Chrysler RG Voyager. Manual — part 483
OIL FILTER
DESCRIPTION
The oil filter is a high quality, full flow, disposable
style. (Fig. 93).
REMOVAL
NOTE: Capture any residual oil spill while removing
filter and wipe any oil that comes in contact with
other components
(1) Raise vehicle on hoist.
(2) Twist oil filter counterclockwise with a suitable
oil filter wrench to remove. (Fig. 93)
INSTALLATION
(1) Lubracate oil filter seal with clean engine oil.
(2) Turning clockwise, seat the oil filter then
tighten the oil filter 1/2 turn more (Fig. 93).
(3) Lower vehicle from hoist.
(4) Start engine and check for leaks.
(5) Check and adjust oil level as necessary.
OIL JET
DESCRIPTION
There are four oil jets installed in the engine block.
These oil jets are used to cool and lubricate the pis-
ton assemblies (Fig. 94).
REMOVAL
CAUTION: Use caution when removing and install-
ing oil jets. Damage to oil jet nozzle could cause
severe engine damage.
NOTE: Remove oil jets Before removing pistons,
crankshaft or liners
(1) Disconnect negative battery cable.
(2) Raise vehicle on hoist.
(3) Remove oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - REMOVAL).
(4) Using special tool VM.1060 to hold oil jet.
Remove oil jet retaining bolt and remove oil jet from
engine block (Fig. 95).
INSTALLATION
CAUTION: Use caution when removing and installa-
ing oil jets. Damage to oil jet nozzle could cause
severe engine damage.
NOTE: Carefully install the oil jets After assembling
the engine liners, crankshaft and pistons.
(1) Lubricate o-ring on oil jet.
(2) Using special tool VM.1060, install oil jet in
engine block (Fig. 95).
(3) Install oil jet retaining bolt. Torque bolt to
10.8N·m.
Fig. 93 OIL FILTER
1 - OIL FILTER
2 - ENGINE OIL COOLER
Fig. 94 OIL JET ASSEMBLY
1 - RETAINING BOLT
2 - OIL JET
3 - O-RING
9 - 64
ENGINE
RG
(4) Install oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION).
(5) Refill engine oil to proper level.
(6) Connect negative battery cable.
INTAKE MANIFOLD
DESCRIPTION
(Refer to 9 - ENGINE/CYLINDER HEAD/CYLIN-
DER HEAD COVER(S) - DESCRIPTION)
REMOVAL
(1) (Refer to 9 - ENGINE/CYLINDER HEAD/CYL-
INDER HEAD COVER(S) - REMOVAL)
INSTALLATION
(1) (Refer to 9 - ENGINE/CYLINDER HEAD/CYL-
INDER HEAD COVER(S) - INSTALLATION)
EXHAUST MANIFOLD
REMOVAL
(1) Remove the battery and tray assembly (Refer
to 8 - ELECTRICAL/BATTERY SYSTEM/TRAY -
REMOVAL).
(2) Remove the wiper cowl assembly (Refer to 23 -
BODY/EXTERIOR/COWL GRILLE - REMOVAL).
(3) Raise and support the vehicle.
(4) Drain the cooling system (Refer to 7 - COOL-
ING/ENGINE/COOLANT
-
STANDARD
PROCE-
DURE).
(5) Loosen the clamp retaining the upper charge
air tube to the turbocharger (Fig. 96).
(6) Lower the vehicle.
(7) Remove the auxiliary heater coolant pipe upper
retaining nut.
(8) Remove the coolant recovery pressure contain-
er(Refer
to
7
-
COOLING/ENGINE/COOLANT
RECOVERY PRESS CONTAINER - REMOVAL).
(9) Disconnect the upper radiator hose from the
coolant tube.
(10) Remove the coolant tube fasteners and tube.
Fig. 95 OIL JET REMOVAL/INSTALLATION
1 - SPECIAL TOOL VM.1060
2 - OIL JET
3 - CONNECTING ROD
4 - CRANKSHAFT
Fig. 96 TURBOCHARGER AND COOLANT PIPES
1 - TURBOCHARGER OUTLET PIPE RETAINING BOLT
2 - TURBOCHARGER OUTLET PIPE
3 - ADAPTOR HOSE
4 - HOSE CLAMPS
5 - TURBOCHARGER INLET PIPE RETAINING BOLT
6 - TURBOCHARGER INLET PIPE
7 - ADAPTOR HOSE
8 - HOSE CLAMPS
9 - EGR VALVE TO INTAKE AIR INLET PIPE
10 - CLAMP
11 - THERMOSTAT HOUSING TO UPPER RADIATOR HOSE PIPE
RG
ENGINE
9 - 65
OIL JET (Continued)
(11) Disconnect the charger air inlet at the tube
and remove the tube.
(12) Disconnect the EGR cooler coolant hoses.
(13) Disconnect the EGR cooler tube clamp.
(14) Disconnect the EGR vacuum hose.
(15) Remove the engine lift bracket (Fig. 97).
(16) Remove the exhaust manifold shields (Fig.
97).
