lock CHRYSLER CARAVAN 2002 Service Manual

(2) Attach exhaust pipe to exhaust manifold and
tighten fasteners to 37 N´m (27 ft. lbs.).
(3) Install and connect the oxygen sensor. (Refer to
14 - FUEL SYSTEM/FUEL INJECTION/O2 SENSOR
- COMPONENT LOCATION)
TIMING BELT COVER(S)
REMOVAL
FRONT COVER
(1) Remove crankshaft vibration damper. (Refer to
9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL)
(2) Remove generator drive belt tensioner assem-
bly. (Refer to 7 - COOLING/ACCESSORY DRIVE/
BELT TENSIONERS - REMOVAL)
(3) Remove timing belt front cover bolts (Fig. 112)
and remove covers.
REAR COVER
(1) Remove front covers.
(2) Remove engine mount bracket (Fig. 113).
(3) Remove timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL)
(4) Hold camshaft sprocket with Special Tool 6847
while removing center bolt (Fig. 114).
(5) Remove timing belt idler pulley.
(6) Remove rear cover fasteners and remove cover
from engine (Fig. 115).
INSTALLATION
REAR COVER
(1) Install timing belt rear cover and bolts (Fig.
115).CAUTION: Do not use an impact wrench for tighten-
ing camshaft sprocket bolt. Damage to the timing
locating pin can occur. Hand tighten using a
wrench ONLY.
(2) Install camshaft sprockets. Hold sprockets with
Special Tool 6848 and tighten center bolt to 101 N´m
(75 ft. lbs.).
(3) Install timing belt idler pulley and tighten
mounting bolt to 61 N´m (45 ft. lbs.).
(4) Install timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION)
(5) Install engine mount bracket and tighten bolts
to 61 N´m (45 ft. lbs.) (Fig. 113).
(6) Install front covers.
FRONT COVER
(1) Install timing belt front covers (Fig. 112).
Tighten fasteners to 7 N´m (60 in. lbs.).
(2) Install generator drive belt tensioner. (Refer to
7 - COOLING/ACCESSORY DRIVE/BELT TEN-
SIONERS - INSTALLATION)
Fig. 111 Exhaust Manifold Tightening Sequence
Fig. 112 Timing Belt Front Covers
1 - BOLTS - UPPER FRONT COVER 7 N´m (60 in. lbs.)
2 - BOLTS - LOWER FRONT COVER 7 N´m (60 in. lbs.)
RSENGINE 2.4L9-63
EXHAUST MANIFOLD (Continued)
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(3) Install crankshaft vibration damper. (Refer to 9
- ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
INSTALLATION)
TIMING BELT AND
SPROCKET(S)
REMOVAL
REMOVAL - TIMING BELT
(1) Remove air cleaner upper cover, housing, and
clean air tube.
(2) Remove make-up air hose from cylinder head
cover.
(3) Raise vehicle on hoist.
(4) Remove right front wheel.
(5) Remove right inner splash shield.
(6) Remove accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/BELT TENSION-
ERS - REMOVAL)
Fig. 113 ENGINE FRONT MOUNT BRACKET
1 - ENGINE MOUNT BRACKET
2 - BOLTS - 61 N´m (45 ft. lbs.)
Fig. 114 Camshaft Sprocket - Removal/Installation
1 - SPECIAL TOOL 6847
Fig. 115 Timing Belt Rear Cover
1 - BOLTS - REAR COVER 12 N´m (105 in. lbs.)
2 - BOLTS - REAR COVER 28 N´m (250 in. lbs.)
3 - TIMING BELT TENSIONER
9 - 64 ENGINE 2.4LRS
TIMING BELT COVER(S) (Continued)
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(7) Remove crankshaft vibration damper. (Refer to
9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL)
(8) Remove air conditioner/generator belt tensioner
and pulley assembly. (Refer to 7 - COOLING/ACCES-
SORY DRIVE/BELT TENSIONERS - REMOVAL)
(9) Remove timing belt lower front cover bolts and
remove cover. (Refer to 9 - ENGINE/VALVE TIMING/
TIMING BELT / CHAIN COVER(S) - REMOVAL)
(10) Lower vehicle.
(11) Remove bolts attaching timing belt upper
front cover and remove cover. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT / CHAIN COVER(S)
- REMOVAL)
(12) Remove right engine mount. (Refer to 9 -
ENGINE/ENGINE MOUNTING/RIGHT MOUNT -
REMOVAL)
(13) Remove engine mount bracket (Fig. 116).CAUTION: When aligning crankshaft and camshaft
timing marks always rotate engine from crankshaft.
