shaft CHRYSLER CARAVAN 2002 Service Manual

TMNG BELT/CHAIN
TENSIONER
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(3) Remove air cleaner housing.
(4) Support engine and remove right engine
mount.
(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 vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(8) Remove timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(9) Loosen and remove timing belt tensioner (Fig.
96).
INSTALLATION
(1) Install timing belt tensioner and retaining bolt
(Fig. 96).
(2) Adjust timing belt tensioner (Refer to 9 -
ENGINE/VALVE TIMING/TMNG BELT/CHAIN
TENSIONER&PULLEY - ADJUSTMENTS) .
(3) Install timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(4) Install vibration damper (Refer to 9 - ENGINE/
ENGINE BLOCK/VIBRATION DAMPER - INSTAL-
LATION).
(5) Install accessory drive belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).(6) Install power steering belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(7) Install right engine mount.
(8) Install air cleaner housing.
(9) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
(10) Connect negative battery cable.Fig. 96 TIMING BELT AND SPROCKETS
1 -CAMSHAFT SPROCKETS
2 - INJECTION PUMP SPROCKET
3 - INJECTION PUMP SPROCKET RETAINING NUT
4 - TIMING BELT
5 - TIMING BELT TENSIONER RETAINING BOLT
6 - TIMING BELT TENSIONER
7 - TENSIONER ALIGNMENT PIN
8 - IDLER PULLEY
9 - CAMSHAFT SPROCKET RETAINING BOLT
RGENGINE9a-59
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ADJUSTMENTS
ADJUSTMENT - TIMING BELT TENSIONER
(1) With timing belt outer cover removed and tim-
ing belt installed.
(2) Loosen timing belt tensioner (Fig. 97).
(3) Align timing belt tensioner spring stop with
tensioner as shown (Fig. 98) and torque timing belt
tensioner retaining bolt to 34.7N´m.
(4) Rotate engine 2 complete revolution and then
recheck tensioner alignment. Readjust tensioner
alignment as necessary.
TIMING BELT/CHAIN AND
SPROCKETS
REMOVAL
CAUTION: Before removing the timing belt, the
engine must put at 90É after TDC. Failure to do so
could result in valve and/or piston damage during
reassembly. (Refer to 9 - ENGINE/VALVE TIMING -
STANDARD PROCEDURE)
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(3) Remove air cleaner housing assembly.
(4) Support engine and remove right engine
mount.
(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 vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
Fig. 97 TIMING BELT TENSIONER ADJUSTMENT
1 - TIMING BELT IDLER PULLEY
2 - ENGINE FRONT COVER
3 - CRANKSHAFT HUB
4 - TIMING BELT TENSIONER
5 - TIMING BELT
Fig. 98 TIMING BELT TENSIONER ALIGNMENT
1 - TENSIONER SPRING STOP
2 - TIMING BELT TENSIONER
3 - TIMING BELT TENSIONER
4 - TIMING BELT
5 - TIMING BELT INNER COVER
9a - 60 ENGINERG
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(8) Remove timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(9) Loosen timing belt tensioner and remove tim-
ing belt (Fig. 99).
INSTALLATION
(1) With both camshaft alignment pins still
installed and the engine locked at 90É after TDC.
(2) Align timing mark on injection pump sprocket
with timing mark on timing belt (Fig. 100).(3) Install timing belt.
(4) Adjust the timing belt tensioner (Refer to 9 -
ENGINE/VALVE TIMING/TMNG BELT/CHAIN
TENSIONER&PULLEY - ADJUSTMENTS) .
(5) Remove both camshaft alignment pins from cyl-
inder head cover/intake manifold and engine locking
pin from engine block (Refer to 9 - ENGINE/VALVE
TIMING - STANDARD PROCEDURE).
(6) Install timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(7) Install vibration damper (Refer to 9 - ENGINE/
ENGINE BLOCK/VIBRATION DAMPER - INSTAL-
LATION).
(8) Install accessory drive belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(9) Install power steering belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(10) Install right engine mount.
(11) Install air cleaner housing.
(12) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
(13) Connect negative battery cable.
