Chrysler RG Voyager. Manual — part 473
AIR CLEANER HOUSING
REMOVAL
(1) Disconnect the negative battery cable.
(2) Disconnect the air inlet hose from the air
cleaner housing cover (Fig. 11).
(3) Remove the air duct from the air cleaner hous-
ing cover.
(4) Remove the bolt for air cleaner housing at
upper radiator cross member.
(5) Pull air cleaner housing up and off over the
locating pins.
(6) Remove housing from vehicle.
INSTALLATION
(1) Install air cleaner housing into vehicle and
onto the locating pins (Fig. 11).
(2) Install bolt to hold housing to the upper radia-
tor cross member.
(3) Install the air inlet duct to the housing.
(4) Connect the air inlet hose to the housing.
(5) Connect the negative battery cable.
VM.1084 2.8L 90 DEGREES AFTER TDC LOCATING
PIN
VM.9075 FUEL INJECTOR EXTRACTOR
VM.9095 CRANKSHAFT SUPPORT RETAINER
Fig. 11 AIR CLEANER HOUSING
1 - AIR CLEANER HOUSING
2 - AIR DUCT
3 - MASS AIR FLOW SENSOR
4 - LOCATING PIN
5 - LOCATING RINGS
6 - BOLT
9 - 24
ENGINE
RG
ENGINE 2.5L/2.8 TURBO DIESEL (Continued)
CYLINDER HEAD
STANDARD PROCEDURE
STANDARD PROCEDURE - VALVE SERVICE
This procedure is done with the engine cylinder
head removed from the block.
DISASSEMBLY
(1) Remove the engine cylinder head from the cyl-
inder block. Refer to cylinder head removal and
installation in this section.
(2) Use Valve Spring Compressor Tool and com-
press each valve spring.
(3) Remove the valve locks, retainers, and springs.
(4) Inspect and remove any burrs on the top of the
valve stem, especially around the groove for the
locks.
(5) Remove the valves, and place them in a rack in
the same order as removed.
VALVE CLEANING
(1) Clean all carbon deposits from the combustion
chambers, valve ports, valve stems, valve stem
guides and head.
(2) Clean all build-up and gasket material from
the engine cylinder head machined gasket surface.
INSPECTION
(1) Inspect for cracks in the combustion chambers
and valve ports.
(2) Inspect for cracks on the exhaust seat.
(3) Inspect for cracks in the gasket surface at each
coolant passage.
(4) Inspect valves for burned, cracked or warped
heads.
(5) Inspect for scuffed or bent valve stems.
(6) Replace valves displaying any damage.
(7) Check valve spring height.
VALVE REFACING
(1) Use a valve refacing machine to reface the
intake and exhaust valves to the specified angle.
(2) After refacing, a margin of at least 4.52-4.49
mm (.178-.177 inch) must remain (Fig. 12). If the
margin is less than 4.49 mm (.177 inch), the valve
must be replaced.
VALVE SEAT REFACING
(1) Install a pilot of the correct size in the valve
guide bore. Reface the valve seat to the specified
angle with a good dressing stone. Remove only
enough metal to provide a smooth finish.
(2) Use tapered stones to obtain the specified seat
width when required.
Fig. 12 VALVE SPECS.
MEASUREMENT
INTAKE
EXHAUST
A
7.940-7.960
7.922-7.940
B
8.00-8.015
8.000-8.015
C
1.08-1.34
0.990-1.250
+0.07
D
2.2 ± 0.08
2.09
2
0.09
E
1.80-2.20
1.65-2.05
F
2.73-3.44
2.45-3.02
G
41.962-41.985
35.964-35.987
H
42.070-42.086
36.050-36.066
I
7.14-7.19
7.00-7.05
L
3.11-3.26
3.10-3.25
RG
ENGINE
9 - 25
VALVE STAND DOWN
Valve stand down is to maintain the adequate com-
pression ratio.
(1) Invert cylinder head.
(2) Fit each valve to its respective valve guide.
(3) Using a straight edge and feeler gauge, check
valve head stand down: Inlet valve head stand down
1.08 to 1.34 mm (.042 to .052 ins.) and exhaust valve
stand down .99 to 1.25 mm (.035 to .049 ins.).
(4) If valve head stand down is not in accordance
with above, discard original valves, check stand down
with new valves and recut valve seat inserts to
obtain correct stand down.
VALVE GUIDES
(1) Valve Guides height requirement.