Camshaft should not be rotated after timing belt is
removed. Damage to valve components may occur.
Always align timing marks before removing timing
belt.
(14) Before the removal of the timing belt, rotate
crankshaft until the TDC mark on oil pump housing
aligns with the TDC mark on crankshaft sprocket
(trailing edge of sprocket tooth) (Fig. 117).
NOTE: The crankshaft sprocket TDC mark is
located on the trailing edge of the sprocket tooth.
Failure to align trailing edge of sprocket tooth to
TDC mark on oil pump housing will cause the cam-
shaft timing marks to be misaligned.
(15) Install 6 mm Allen wrench into belt tensioner.
Before rotating the tensioner, insert the long end of a
1/8º or 3 mm Allen wrench into the pin hole on the
front of the tensioner (Fig. 118). While rotating the
tensioner counterclockwise, push in lightly on the
1/8º or 3 mm Allen wrench, until it slides into the
locking hole.
(16) Remove timing belt.
Fig. 116 Engine Mount Bracket
1 - ENGINE MOUNT BRACKET
2 - BOLTS - 61 N´m (45 ft. lbs.)
Fig. 117 Crankshaft and Camshaft Timing
1 - CAMSHAFT TIMING MARKS
2 - CRANKSHAFT TDC MARKS
3 - TRAILING EDGE OF SPROCKET TOOTH
RSENGINE 2.4L9-65
TIMING BELT AND SPROCKET(S) (Continued)
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REMOVAL - CRANKSHAFT SPROCKET
(1) Disconnect negative battery cable.
(2) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL).
(3) Remove crankshaft sprocket using Special
Tools 6793 and insert C-4685-C2 (Fig. 119).
CLEANING
Do Not attempt to clean a timing belt. If contami-
nation from oil, grease, or coolants have occurred, the
timing belt should be replaced.
Clean all sprockets using a suitable solvent. Clean
all sprocket grooves of any debris.
INSTALLATION
INSTALLATION - CRANKSHAFT SPROCKET
CAUTION: The crankshaft sprocket is set to a pre-
determined depth from the factory for correct tim-
ing belt tracking. If removed, use of Special Tool
6792 is required to set the sprocket to original
installation depth. An incorrectly installed sprocket
will result in timing belt and engine damage.
(1) Install crankshaft sprocket using Special Tool
6792 (Fig. 120).
(2) Install timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION)
Fig. 118 Locking Timing Tensioner
1 - 1/8 OR 3mm ALLEN WRENCH
2 - BELT TENSIONER
3 - 6mm ALLEN WRENCH
Fig. 119 Crankshaft Sprocket - Removal
1 - SPECIAL TOOL 6793
2 - SPECIAL TOOL C-4685±C2
3 - CRANKSHAFT SPROCKET
Fig. 120 Crankshaft Sprocket - Installation
1 - SPECIAL TOOL 6792
2 - TIGHTEN NUT TO INSTALL
9 - 66 ENGINE 2.4LRS
TIMING BELT AND SPROCKET(S) (Continued)
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INSTALLATION - TIMING BELT
CAUTION: The crankshaft sprocket is set to a pre-
determined depth from the factory for correct tim-
ing belt tracking. If removed, use of Special Tool
6792 is required to set the sprocket to original
installation depth. An incorrectly installed sprocket
will result in timing belt and engine damage.
(1) Set crankshaft sprocket to TDC by aligning the
sprocket with the arrow on the oil pump housing.
(2) Set camshafts timing marks so that the
exhaust camshaft sprocket is a 1/2 notch below the
intake camshaft sprocket (Fig. 121).
CAUTION: Ensure that the arrows on both camshaft
sprockets are facing up.
(3) Install timing belt. Starting at the crankshaft,
go around the water pump sprocket, idler pulley,
camshaft sprockets and then around the tensioner
(Fig. 122).
(4) Move the exhaust camshaft sprocket counter-
clockwise (Fig. 122) to align marks and take up belt
slack.NOTE: A new tensioner is held in the wound posi-
tion by a pull pin.
Fig. 121 Camshaft Sprocket Alignment
1 - CAMSHAFT SPROCKET-EXHAUST
2 - CAMSHAFT SPROCKET-INTAKE
3 - 1/2 NOTCH LOCATIONFig. 122 Timing Belt - Installation
1 - ROTATE CAMSHAFT SPROCKET TO TAKE UP BELT SLACK
2 - CAMSHAFT TIMING MARKS 1/2 NOTCH LOCATION
3 - CRANKSHAFT AT TDC
4 - INSTALL BELT IN THIS DIRECTION
RSENGINE 2.4L9-67
TIMING BELT AND SPROCKET(S) (Continued)
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(5) Remove the pull pin or Allen wrench from the
belt tensioner.
