are
already coated with an anti scuff treatment.

(1) Position the fly wheel and install the fasteners

hand tight (Fig. 51).

(2) Tighten each fastener to 50 N·m (37 lbs. ft.) fol-

lowing a clockwise cross sequence.

(3) At this point, loosen only one fastener at a time

and with a torque wrench set to 25 N·m (19 lbs. ft.)
tighten the bolt, then with a torque angle gauge
tighten that bolt an additional 60 degrees.

(4) Perform the above procedure for each fastener

in a cross sequence.

CYLINDER LINERS

DESCRIPTION

The cylinder wall liner used on this engine is of

the wet design. O-rings are used to seal the liner to
the engine block.

REMOVAL

(1) Remove engine from vehicle.
(2) With engine completely disassembled, use spe-

cial tool VM.1001 to remove liner assembly (Fig. 52).

(3) Tighten bolt on VM.1001 to remove liner from

block (Fig. 53).

(4) Remove shims from cylinder liner or cylinder

block recess. Keep shims with each cylinder liner.

Fig. 51 FLY WHEEL

1 - 60 MM FLY WHEEL BOLTS
2 - FLY WHEEL
3 - TRANSMISSION ADAPTOR PLATE
4 - REAR MAIN BEARING SUPPORT
5 - O-RING
6 - DOWL
7 - ENGINE BLOCK
8 - CRANKSHAFT
9 - RELUCTOR WHEEL
10 - ADAPTOR PLATE BOLT

Fig. 52 CYLINDER LINER REMOVER

ENGINE

9 - 45

INSPECTION

The cylinder walls should be checked for out-of-

round and taper with a dial bore gauge. The cylinder
bore out-of-round is 0.100 mm (.0039 in.) maximum
and cylinder bore taper is 0.100 mm (.0039 in.) max-
imum. If the cylinder walls are badly scuffed or
scored, new liners should be installed and honed, and
new pistons and rings fitted.

Measure the cylinder bore at three levels in direc-

tions A and B (Fig. 54). Top measurement should be
10 mm (3/8 in.) down and bottom measurement
should be 10 mm (3/8 in.) up from the bottom bore.

INSTALLATION

CAUTION: Cylinder liner O-rings have different
diameters. Care should be taken when installing
replacement O-rings because they are engine spe-
cific.

(1) Carefully clean liner and engine block, and

degrease the engine block where it comes into contact
with the liners. Install the liners in the engine block
as shown, rotating them back and forth by 45° in
order to guarantee correct positioning (Fig. 55).

(2) Measure the liner recess relative to block deck

with a dial indicator mounted on a special tool
VM-1010 A. All the measurements must be taken
on high pressure pump side of engine block. .
Zero dial gauge on block deck.

(3) Move dial gauge to cylinder liner record read-

ing on dial gauge.

(4) Remove liner and special tool.
(5) Then select the correct shim thickness to give

proper protrusion (0.00 - 0.05 mm).

(6) Fit the shim and the O-rings onto the liner.
(7) Lubricate the lower liner location in the block.

Fig. 53 CYLINDER LINER REMOVAL

1 - SPECIAL TOOL VM.1001
2 - CYLINDER LINER
3 - ENGINE BLOCK

Fig. 54 LINER INSPECTION

Fig. 55 LINER INSTALLATION

1 - CYLINDER LINER
2 - SHIMS
3 - O-RINGS
4 - BLOCK LEDGE
5 - ENGINE BLOCK

9 - 46

ENGINE

CYLINDER LINERS (Continued)

(8) Fit the liners in the crankcase making sure

that the shim is positioned correctly in the seat. Lock
the liners in position using special tool (VM.1076)
and bolts (Fig. 56).

(9) Recheck the liner protrusion. It should be 0.00

- 0.05 mm.

(10) Reassemble engine.
(11) Install engine in vehicle.

INTERNAL VACUUM PUMP

DESCRIPTION

The diesel engine uses a internal vacuum pump.

This vacuum pump is mounted in the front of the
engine block under the engine front cover (Fig. 57).
The vacuum pump is driven by a sprocket on the
crankshaft.

REMOVAL

(1) Disconnect negative battery cable.
(2) Remove air cleaner housing.
(3) Remove power steering belt (Refer to 7 -

COOLING/ACCESSORY

DRIVE/DRIVE

BELTS

REMOVAL).

(4) Remove accessory drive belt (Refer to 7 -

COOLING/ACCESSORY

DRIVE/DRIVE

BELTS

REMOVAL).

(5) Support engine and remove right engine mount

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

(6) Remove

vibration

damper/crankshaft

pulley

(Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL).

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

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

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

VALVE

TIMING/TIMING

BELT/CHAIN

AND

SPROCKETS - REMOVAL).

(9) Remove timing belt inner cover (Refer to 9 -

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

NOTE: Crankshaft hub has LHD thread.

(10) Remove crankshaft hub.
(11) Remove front engine cover (Refer to 9 -

ENGINE/ENGINE

BLOCK/ENGINE

COVER

REMOVAL).

(12) Remove crankshaft sprocket (Fig. 58).
(13) Remove vacuum pump (Fig. 58).

INSTALLATION

NOTE: Verify the 3 blades on the vacuum pump are
in place and correctly assembled. The tapered edge
should be on the outer side. Make sure the pump
rotates before installation.

(1) Lubricate vacuum pump blades and install in

vacuum pump body as shown (Fig. 59).

(2) Install vacuum pump in engine block (Fig. 58).

Torque bolts to 10.8N·m.

(3) Install crankshaft sprocket (Fig. 58). Torque

bolts to 10.8N·m.

(4) Install

front

engine

cover

(Refer

ENGINE/ENGINE

BLOCK/ENGINE

COVER

INSTALLATION).

(5) Install front crankshaft hub. Torque bolt to

304N·m.

Fig. 56 LINER CLAMP LOCATION

1 - ENGINE BLOCK
2 - LINER RETAINER VM.1076
3 - CYLINDER LINER

Fig. 57 VACUUM PUMP

ENGINE

9 - 47

CYLINDER LINERS (Continued)

Content .. 476 477 478 479 ..