(17) Remove the exhaust manifold upper fasteners
(Fig. 97).
(18) Raise and support the vehicle.
(19) Remove the turbocharger (Refer to 11 -
EXHAUST
SYSTEM/TURBOCHARGER
SYSTEM/
TURBOCHARGER - REMOVAL).
(20) Remove the lower exhaust manifold fasteners
and exhaust manifold (Fig. 97).
INSTALLATION
(1) Clean exhaust manifold mating surfaces.
NOTE: The exhaust manifold tightening sequence
must be repeated after the original sequence is
completed.
(2) Install the exhaust manifold gasket and care-
fully position the exhaust manifold onto the cylinder
head. Tighten the fasteners in a cross pattern work-
ing from the inside out to 36 N·m (26.5 lbs. ft.) (Fig.
97).
(3) Install
the
turbocharger(Refer
to
11
-
EXHAUST
SYSTEM/TURBOCHARGER
SYSTEM/
TURBOCHARGER - INSTALLATION).
(4) Lower the vehicle
(5) Install the exhaust manifold heat shields.
Tighten shield fasteners to 27.5 N·m (21 lbs. ft.) (Fig.
97).
(6) Connect the EGR vacuum hose and cooler
hoses.
(7) Connect the EGR Cooler tube.
(8) Install the engine lift bracket (Fig. 97).
(9) Install the charge air tube (Fig. 96).
(10) Install the coolant tube and fasteners (Fig.
96).
(11) Connect the upper radiator to the coolant
tube.
(12) Install the coolant reservoir (Refer to 7 -
COOLING/ENGINE/COOLANT RECOVERY PRESS
CONTAINER - INSTALLATION).
(13) Install the auxiliary heater tube fastener.
Tighten fastener to 27.5 N·m (21 lbs. ft.).
(14) Raise and support the vehicle.
(15) Connect and tighten the charge air hose to
the turbocharger (Fig. 96).
(16) Lower the vehicle.
(17) Install the wiper cowl assembly (Refer to 23 -
BODY/EXTERIOR/COWL
GRILLE
-
INSTALLA-
TION).
(18) Install the battery and tray assembly (Refer
to 8 - ELECTRICAL/BATTERY SYSTEM/TRAY -
INSTALLATION).
(19) Start engine and inspect for leaks.
Fig. 97 EXHAUST MANIFOLD AND
TURBOCHARGER
1 - TURBOCHARGER OIL SUPPLY BANJO BOLT
2 - COPPER WASHER
3 - EXHAUST MANIFOLD GASKET
4 - COPPER WASHER
5 - EXHAUST MANIFOLD HEAT SHIELD RETAINING BOLT
6 - TURBOCHARGER
7 - ENGINE LIFT HOOK
8 - ENGINE LIFT HOOK RETAINING BOLT
9 - SPACER
10 - EXHAUST MANIFOLD RETAINING NUT
11 - TURBOCHARGER OIL RETURN HOSE
12 - HOSE CLAMPS
13 - EXHAUST MANIFOLD STUDS
9 - 66
ENGINE
RG
EXHAUST MANIFOLD (Continued)
VALVE TIMING
STANDARD PROCEDURE - LOCKING ENGINE
90° AFTER TDC
(1) Disconnect negative battery cable.
(2) Remove starter motor (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - REMOVAL).
NOTE: Crankshaft hub retaining bolt is left hand
thread.
(3) Rotate engine untill notch in hub is in the fol-
lowing position (Fig. 98).
(4) Remove the yellow plastic plug and install spe-
cial tool VM.1068 in the engine block as shown at
this time (Fig. 99). This will lock the engine at 90°
after TDC.
(5) Remove front wiper unit (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER
MODULE
-
REMOVAL).
(6) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(7) Remove plug in cylinder head cover/intake
manifold and insert VM.1053 to lock exhaust cam-
shaft in position (Fig. 100).
(8) Remove generator (Refer to 8 - ELECTRICAL/
CHARGING/GENERATOR - REMOVAL).
Fig. 98 CRANKSHAFT HUB ALIGNMENT
1 - VIBRATION DAMPER/CRANKSHAFT PULLEY
2 - CRANKSHAFT HUB NOTCH
3 - VIBRATION DAMPER/CRANKSHAFT PULLEY TO
CRANKSHAFT HUB BOLTS
4 - ACCESSORY DRIVE BELT
Fig. 99 90 DEGREES AFTER TDC ALIGNMENT PIN
LOCATION
1 - ENGINE BLOCK
2 - VM.1051 TDC PIN OR VM.1068 90 DEGREES ATDC PIN
3 - FLYWHEEL
Fig. 100 EXHAUST CAMSHAFT LOCKING PIN
VM.1053
1 - EXHAUST MANIFOLD HEAT SHIELD
2 - EXHAUST CAMSHAFT LOCKING PIN VM.1053
3 - COOLANT TUBE FROM THERMOSTAT HOUSING TO UPPER
RADIATOR HOSE
4 - CYLINDER HEAD COVER/INTAKE MANIFOLD
RG
ENGINE
9 - 67
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