(6) Once the timing belt has been installed and
tensioner released, rotate the crankshaft two (2) com-
plete revolutions. Verify that the TDC marks on
crankshaft and timing marks on the camshafts are
aligned as shown in (Fig. 123).
(7) Install engine mount bracket to engine (Fig.
116).
(8) Install timing belt front covers and bolts.
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT / CHAIN COVER(S) - INSTALLATION)
(9) Install air conditioning/generator belt tensioner
and pulley. (Refer to 7 - COOLING/ACCESSORY
DRIVE/BELT TENSIONERS - INSTALLATION)
(10) Install right engine mount. (Refer to 9 -
ENGINE/ENGINE MOUNTING/RIGHT MOUNT -
INSTALLATION)(11) Install crankshaft vibration damper. (Refer to
9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - INSTALLATION)
(12) Install accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION)
(13) Install drive belt splash shield.
(14) Install right front wheel.
(15) Connect make-up air hose to cylinder head
cover.
(16) Install air cleaner housing, upper cover, and
clean air tube.
TIMING BELT TENSIONER &
PULLEY
REMOVAL
(1) Remove the timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
REMOVAL).
(2) Remove timing belt idler pulley.
(3) Hold camshaft sprocket with Special Tool 6847
while removing bolt (Fig. 124). Remove both cam
sprockets.
Fig. 123 Crankshaft and Camshaft Timing
1 - CAMSHAFT TIMING MARKS
2 - CRANKSHAFT TDC MARKS
3 - TRAILING EDGE OF SPROCKET TOOTH
Fig. 124 Camshaft Sprocket - Removal/Installation
1 - SPECIAL TOOL 6847
9 - 68 ENGINE 2.4LRS
TIMING BELT AND SPROCKET(S) (Continued)
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(4) Remove rear timing belt cover fasteners and
remove cover from engine (Fig. 125).
(5) Remove lower bolt attaching timing belt ten-
sioner assembly to engine and remove tensioneras
an assembly(Fig. 126).
INSTALLATION
(1) Align timing belt tensioner assembly to engine
and install lower mounting boltbut do not tighten
(Fig. 126). To properly align tensioner assemblyÐin-
stall one of the engine bracket mounting bolts (M10)
5 to 7 turns into the tensioner's upper mounting loca-
tion (Fig. 126).
(2) Torque the tensioner's lower mounting bolt to
61 N´m (45 ft. lbs.). Remove the upper bolt used for
tensioner alignment.(3) Install rear timing belt cover and fasteners
(Fig. 125).
(4) Install timing belt idler pulley and torque
mounting bolt to 61 N´m (45 ft. lbs.).
(5) Install camshaft sprockets. Use Special Tool
6847 to hold sprockets (Fig. 124), torque bolts to 101
N´m (75 ft. lbs.).
(6) Install the timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
INSTALLATION).BALANCE SHAFTS AND
CARRIER ASSEMBLY
DESCRIPTION
The 2.4L engine is equipped with two nodular cast
iron balance shafts installed in a cast aluminum car-
rier attached to the lower cylinder block (Fig. 127).
Fig. 125 Rear Timing Belt Cover Fasteners
1 - BOLTS - REAR COVER 12 N´m (105 in. lbs.)
2 - BOLTS - REAR COVER 28 N´m (250 in. lbs.)
3 - TIMING BELT TENSIONER
Fig. 126 Timing Belt Tensioner AssemblyÐRemoval/
Installation
1 - TIMING BELT TENSIONER ASSEMBLY
2 - TENSIONER ASSEMBLY UPPER BOLT
3 - TENSIONER ASSEMBLY LOWER BOLT
RSENGINE 2.4L9-69
TIMING BELT TENSIONER & PULLEY (Continued)
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(9) With balance shaft keyways pointing up (12
o'clock) slide the balance shaft sprocket onto the nose
of the balance shaft. The balance shaft may have to
be pushed in slightly to allow for clearance.
NOTE: THE TIMING MARK ON THE SPROCKET, THE
(LOWER) NICKEL PLATED LINK, AND THE ARROW
ON THE SIDE OF THE GEAR COVER SHOULD LINE
UP WHEN THE BALANCE SHAFTS ARE TIMED
CORRECTLY.