Fig. 99 TIMING BELT AND SPROCKETS
1 -CAMSHAFT SPROCKETS
2 - INJECTION PUMP SPROCKET
3 - INJECTION PUMP SPROCKET RETAINING NUT
4 - TIMING BELT
5 - TIMING BELT TENSIONER RETAINING BOLT
6 - TIMING BELT TENSIONER
7 - TENSIONER ALIGNMENT PIN
8 - IDLER PULLEY
9 - CAMSHAFT SPROCKET RETAINING BOLT
Fig. 100 INJECTION PUMP GEAR TIMING MARKS
1 - TIMING MARK ON COVER
2 - TIMING MARK ON INJECTION PUMP SPROCKET
3 - INJECTION PUMP SPROCKET
RGENGINE9a-61
TIMING BELT/CHAIN AND SPROCKETS (Continued)
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OPERATION
Heat shields are needed to protect both the vehicle
and the environment from the high temperatures
developed near the catalytic converter.
Avoid application of rust prevention com-
pounds or undercoating materials to exhaust
system floor pan heat shields on cars so
equipped. Light over spray near the edges is
permitted. Application of coating will greatly
reduce the efficiency of the heat shields result-
ing in excessive floor pan temperatures and
objectionable fumes.
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove fasteners attaching applicable heat
shield (Fig. 7), (Fig. 8), or (Fig. 9).
(3) Remove heat shield(s).
INSTALLATION
(1) Position heat shield(s) to underbody.
(2) Install heat shield fasteners and tighten to 2.6
N´m (23 in. lbs.) (Fig. 7), (Fig. 8), or (Fig. 9).
(3) Lower vehicle.
MUFFLER
REMOVAL
(1) Raise vehicle on a body contact type hoist.
NOTE: To provide removal clearance between muf-
fler/resonator pipe and rear axle parts, the rear sus-
pension must be relieved of all body weight.
(2) Apply a penetrating oil to clamp nuts of com-
ponent requiring removal.
CAUTION: When servicing the exhaust system, care
must be exercised not to dent or bend the bellows
of the flex-joint. Should this occur, the flex-joint will
eventually fail, requiring replacement of the cata-
lytic converter.
(3) Disconnect the right side axle half shaft from
the rear differential module (AWD equipped only).
Fig. 7 CATALYTIC CONVERTER HEAT SHIELD
1 - HEAT SHIELD - CATALYTIC CONVERTER
2 - SCREW (QTY. 4)
Fig. 8 MUFFLER HEAT SHIELD
1 - HEAT SHIELD - MUFFLER
2 - SCREW (QTY. 6)
Fig. 9 RESONATOR PIPE HEAT SHIELD
1 - SCREW (QTY. 3)
2 - HEAT SHIELD - RESONATOR PIPE
3 - MUFFLER
RSEXHAUST SYSTEM11-7
HEAT SHIELDS (Continued)
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CAUTION: Band clamps should never be tightened
such that the two sides of the clamps are bottomed
out against the center hourglass shaped center
block. Once this occurs, the clamp band has been
stretched and has lost its clamping force and must
be replaced.
To replace the band clamp; remove the nut and peel
back the ends of the clamp until spot weld breaks.
Clean remaining spot weld from the pipe using a
file or grinder until surface is smooth.
NOTE: Maintain proper clamp orientation when
replacing with new clamp.
(5) Tighten the band clamp to 55 N´m (40 ft. lbs.)
(Fig. 12).
(6) Connect the right side half shaft to the rear
differential module (AWD equipped only).
RESONATOR
REMOVAL
(1) (Refer to 11 - EXHAUST SYSTEM/MUFFLER -
REMOVAL)
INSTALLATION
(1) (Refer to 11 - EXHAUST SYSTEM/MUFFLER -
INSTALLATION)
Fig. 12 Band Clamp
1 - BAND CLAMP
2 - TORQUE SPECIFICATION
RSEXHAUST SYSTEM11-9
MUFFLER (Continued)
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TURBOCHARGER SYSTEM
DESCRIPTION
CAUTION: The turbocharger is a performance part
and must not be tampered with. The wastegate
bracket is an integral part of the turbocharger. Tam-
pering with the wastegate components can reduce
durability by increasing cylinder pressure and ther-
mal loading due to incorrect inlet and exhaust man-
ifold pressure. Poor fuel economy and failure to
meet regulatory emissions laws may result. Increas-
ing the turbocharger boost WILL NOT increase
engine power.
