Chrysler Town, Dodge Caravan. Manual - part 1089

SPECIFICATIONS

SPECIFICATIONS - 2.5L COMMON RAIL
DIESEL ENGINE

ENGINE SPECIFICATIONS

DESCRIPTION

SPECIFICATION

Type

R2516C

Number of Cylinders

4

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 PS) @ 4000

RPM

Peak Torque

340Nm @ 2600 RPM

CRANKSHAFT

Front Journal Diameter

Nominal

62.985-63.005 mm

-0.25

62.735-62.755 mm

Front Bearing Diameter

Nominal

63.045-63.074 mm

-0.25

62.795-62.824 mm

Clearance Between

Journal and Bearing

0.040-0.089 mm

Center Journal Diameter

Nominal

63.005-63.020 mm

-0.25

62.755-62.770 mm

Center Bearing Diameter

Nominal

63.005-63.020 mm

-0.25

62.755-62.770 mm

Clearance Between

Journal and Bearing

0.008-0.051 mm

Rear Journal Diameter

Nominal

89.980-90.000 mm

-0.25

89.730-99.750 mm

Rear Bearing Diameter

Nominal

90.045-90.065 mm

-0.25

89.795-89.815 mm

Clearance Between

Journal and Bearing

0.045-0.080 mm

Connecting Rod Journal

Nominal

53.940-53.955 mm

-0.25

53.690-53.705 mm

DESCRIPTION

SPECIFICATION

Connecting Rod Bearing

Nominal

53.977-54.016 mm

-0.25

53.727-53.766 mm

Clearance Between

Journal and Bearing

0.022-0.076 mm

Crankshaft End Play

End Play

0.080-0.280 mm

Adjustment

Thrust Washers

Thrust Washers Available

2.31-2.36 mm

2.41-2.46 mm

2.51-2.56 mm

Carrier with thrust

washers installed

27.670-27.820 mm

MAIN BEARING CARRIERS

Internal Diameter

Front

67.025-67.050 mm

Center

66.670-66.690 mm

Rear

85.985-86.005 mm

LINERS

Internal Diameter

91.997-92.015 mm

Protrusion

0.00-0.05 mm

Adjustment

Shims

Available Shims

0.15 mm

0.17 mm

0.20 mm

0.23 mm

0.25 mm

CYLINDER HEAD

Minimum Thickness

94.95-95.05 mm

Gasket Thickness

1.32 mm ± 0.08, 0

notches

1.42 mm ± 0.08, 1 notch

1.52 mm ± 0.08, 2

notches

CONNECTING RODS

Small End Bearing

Internal Diameter

32.035-32.050 mm

Large End Internal

Diameter

53.977-54.016 mm

PISTONS

Skirt Diameter (measured

at approximately 10 mm

above the bottom of the

skirt)

91.912-91.928 mm

RG

ENGINE

9 - 9

ENGINE 2.5L TURBO DIESEL (Continued)

DESCRIPTION

SPECIFICATION

Piston Clearance

0.065-0.083 mm

Top of Piston to Cylinder

Head

0.69-0.83 mm

Piston Potrusion

0.49-0.60 Fit Gasket

Number (1.32), 0 notches

or holes

0.61-0.70 Fit Gasket

Number (1.42), 1 notch

or hole

0.71-0.83 Fit Gasket

Number (1.52), 2 notches

or holes

PISTON PINS

Type

Full Floating

Pin Diameter

31.990-31.996 mm

32.000-32.004

Clearance

0.010-0.020 mm

0.004-0.012

PISTON RINGS

Clearance in Groove

Top

0.078-0.137 mm

Second

0.065-0.110 mm

Oil Control

0.035-0.080 mm

Fitted Gap

Top

0.30-0.45 mm

Second

0.35-0.50 mm

Oil Control

0.25-0.50 mm

CAMSHAFT

Journal Diameter–Front

29.960-29.980 mm

Bearing Clearance

0.03-0.08 mm

Journal Diameter–Center

39.250-39.270 mm

Bearing Clearance

0.03-0.08 mm

Journal Diameter–Rear

39.250-39.270 mm

Bearing Clearance

0.03-0.08 mm

HYDRAULIC LIFTER

Outside Diameter

11.994 ± 0.006 mm

VALVES

Intake Valve

Opens

15.6° ± 2° A.T.D.C.