(10) If the sprockets are timed correctly, install the
balance shaft bolts and tighten to 28 N´m (250 in.
lbs.). A wood block placed between crankcase and
crankshaft counterbalance will prevent crankshaft
and gear rotation.(11)CHAIN TENSIONING:
(a) Install chain tensioner loosely assembled.
(b) Position guide on double ended stud making
sure tab on the guide fits into slot on the gear
cover. Install and tighten nut/washer assembly to
12 N´m (105 in. lbs.).
(c) Place a shim 1 mm (0.039 in.) thick x 70 mm
(2.75 in.) long or between tensioner and chain.
Push tensioner and shim up against the chain.
Apply firm pressure 2.5±3 Kg (5.5±6.6 lbs.)
directly behind the adjustment slot to take up
all slack.Chain must have shoe radius contact as
shown in (Fig. 136).
(d) With the load applied, tighten top tensioner
bolt first, then bottom pivot bolt. Tighten bolts to
12 N´m (105 in. lbs.). Remove shim.
(e) Install carrier covers and tighten screws to
12 N´m (105 in. lbs.).
(12) If removed, install oil pump (Refer to 9 -
ENGINE/LUBRICATION/OIL PUMP - INSTALLA-
TION).
(13) Install pick-up tube and oil pan (Refer to 9 -
ENGINE/LUBRICATION/OIL PAN - INSTALLA-
TION).
(14) Fill engine crankcase with proper oil to cor-
rect level.
Fig. 135 Balance Shaft Timing
1 - MARK ON SPROCKET
2 - KEYWAYS UP
3 - ALIGN MARKS
4 - PLATED LINK
5 - PARTING LINE (BEDPLATE TO BLOCK)
6 - PLATED LINK
Fig. 136 Chain Tension Adjustment
1 - 1MM (0.039 IN.) SHIM
2 - TENSIONER (ADJUSTER) BOLT
3 - PIVOT BOLT
RSENGINE 2.4L9-73
BALANCE SHAFTS AND CARRIER ASSEMBLY (Continued)
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ENGINE 3.3/3.8L
TABLE OF CONTENTS
page page
ENGINE 3.3/3.8L
DESCRIPTION.........................76
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION...........77
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - PERFORMANCE...........78
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - MECHANICAL.............80
DIAGNOSIS AND TESTING - ENGINE OIL
LEAK INSPECTION....................82
DIAGNOSIS AND TESTING - CYLINDER
COMPRESSION PRESSURE TEST........83
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE
TEST...............................83
STANDARD PROCEDURE
STANDARD PROCEDURE - MEASURING
BEARING CLEARANCE USING
PLASTIGAGE........................84
STANDARD PROCEDURE - FORM-IN-
PLACE GASKETS AND SEALERS.........84
STANDARD PROCEDURE - ENGINE
GASKET SURFACE PREPARATION........85
STANDARD PROCEDURE - HYDROSTATIC
LOCKED ENGINE.....................86
STANDARD PROCEDURE - REPAIR OF
DAMAGED OR WORN THREADS.........86
STANDARD PROCEDURE - ENGINE CORE
AND OIL GALLERY PLUGS..............86
REMOVAL - ENGINE ASSEMBLY...........87
INSTALLATION - ENGINE ASSEMBLY........90
SPECIFICATIONS
3.3/3.8L ENGINE......................92
SPECIFICATIONS - TORQUE............95
SPECIAL TOOLS
3.3/3.8L ENGINE......................96
AIR CLEANER ELEMENT
REMOVAL.............................99
INSTALLATION.........................99
AIR CLEANER HOUSING
REMOVAL.............................99
INSTALLATION........................100
CYLINDER HEAD
DESCRIPTION........................100
OPERATION..........................100
DIAGNOSIS AND TESTINGÐCYLINDER HEAD
GASKET...........................100
REMOVAL - CYLINDER HEAD............100
CLEANING...........................101INSPECTION.........................101
INSTALLATION - CYLINDER HEAD.........102
CYLINDER HEAD COVER(S)
DESCRIPTION........................103
CYLINDER HEAD COVER - RIGHT
REMOVAL............................103
INSTALLATION........................103
CYLINDER HEAD COVER - LEFT
REMOVAL............................105
INSTALLATION........................105
INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION........................105
OPERATION..........................105
STANDARD PROCEDURE - REFACING
VALVESANDVALVESEATS ............105
REMOVAL............................106
CLEANING...........................106
INSPECTION.........................106
INSTALLATION........................107
VALVE SPRINGS
DESCRIPTION........................107
OPERATION..........................107
REMOVAL
REMOVAL - CYLINDER HEAD OFF.......108
REMOVAL - CYLINDER HEAD ON........108
INSPECTION.........................109
INSTALLATION
INSTALLATION - CYLINDER HEAD OFF . . . 109
INSTALLATION - CYLINDER HEAD ON....109
ROCKER ARMS
DESCRIPTION
DESCRIPTION - ROCKER ARMS.........110
DESCRIPTION - PUSHRODS............110
OPERATION
OPERATION - ROCKER ARMS..........110