The turbocharger is an exhaust-driven super-
charger which increases the pressure and density of
the air entering the engine. With the increase of air
entering the engine, more fuel can be injected into
the cylinders, which creates more power during com-
bustion.
The turbocharger assembly consists of four (4)
major component systems (Fig. 1) (Fig. 2):
²Turbine section
²Compressor section
²Bearing housing
²Wastegate
OPERATION
Exhaust gas pressure and energy drive the tur-
bine, which in turn drives a centrifugal compressor
that compresses the inlet air, and forces the air into
the engine through the charge air cooler and plumb-
ing. Since heat is a by-product of this compression,
the air must pass through a charge air cooler to cool
the incoming air and maintain power and efficiency.
Increasing air flow to the engine provides:
²Improved engine performance
²Lower exhaust smoke density
²Improved operating economy
²Altitude compensation
²Noise reduction.
The turbocharger also uses a wastegate (Fig. 3),
which regulates intake manifold air pressure and
prevents over boosting at high engine speeds. When
the wastegate valve is closed, all of the exhaust gases
flow through the turbine wheel. As the intake mani-
fold pressure increases, the wastegate actuator opens
the valve, diverting some of the exhaust gases away
from the turbine wheel. This limits turbine shaft
speed and air output from the impeller.
The turbocharger is lubricated by engine oil that is
pressurized, cooled, and filtered. The oil is delivered
to the turbocharger by a supply line that is tapped
into the oil filter head. The oil travels into the bear-
ing housing, where it lubricates the shaft and bear-
ings (Fig. 4). A return pipe at the bottom of the
Fig. 1 Turbocharger Operation
1 - TURBINE SECTION
2 - EXHAUST GAS
3 - BEARING HOUSING
4 - COMPRESSOR SECTION
5 - INLET AIR
6 - COMPRESSED AIR TO ENGINE
7 - EXHAUST GAS
8 - EXHAUST GAS TO EXHAUST PIPE
Fig. 2 Turbocharger Wastegate Actuator
1 - TURBOCHARGER
2 - DIAPHRAGM
3 - WASTE GATE ACTUATOR
11a - 2 EXHAUST SYSTEM AND TURBOCHARGERRG
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bearing housing, routes the engine oil back to the
crankcase.
The most common turbocharger failure is bearing
failure related to repeated hot shutdowns with inad-
equate ªcool-downº periods. A sudden engine shut
down after prolonged operation will result in the
transfer of heat from the turbine section of the tur-
bocharger to the bearing housing. This causes the oil
to overheat and break down, which causes bearing
and shaft damage the next time the vehicle is
started.Letting the engine idle after extended operation
allows the turbine housing to cool to normal operat-
ing temperature. The following chart should be used
as a guide in determining the amount of engine idle
time required to sufficiently cool down the turbo-
charger before shut down, depending upon the type
of driving and the amount of cargo.
TURBOCHARGER(COOL DOWN(CHART
Driving Load Turbocharger Idle Time
(in
minuetes)
Condition Temperature Before
Shut Down
Stop & Go Empty Cool Less than 1
Stop & Go Medium Warm 1
Highway
SpeedsMedium Warm 2
City Traffic Max.
GCWRWarm 3
Highway
SpeedsMax.
GCWRWarm 4
Uphill
GradeMax.
GCWRHot 5
Fig. 3 Wastegate Operation
1 - SIGNAL LINE
2 - EXHAUST BYPASS VALVE
3 - WASTEGATE
4 - EXHAUST
5 - TURBINE
6 - EXHAUST BYPASS VALVE
7 - WASTEGATE
8 - EXHAUST
9 - TURBINE
10 - SIGNAL LINE
Fig. 4 Turbocharger Oil Supply and Drain
1 - BEARINGS
2 - OIL SUPPLY (FROM ENGINE BLOCK)
3 - OIL RETURN (TO OIL PAN)
RGEXHAUST SYSTEM AND TURBOCHARGER11a-3
TURBOCHARGER SYSTEM (Continued)
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REMOVAL
The front cradle crossmember must be installed in
the design location to achieve proper front end sus-
pension alignment. If the cradle crossmember is
removed without applying reference marks on the
frame rails, align the cradle crossmember according
to the dimensions provided in this group.
NOTE: If the caged nuts in the frame rails become
damaged and cannot be reused, a replacement nut
can be obtained through MoparT.
