Index Chrysler Chrysler TOWN & COUNTRY, VOYAGER, Dodge Caravan - service repair manual 2001-2007 year

Content .. 1085 1086 1087 1088 ..

Chrysler Town, Dodge Caravan. Manual - part 1087

ENGINE

TABLE OF CONTENTS

page

page

ENGINE 2.5L TURBO DIESEL

DESCRIPTION - 2.5L COMMON RAIL

DIESEL ENGINE . . . . . . . . . . . . . . . . . . . . . . . 3

DESCRIPTION - ENGINE COVER

. . . . . . . . . . 3

REMOVAL - 2.5L DIESEL ENGINE

. . . . . . . . . . 3

REMOVAL - ENGINE COVER

. . . . . . . . . . . . . 7

INSTALLATION - 2.5L TURBO DIESEL

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

INSTALLATION - ENGINE COVER

. . . . . . . . . . 8

SPECIFICATIONS - 2.5L COMMON RAIL

DIESEL ENGINE . . . . . . . . . . . . . . . . . . . . . . . 9

SPECIFICATIONS - TORQUE

. . . . . . . . . . . . . 11

. . . . . . . . . . . . . . . . . . . . . . . 13

CYLINDER HEAD

STANDARD PROCEDURE

STANDARD PROCEDURE - VALVE

SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

STANDARD PROCEDURE - MEASURING

PISTON PROTRUSION . . . . . . . . . . . . . . . . . 21

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

. . . . . . . . . . . . . . . . . . . . . . . . . . 23

. . . . . . . . . . . . . . . . . . . . . . . . . 23

CAMSHAFT(S)

. . . . . . . . . . . . . . . . . . . . . . . . . 25

. . . . . . . . . . . . . . . . . . . . . . . . . . . 25

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

. . . . . . . . . . . . . . . . . . . . . . . . . 25

CYLINDER HEAD COVER(S)

. . . . . . . . . . . . . . . . . . . . . . . . . 26

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

. . . . . . . . . . . . . . . . . . . . . . . . . 28

CAMSHAFT OIL SEAL(S)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

. . . . . . . . . . . . . . . . . . . . . . . . . 29

ROCKER ARMS

. . . . . . . . . . . . . . . . . . . . . . . . . 30

. . . . . . . . . . . . . . . . . . . . . . . . . . . 30

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

. . . . . . . . . . . . . . . . . . . . . . . . . 30

HYDRAULIC LIFTERS

. . . . . . . . . . . . . . . . . . . . . . . . . 31

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

. . . . . . . . . . . . . . . . . . . . . . . . . . 32

. . . . . . . . . . . . . . . . . . . . . . . . . 32

ENGINE BLOCK

. . . . . . . . . . . . . . . . . . . . . . . . . 32

CRANKSHAFT

. . . . . . . . . . . . . . . . . . . . . . . . . 33

. . . . . . . . . . . . . . . . . . . . . . . . . . . 33

STANDARD PROCEDURE - CHECKING

CRANKSHAFT END PLAY

. . . . . . . . . . . . . . . 33

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

. . . . . . . . . . . . . . . . . . . . . . . . . 34

CYLINDER LINERS

. . . . . . . . . . . . . . . . . . . . . . . . . 36

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

. . . . . . . . . . . . . . . . . . . . . . . . . . 36

. . . . . . . . . . . . . . . . . . . . . . . . . 37

INTERNAL VACUUM PUMP

. . . . . . . . . . . . . . . . . . . . . . . . . 38

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

. . . . . . . . . . . . . . . . . . . . . . . . . 38

PISTON & CONNECTING ROD

. . . . . . . . . . . . . . . . . . . . . . . . . 39

STANDARD PROCEDURE - PISTON RING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

