service CHRYSLER CARAVAN 2003 Service Manual
[x] Cancel search | Manufacturer: CHRYSLER, Model Year: 2003, Model line: CARAVAN, Model: CHRYSLER CARAVAN 2003Pages: 2177, PDF Size: 59.81 MB
Page 1192 of 2177
REMOVAL - ENGINE ASSEMBLY
(1) Perform fuel pressure release procedure (Refer
to 14 - FUEL SYSTEM/FUEL DELIVERY - STAN-
DARD PROCEDURE)
(2) Disconnect battery negative cable.
(3) Remove air cleaner housing and inlet tube.
(4) Disconnect the fuel line from fuel rail. (Refer to
14 - FUEL SYSTEM/FUEL DELIVERY/FUEL LINES
- STANDARD PROCEDURE)
(5) Disconnect all vacuum hoses.
(6) Drain cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(7) Remove radiator fans. (Refer to 7 - COOLING/
ENGINE/RADIATOR FAN - REMOVAL)
(8) Remove radiator upper and lower hoses.
NOTE: When the transaxle cooler lines are removed
from the rolled-groove type fittings at the transaxle,
damage to the inner wall of the hose will occur. To
prevent prevent potential leakage, the cooler hoses
must be cut off flush at the transaxle fitting, and a
service cooler hose splice kit must be installed
upon reassembly.(9) Using a blade or suitable hose cutter, cut trans-
axle oil cooler lines off flush with fittings. Plug cooler
lines and fittings to prevent debris from entering
transaxle or cooler circuit. A service splice kit will be
installed upon reassembly.
(10) Disconnect transmission shift linkage and
electrical connectors.
(11) Disconnect throttle body linkage.
(12) Disconnect engine wiring harness.
(13) Disconnect heater hoses from heater (Fig. 5).
(14) Discharge air conditioning system. (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING
- STANDARD PROCEDURE)
(15) Hoist vehicle and remove front wheels and
tires.
(16) Remove accessory drive belt splash shield.
(17) Remove accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)
Fig. 5 HEATER HOSES - 2.4L
1 - HEATER HOSES TO HEATER 3 - HEATER HOSE TO ENGINE - SUPPLY AND RETURN
2 - BOLT - HEATER TUBE SUPPORT
RSENGINE 2.4L9-13
ENGINE 2.4L (Continued)
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Page 1195 of 2177
INSTALLATION - ENGINE ASSEMBLY
(1) Position engine and transmission assembly
under vehicle and slowly lower the vehicle over the
engine and transmission.
(2) Align engine and transmission mounts to
attaching points. Install mounting bolts at the right
(Fig. 9) and left mounts (Fig. 10).
(3) Remove safety straps.
(4) Slowly raise vehicle enough to remove the
engine dolly and cradle Special Tools 6135 and 6710.
(5) Install rear mount bracket and rear mount
through bolt. (Refer to 9 - ENGINE/ENGINE
MOUNTING/REAR MOUNT - INSTALLATION)
(6) Install the flex plate to torque converter bolts.
(7) Install structural collar. (Refer to 9 - ENGINE/
ENGINE BLOCK/STRUCTURAL COVER - INSTAL-
LATION)
(8) Install front mount bracket and front mount
through bolt. (Refer to 9 - ENGINE/ENGINE
MOUNTING/FRONT MOUNT - INSTALLATION)
(9) Connect exhaust system to manifold (Fig. 7).
(10) Install crossmember cradle plate (Fig. 6).
(11) Install new oil filter.
(12) Install power steering pump and bracket.
(13) Connect power steering supply line to pump
and remove pinch-off pliers.(14) Connect A/C compressor hoses to compressor.
(15) Install accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION)
(16) Install axle shafts. (Refer to 3 - DIFFEREN-
TIAL & DRIVELINE/HALF SHAFT - INSTALLA-
TION)
(17) Install accessory drive belt splash shield.
(18) Install front wheels and tires.
(19) Remove plugs from transmission cooler hoses
and install transaxle oil cooler line service splice kit.
Refer to instructions included with kit.
(20) Connect the transaxle shift linkage and elec-
trical connectors.
(21) Connect heater hoses (Fig. 5).
(22) Install ground straps.