Closes

64.4° ± 2° A.B.D.C.

Exhaust Valve

Opens

66° ± 2° B.B.D.C.

Closes

32 ±2° B.T.D.C.

DESCRIPTION

SPECIFICATION

Face Angle

Intake

45° 25’-55° 35’

Exhaust

45° 25’-45° 35’

Head Diameter

Intake

32.30-32.50 mm

Exhaust

30.80-31.00 mm

Head Stand Down

Intake

1.08-1.34 mm

Exhaust

0.99-1.25 mm

Stem Diameter

Intake

5.952-5.970 mm

Exhaust

5.942-5.960 mm

Clearance in Guide

Intake

0.030-0.060 mm

Exhaust

0.040-0.070 mm

VALVE GUIDE

Inside Diameter

6.00-6.012 mm

Fitted Height

Intake

14.5-15.0 mm

Exhaust

16.5-17.0 mm

VALVE SPRINGS

Free Length

45.26 mm

Fitted Length

38.00 mm

Load at Fitted Length

182 ± 5-10% Kg

Load at Top of Lift

395 ± 5% Kg

Number of Coils

8

LUBRICATION

Pressure Relief Valve

Opens

6.50 bar

Pressure Relief Valve

Spring-Free Length

51.5 mm

OIL PUMP

Outer Rotor End Float

0.060-0.160 mm

Inner Rotor End Float

0.060-0.160 mm

Outer Rotor to Body

Diameter Clearance

0.130-0.240 mm

Rotor Body to Drive Gear

Clearance (pump not

fitted)

0.90-1.50 mm

9 - 10

ENGINE

RG

ENGINE 2.5L TURBO DIESEL (Continued)

SPECIFICATIONS - TORQUE

2.5L 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 - 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

47.1

35

—

Oil Cooler Mounting Stud

50

37

—

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

—

Front Engine Cover Bolts

11.8

8

96

Transmission to Engine

Bolts

83.4

62

—

Cylinder Head Cover /

Intake Manifold Bolts

27.5

20

—

Camshaft Access Plugs

80

59

—

Oil Separator Bolts

10.8

8

96

Camshaft Position Sensor

Bolt

10.8

8

96

Boost Pressure / Intake

Air Temp. Sensor Bolts

5.4

—

48

Accessory Drive Bracket

Bolts

47.1

35

—

Vacuum Line Fitting Bolt

56.9

42

—

Fuel Pump Nuts

27.5

21

—

Fuel Line Fittings at Pump

27.5

21

—

Inner Timing Belt Cover

Bolts

RG

ENGINE

9 - 11

ENGINE 2.5L TURBO DIESEL (Continued)

DESCRIPTION

N·m

Ft. Lbs.

In. Lbs.

8mm

10.8

8

96

10mm

47.1

35

—

Outer Timing Belt Cover

Bolts

3mm

6

—

54

8mm

10.8

8

96

Engine Mount Bracket to

Cylinder Head Bolts

47.1

35

—

Intake Inlet Tube Bolts

10.1

8

89

Camshaft Sprocket Bolts

108

80

—

Timing Belt Idler Pulley

Bolt

47.1

35

—

Timing Belt Tensioner Bolt

34.7

26

—

Fuel Pump Nut

88.3

65

—

Engine Lift Hook Bolts

32.4

24

—

Thermostat Housing Bolts

27.5

21

—

Turbocharger Oil Feed

Line Fitting

24.5

18

217

Exhaust Manifold Nuts

(Must recheck each nut

after tightening sequence

is completed)

36

26.5

—

Exhaust Manifold

Heatshield Bolts

27.5

21

—

EGR Valve Nuts

32.4

24

—

EGR Pipe to EGR Bolts

32.4

24

—

Turbocharger Downpipe

Nuts

32.4

24

—

Turbocharger Bracket

Bolts

47.1

35

—

Vibration Damper to

Crankshaft Hub Bolts

27.5

21

—

Crankshaft Support Bolts

44.1

33

—

Turbocharger to Exhaust

Manifold Nuts

32.4

24

—

9 - 12

ENGINE

RG

ENGINE 2.5L TURBO DIESEL (Continued)