. . . . . . . . . . . . . . . . . . . . . . . . . . 40

. . . . . . . . . . . . . . . . . . . . . . . . . 42

CRANKSHAFT OIL SEAL - FRONT

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

. . . . . . . . . . . . . . . . . . . . . . . . . 44

VIBRATION DAMPER

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

. . . . . . . . . . . . . . . . . . . . . . . . . 45

ENGINE COVER - FRONT

. . . . . . . . . . . . . . . . . . . . . . . . . 45

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

. . . . . . . . . . . . . . . . . . . . . . . . . 46

CRANKSHAFT MAIN BEARINGS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

. . . . . . . . . . . . . . . . . . . . . . . . . 48

CRANKSHAFT OIL SEAL - REAR

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

. . . . . . . . . . . . . . . . . . . . . . . . . 49

OIL PAN

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

. . . . . . . . . . . . . . . . . . . . . . . . . 49

OIL PUMP

. . . . . . . . . . . . . . . . . . . . . . . . . . . 50

. . . . . . . . . . . . . . . . . . . . . . . . . . . 50

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ENGINE

9 - 1

. . . . . . . . . . . . . . . . . . . . . . . 50

. . . . . . . . . . . . . . . . . . . . . . . 51

OIL PRESSURE SENSOR/SWITCH

. . . . . . . . . . . . . . . . . . . . . . . . . 51

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

. . . . . . . . . . . . . . . . . . . . . . . . . 51

OIL PRESSURE RELIEF VALVE

. . . . . . . . . . . . . . . . . . . . . . . . . 51

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

. . . . . . . . . . . . . . . . . . . . . . . . . 52

OIL COOLER & LINES

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

. . . . . . . . . . . . . . . . . . . . . . . . . 53

OIL FILTER

. . . . . . . . . . . . . . . . . . . . . . . . . 53

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

. . . . . . . . . . . . . . . . . . . . . . . . . 53

OIL JET

. . . . . . . . . . . . . . . . . . . . . . . . . 54

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

. . . . . . . . . . . . . . . . . . . . . . . . . 54

INTAKE MANIFOLD

. . . . . . . . . . . . . . . . . . . . . . . . . 54

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

. . . . . . . . . . . . . . . . . . . . . . . . . 54

VALVE TIMING

STANDARD PROCEDURE - LOCKING ENGINE

. . . . . . . . . . . . . . . . . . . . . . . 55

BALANCE SHAFT

. . . . . . . . . . . . . . . . . . . . . . . . . 56

. . . . . . . . . . . . . . . . . . . . . . . . . . . 56

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

. . . . . . . . . . . . . . . . . . . . . . . . . 57

TIMING BELT COVER

REMOVAL - TIMING BELT OUTER COVER

REMOVAL - TIMING BELT INNER COVER

INSTALLATION - TIMING BELT OUTER

COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

INSTALLATION - TIMING BELT INNER

COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

TIMING BELT IDLER PULLEY

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

. . . . . . . . . . . . . . . . . . . . . . . . . 60

TIMING BELT TENSIONER & PULLEY

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

. . . . . . . . . . . . . . . . . . . . . . . . . 61

ADJUSTMENT - TIMING BELT TENSIONER

TIMING BELT AND SPROCKETS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

. . . . . . . . . . . . . . . . . . . . . . . . . 63

9 - 2

ENGINE

RG

ENGINE 2.5L TURBO DIESEL

DESCRIPTION

DESCRIPTION - 2.5L COMMON RAIL DIESEL
ENGINE

This 2.5 Liter (2500cc) four-cylinder “common rail”

direct injection engine is an in-line overhead valve
diesel engine. This engine utilizes a cast iron cylin-
der block and an aluminum cylinder head. The
engine is turbocharged and intercooled. The engine
also has four valves per cylinder and dual overhead
camshafts (Fig. 1).

DESCRIPTION

SPECIFICATION

Displacement

2.5L (2499 cc)

Bore

92.00

Stroke

94.00

Compression Ratio

17.5:1

Vacuum at Idle

685.8 mm/Hg (27.0 In/Hg)

Belt Tension

Automatic Belt Tensioner

Thermostat Opening

88°C ± 2°C

Generator Rating

Denso 12V-95A

Cooling System Capacity

13.8 Liters W/O Auxiliary
Heater
16.6 Liters With Auxiliary
Heater

Engine Oil Capacity

6.0L With Filter Change

Timing System

Belt Driven Camshafts In
Cylinder Head Cover

Air Intake

Dry Filter

Fuel Feed

Vane Pump Incorporated
In Injection Pump

Fuel System

Direct Fuel Injection

Combustion Cycle

4 Stroke

Cooling System

Water Cooling

High Pressure Injection
Pump

Common Rail

Lubrication

Pressure Lubricated By
Rotary Pump

Engine Rotation

Clockwise Viewed From
Front Cover

Cylinder Compression

Maximum Difference
Between Cylinders Minus
5 Bar

Minimum Oil Pressure,
Warm Engine

0.7 Bar at Idle, 2 Bar at
3800 RPM

DESCRIPTION - ENGINE COVER

The engine cover is a black plastic cover used to

cover the top of the engine (Fig. 10). It is used to iso-
late engine noises.

REMOVAL

REMOVAL - 2.5L DIESEL ENGINE

(1) Disconnect negative battery cable.
(2) Remove engine cover (Fig. 2). (Refer to 9 -

ENGINE - REMOVAL)

Fig. 1 2.5L COMMON RAIL DIESEL

Fig. 2 ENGINE COVER

1 - ENGINE COVER MOUNTING BOLTS
2 - ENGINE COVER

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ENGINE

9 - 3

(3) Remove air cleaner housing, MAF sensor, and

air intake tube assembly (Fig. 3).

(4) Remove coolant pressure tank pressure cap.
(5) Raise vehicle on hoist.
(6) Drain cooling system (Refer to 7 - COOLING/

ENGINE/COOLANT - STANDARD PROCEDURE).

(7) Remove lower splash shield.
(8) Remove splash shield side panels.
(9) Remove power steering reservoir hose from

power steering pump and drain power steering fluid
(Fig. 4).

(10) Disconnect high pressure power steering line

at pump (Fig. 4).

(11) Disconnect power steering pump return hose

clamp (Fig. 4).

(12) Remove power steering return line retaining

clamp (Fig. 4).

(13) Remove power steering line clamps from oil

pan (Fig. 4).

(14) Remove power steering pump reservoir and

bracket (Fig. 4).

(15) Drain coolant system (Refer to 7 - COOLING/

ENGINE/COOLANT - STANDARD PROCEDURE).

Fig. 3 MASS AIR FLOW (MAF) SENSOR LOCATION

1 - MAF SENSOR ELECTRICAL CONNECTOR
2 - RETAINING CLAMPS
3 - MASS AIR FLOW (MAF) SENSOR
4 - AIR CLEANER HOUSING

Fig. 4 RESERVOIR AND HOSES - 2.5L DIESEL

1 - POWER STEERING FLUID RESERVOIR
2 - RESERVOIR BRACKET
3 - SUPPLY HOSE BRACKET
4 - RETURN HOSE FROM GEAR
5 - ROUTING CLIP
6 - PRESSURE HOSE TO GEAR
7 - SUPPLY HOSE (PUMP END)
8 - PRESSURE HOSE (PUMP END)
9 - SUPPLY HOSE
10 - RETURN HOSE

9 - 4

ENGINE

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ENGINE 2.5L TURBO DIESEL (Continued)

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