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
INSTALLATION - 2.5L TURBO DIESEL
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SPECIFICATIONS - 2.5L COMMON RAIL
DIESEL ENGINE . . . . . . . . . . . . . . . . . . . . . . . 9
. . . . . . . . . . . . . . . . . . . . . . . 13
CYLINDER HEAD
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
. . . . . . . . . . . . . . . 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
RG
ENGINE 2.5L TURBO DIESEL (Continued)
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