(2) Measurement A (Fig. 13): 16.50 - 17.00 mm.
Measurment B : 14.50 - 15.00 mm.
VALVE STEM-TO-GUIDE CLEARANCE
MEASUREMENT
(1) Measure and record internal diameter of valve
guides. Valve guide internal diameter is 8.0 to 8.015
mm (.3149 to .3155 ins.).
(2) Measure valve stems and record diameters.
Intake valve stem diameter 7.94 to 7.96 mm (.3125 to
.3133 in). Exhaust valve stem diameter 7.92 to 7.94
mm (.3118 to .31215 in).
(3)
Subtract diameter of valve stem from internal
diameter of its respective valve guide to obtain valve
stem clearance in valve guide. Clearance of inlet
valve stem in valve guide is .040 to .075 mm (.0015
to .0029 in). Clearance of exhaust valve stem in valve
guide is .060 to .093 mm (.0023 to .0036 in).
(4) If valve stem clearance in valve guide exceeds
tolerances, new valve guides must be installed.
STANDARD PROCEDURE - MEASURING
PISTON PROTRUSION
(1) Use special tool VM.1010 with dial indicator
special tool VM.1013 (Fig. 14).
(2) Bring the piston of cylinder no. 1 exactly to top
dead center.
(3) Zero the dial indicator on the cylinder block
mating surface.
(4) Setup the dial indicator on the piston crown
(above the center of the piston pin) 5mm (1/8 in.)
from the edge of the piston and note the measure-
ment (Fig. 14).
(5) Repeat the procedure with the rest of the cyl-
inders.
(6) Establish the thickness of the steel gasket by
averaging the four piston potrusion readings.
Fig. 13 VALVE GUIDE HEIGHT
Fig. 14 PISTON PROTRUSION
9 - 26
ENGINE
RG
CYLINDER HEAD (Continued)
Measure Dimension
(mm)
0.460-0.609
Cylinder Head Gasket
Thickness (mm)
1.32
No Holes or Notches
Piston Clearance (mm)
0.71-0.86
Measure Dimension
(mm)
0.610-0.709
Cylinder Head Gasket
Thickness (mm)
1.42
1 Hole or Notch
Piston Clearance (mm)
0.711-0.81
Measure Dimension
(mm)
0.710-0.810
Cylinder Head Gasket
Thickness (mm)
1.52
2 Holes or Notches
Piston Clearance (mm)
0.71-0.81
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove front wiper unit (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER
MODULE
-
REMOVAL).
(3) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(4) Drain cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(5) Remove power steering belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
REMOVAL).
(6) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
REMOVAL).
(7) Remove generator (Refer to 8 - ELECTRICAL/
CHARGING/GENERATOR - REMOVAL).
(8) Support engine and remove right engine mount
(Refer to 9 - ENGINE/ENGINE MOUNTING/RIGHT
MOUNT - REMOVAL).
CAUTION: Before removing the cylinder head cover/
intake manifold or timing belt the engine must put
at 90° after TDC. Failure to do so could result in
valve and/or piston damage during reassembly.
(Refer to 9 - ENGINE/VALVE TIMING - STANDARD
PROCEDURE)
(9) Remove timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(10) Remove timing belt (Refer to 9 - ENGINE/
VALVE
TIMING/TIMING
BELT/CHAIN
AND
SPROCKETS - REMOVAL).
(11) Remove timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(12) Remove cylinder head cover/intake manifold
(Fig. 15)(Refer to 9 - ENGINE/CYLINDER HEAD/
CYLINDER HEAD COVER(S) - REMOVAL).
(13) Remove rocker arm and lifter assemblies from
cylinder head.
(14) Remove cylinder head cover/intake manifold
gasket from cylinder head (Fig. 15).
(15) Disconnect glow plug and engine coolant tem-
perature electrical connectors.
Fig. 15 CYLINDER HEADCOVER/INTAKE MANIFOLD
ASSEMBLY
1 - CYLINDER HEAD COVER/INTAKE MANIFOLD BOLTS(LONG)
2 - CYLINDER HEAD COVER/INTAKE MANIFOLD
3 - CYLINDER HEAD
4 - CYLINDER HEAD COVER/INTAKE MANIFOLD GASKET
5 - CYLINDER HEAD COVER/INTAKE MANIFOLD BOLTS(SHORT)
RG
ENGINE
9 - 27
CYLINDER HEAD (Continued)
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