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove steering column lower cover from
instrument panel (Refer to 23 - BODY/INSTRU-
MENT PANEL/STEERING COLUMN OPENING
COVER - REMOVAL).
(3) Remove steering column cover backing plate
(Refer to 23 - BODY/INSTRUMENT PANEL/STEER-
ING COLUMN COVER BACKING PLATE - REMOV-
AL).
(4) Position steering so front wheels are straight
ahead.
CAUTION: Do not rotate steering wheel after disen-
gaging lower coupling from steering gear, damage
to air bag clock spring can result.
(5) Remove clinch bolt attaching steering column
coupling to steering gear shaft (Fig. 10).(6) Remove steering column coupling from tele-
scoping steering gear shaft.
(7) Hoist vehicle and support on safety stands.
(8) Position a drain pan under power steering
pump and oil return hose coupling.
(9) Using a hose pinch-off pliers (C-4390), pinch
power steering oil return hose off between the cross-
member coupling and the pump.
(10) Loosen hose clamp at the cradle crossmember
coupling.
(11) Disconnect return hose from metal tube.
(12) While holding pressure relief valve nut on
back of power steering pump, Remove flare nut
attaching high pressure hose to back of pump.
(13) Remove high pressure hose from pump.
(14) Allow power steering fluid to drain into pan.
(15) Remove bolts attaching anti-lock brake sensor
leads to cradle crossmember.
(16) Position anti-lock brake leads out of the way.
(17) Disconnect stabilizer bar links from ends of
stabilizer bar.
(18) Disconnect lower ball joints from lower steer-
ing knuckles (Refer to 2 - SUSPENSION/FRONT/
LOWER BALL JOINT - REMOVAL).
(19) Remove the rear engine mount heat shield
(Fig. 11).
(20) Remove through bolt attaching rear engine
mount to cradle crossmember (Fig. 12).
(21) Using paint or grease pencil, mark outline of
cradle crossmember on frame rails to aid installation.
(22) Support cradle crossmember on suitable lift-
ing device (Fig. 14).
(23) Remove bolts attaching crossmember to front
frame rails (Fig. 13).
Fig. 10 STEERING COUPLING
1 - STEERING SHAFT BOOT
2 - STEERING SHAFT
3 - CROSSMEMBER
4 - STEERING GEAR
5 - MOUNT
6 - TRANSAXLE
Fig. 11 REAR MOUNT HEAT SHIELD
1 - BOLT
2 - HEAT SHIELD
3 - CLIP
4 - REAR ENGINE MOUNT
13 - 10 FRAME & BUMPERSRS
FRONT CRADLE CROSSMEMBER (Continued)
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INSTALLATION
NOTE: If cradle crossmember requires replacement.
Refer to Group 2, Suspension, to transfer suspen-
sion components and Group 19, Steering, to trans-
fer steering components.
(1) Support crossmember on suitable lifting device
(Fig. 14).
(2) Position crossmember to vehicle.
(3) Loosely install bolts attaching cradle cross-
member to front frame rails.
(4) Align crossmember to previously made marks
on frame rails.
(5) Tighten bolts attaching cradle crossmember to
frame rails.
(6) Install through bolt attaching rear engine
mount to cradle crossmember (Fig. 12) and tighten to
68 N´m (50 ft. lbs.) torque.
(7) Install the rear mount heat shield (Fig. 11).
(8) Connect lower ball joints to steering knuckles
(Refer to 2 - SUSPENSION/FRONT/LOWER BALL
JOINT - INSTALLATION)
(9) Connect stabilizer bar links to ends of stabi-
lizer bar.
(10) Install bolts attaching anti-lock brake sensor
leads to cradle crossmember.
(11) Install high pressure hose to pump.
(12) Connect return hose to metal tube.
(13) Tighten hose clamp at the cradle crossmember
coupling.
(14) Remove pinch-off pliers.
(15) Position steering so front wheels are straight
ahead.
(16) Install steering column coupling to telescoping
steering gear shaft.
(17) Install clinch bolt attaching steering column
coupling to steering gear shaft.