OPERATION - PUSHRODS.............110
REMOVAL - ROCKER ARMS AND SHAFT....110
DISASSEMBLY - ROCKER ARMS AND
SHAFT.............................110
ASSEMBLY - ROCKER ARMS AND SHAFT . . . 111
INSTALLATION - ROCKER ARMS AND
SHAFT.............................111
VALVE STEM SEALS
DESCRIPTION........................112
REMOVAL............................113
INSTALLATION........................113
ENGINE BLOCK
DESCRIPTION........................113
STANDARD PROCEDURE - CYLINDER BORE
HONING............................113
9 - 74 ENGINE 3.3/3.8LRS
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CLEANING...........................113
INSPECTION..........................113
CAMSHAFT & BEARINGS (IN BLOCK)
DESCRIPTION........................114
OPERATION..........................114
REMOVAL............................114
INSPECTION..........................115
INSTALLATION........................115
CONNECTING ROD BEARINGS
STANDARD PROCEDURE - MEASURING
CONNECTING ROD BEARING
CLEARANCE........................115
CRANKSHAFT
DESCRIPTION
DESCRIPTION - 3.3L..................116
DESCRIPTION - 3.8L..................117
OPERATION..........................117
STANDARD PROCEDURE - MEASURING
CRANKSHAFT END PLAY..............117
REMOVAL............................117
INSPECTION..........................118
INSTALLATION........................118
CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDURE - MAIN BEARING
FITTING............................119
REMOVAL - CRANKSHAFT MAIN
BEARINGS..........................121
INSTALLATION - CRANKSHAFT MAIN
BEARINGS..........................121
CRANKSHAFT OIL SEAL - FRONT
REMOVAL............................122
INSTALLATION........................123
CRANKSHAFT OIL SEAL - REAR
REMOVAL............................123
INSTALLATION........................123
CRANKSHAFT REAR OIL SEAL RETAINER
REMOVAL............................124
INSTALLATION........................124
FLEX PLATE
REMOVAL............................124
INSTALLATION........................124
HYDRAULIC LIFTERS (CAM IN BLOCK)
DESCRIPTION........................125
DIAGNOSIS AND TESTING - HYDRAULIC
LIFTERS...........................125
REMOVAL............................126
INSTALLATION........................126
PISTON & CONNECTING ROD
DESCRIPTION........................126
OPERATION..........................126
STANDARD PROCEDURE
STANDARD PROCEDURE - FITTING
CONNECTING RODS..................127
STANDARD PROCEDURE - FITTING
PISTONS...........................127
REMOVAL............................127
INSTALLATION........................128PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING............................130
REMOVAL............................131
INSTALLATION........................131
VIBRATION DAMPER
REMOVAL............................132
INSTALLATION........................132
ENGINE MOUNTING
DESCRIPTION........................133
FRONT MOUNT
REMOVAL............................133
INSTALLATION........................133
LEFT MOUNT
REMOVAL............................134
INSTALLATION........................134
REAR MOUNT
REMOVAL............................135
INSTALLATION........................136
RIGHT MOUNT
REMOVAL............................137
INSTALLATION........................137
LUBRICATION
DESCRIPTION........................137
OPERATION..........................137
DIAGNOSIS AND TESTING - ENGINE OIL
PRESSURE.........................137
OIL
STANDARD PROCEDURE
STANDARD PROCEDURE - ENGINE OIL
AND FILTER CHANGE.................138
STANDARD PROCEDURE - ENGINE OIL
LEVEL CHECK.......................139
OIL COOLER & LINES
DESCRIPTION........................140
OPERATION..........................140
REMOVAL............................140
INSTALLATION........................140
OIL FILTER
REMOVAL............................140
INSTALLATION........................140
OIL FILTER ADAPTER
REMOVAL............................141
INSTALLATION........................141
OIL PAN
REMOVAL............................141
CLEANING...........................141
INSPECTION.........................142
INSTALLATION........................142
OIL PRESSURE RELIEF VALVE
REMOVAL............................142
INSTALLATION........................143
OIL PRESSURE SWITCH
DESCRIPTION........................143
OPERATION..........................143
REMOVAL............................143
INSTALLATION........................143
RSENGINE 3.3/3.8L9-75
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