(18) Install steering column cover backing plate
(Refer to 23 - BODY/INSTRUMENT PANEL/STEER-
ING COLUMN COVER BACKING PLATE -
INSTALLATION)
(19) Install steering column lower cover from
instrument panel (Refer to 23 - BODY/INSTRU-MENT PANEL/STEERING COLUMN OPENING
COVER - INSTALLATION).
(20) Connect battery negative cable.
FRONT CROSSMEMBER
MOUNT BUSHINGS
REMOVAL
(1) Using paint or grease pencil, mark outline of
cradle crossmember on frame rails.
(2) Loosen bolts attaching crossmember to frame
rails.
(3) Remove bolt on bushing that requires replace-
ment.
(4) Allow cradle crossmember to drop down enough
to gain clearance for bushing removal.
(5) Remove bushing from vehicle.
INSTALLATION
(1) Apply rubber lubrication or soap to replace-
ment bushing.
(2) Insert lower half of bushing into square hole in
cradle crossmember.
(3) Place upper half of bushing on top of cross-
member aligned to receive square tube protruding
upward from lower bushing half.
(4) Squeeze bushing halves together to ensure they
are properly mated.
(5) Lift cradle crossmember upward to close gap
between the bushing and frame.
(6) Verify that lower bushing is fully seated into
cradle crossmember and upper bushing.
(7) Install bolt attaching bushing and crossmember
to frame rail hand tight.
(8) Align cradle crossmember to reference marks
on frame rails.
(9) Tighten cradle crossmember to frame rails
attaching bolts to 163 N´m (120 ft. lbs.) torque.
13 - 12 FRAME & BUMPERSRS
FRONT CRADLE CROSSMEMBER (Continued)
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FUEL DELIVERY
DESCRIPTION
DESCRIPTION
The front wheel drive car uses a plastic fuel tank
located rear center of the vehicle.
The Fuel Delivery System consists of: the following
items:
²Electric fuel pump module
²Fuel filter
²Tubes/lines/hoses
²Fuel injectors
The in-tank fuel pump module contains the fuel
pump. The pump is serviced as part of the fuel pump
module. Refer to Fuel Pump Module.
The fuel filter is replaceable, it is mounted on the
outside, on top of, the fuel tank. Refer to the Main-
tenance Schedules in the Introduction section of this
manual for recommended fuel filter replacement
intervals.
DESCRIPTION - FFV REPLACEMENT PARTS
Many components in a Flexible Fuel Vehicle (FFV)
are designed to be compatible with ethanol. Always
be sure that the vehicle is serviced with correct etha-
nol compatible parts.
CAUTION: Replacing fuel system components with
non-ethanol compatible components can damage
your vehicle and may void the warranty.
OPERATION
The fuel system provides fuel pressure by an
in-tank pump module. The PCM controls the opera-
tion of the fuel system by providing battery voltage
to the fuel pump through the fuel pump relay. The
PCM requires only three inputs and a good ground to
operate the fuel pump relay. The three inputs are:²Ignition voltage
²Crankshaft Position (CKP) sensor
²Camshaft Position (CMP) sensor
DIAGNOSIS AND TESTING - FUEL DELIVERY
SYSTEM
(Refer to Appropriate Diagnostic Information)
STANDARD PROCEDURE
STANDARD PROCEDURE - FUEL SYSTEM
PRESSURE RELEASE PROCEDURE
(1) Remove Fuel Pump relay from Power Distribu-
tion Center (PDC). For location of relay, refer to label
on underside of PDC cover.
(2) Start and run engine until it stalls.
(3) Attempt restarting engine until it will no
longer run.
(4) Turn ignition key to OFF position.
(5) Return fuel pump relay to PDC.
(6) One or more Diagnostic Trouble Codes (DTC's)
may have been stored in PCM memory due to fuel
pump relay removal. The DRB IIItscan tool must be
used to erase a DTC.
STANDARD PROCEDURE - DRAINING FUEL
TANK
(1) Release fuel system pressure, refer to the Fuel
System Release Procedure in this section.
(2) Insert a 1/4 inch siphon (max. O. D. 5/16) hose
from a portable fuel siphoning tank through the fuel
filler neck opening into the fuel tank. Hose most
have a 30 degree angle cut on the end to bypass the
check valve in the end of the filler neck. Refer to the
siphoning tank's Manufacturing Instructions.
(3) Drain fuel from fuel tank into siphoning tank.
14 - 2 FUEL DELIVERYRS
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