(23) Connect all engine and throttle body electrical
connections.
(24) Connect all vacuum lines.
(25) Connect the throttle cables.
(26) Connect the fuel line. (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY/QUICK CONNECT FIT-
TING - STANDARD PROCEDURE)
(27) Connect radiator lower and upper hoses.
(28) Install radiator fans. (Refer to 7 - COOLING/
ENGINE/RADIATOR FAN - INSTALLATION)
(29) Fill cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(30) Connect battery cables.
(31) Install air cleaner and inlet hose.
(32) Fill engine crankcase with proper oil to cor-
rect level.
Fig. 9 RIGHT MOUNT TO RAIL AND ENGINE
1 - BOLT - MOUNT TO RAIL 68 N´m (50 ft. lbs.)
2 - BOLT - MOUNT TO ENGINE 54 N´m (40 ft. lbs.)
3 - BOLT - MOUNT TO RAIL (HORIZONTAL) 68 N´m (50 ft. lbs.)
4 - RIGHT ENGINE MOUNT
5 - RIGHT FRAME RAIL
Fig. 10 LEFT MOUNT TO FRAME BRACKET
1 - FRAME BRACKET
2 - FRAME RAIL - LEFT
3 - BOLT
4 - TRANSAXLE MOUNT
9 - 16 ENGINE 2.4LRS
ENGINE 2.4L (Continued)
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Page 1197 of 2177
DESCRIPTION SPECIFICATION
Bore DiameterÐPiston
Pin20.96±20.98 mm
(0.8252±0.8260 in.)
Bore DiameterÐ
Crankshaft End53.007±52.993 mm
(2.0868±2.0863 in.)
Side Clearance 0.13±0.38 mm
(0.005±0.015 in.)
Wear Limit 0.40 mm
(0.016 in.)
WeightÐTotal (Less
Bearing)565.8 grams
(19.96 oz.)
Crankshaft
Connecting Rod Journal
Diameter49.984±50.000 mm
(1.968±1.9685 in.)
Main Bearing Journal
Diameter59.992±60.008 mm
(2.362±2.3625 in.)
Journal Out-of-Round
(Max.)0.0035 mm
(0.0003 in.)
Journal Taper (Max.) 0.007 mm
(0.0001 in.)
End Play 0.09±0.24 mm
(0.0035±0.0094 in.)
Wear Limit 0.38 mm
(0.015 in.)
Main Bearing Diametrical
Clearance0.018±0.062 mm
(0.0007±0.0024 in.)
Hydraulic Lash Adjuster
Body Diameter 15.901±15.913 mm
(0.626±0.6264 in.)
Plunger Travel Minimum
(Dry)3.0 mm
(0.118 in.)
Cylinder Head Camshaft Bearing Bore Diameter
Journals No.1±6 26.020±26.041 mm
(1.024±1.025 in.)
Camshaft
Journal Diameter No. 1±6 25.951±25.970 mm
(1.021±1.022 in.)
Bearing ClearanceÐ
Diametrical0.069±0.071 mm
(0.0027±0.003 in.)
End Play 0.05±0.17 mm
(0.0019±0.0066 in.)
Lift (Zero Lash)
Intake 8.25 mm
(0.324 in.)DESCRIPTION SPECIFICATION
Exhaust 6.60 mm
(0.259 in.)
Intake Valve Timing*
Closes (ABDC) 51É
Opens (BTDC) 1É
Duration 232É
Exhaust Valve Timing*
Closes (ATDC) 7É
Opens (BBDC) 47É
Duration 234É
Valve Overlap 8É
*All readings in crankshaft degrees. Timing points @
4É from top of Ramps.
Cylinder Head
Material Cast Aluminum
Gasket Thickness
(Compressed)0.71 mm
(0.028 in.)
Valve Seat
Angle 44.5±45É
Seat DiameterÐIntake 34.37±34.63 mm
(1.353±1.363 in.)
Seat DiameterÐExhaust 27.06±27.32 mm
(1.065±1.075 in.)
Runout (Max.) 0.05 mm
(0.002 in.)
Valve Seat WidthÐIntake
and Exhaust0.9±1.3 mm
(0.035±0.051 in.)
Service LimitÐIntake 2.0 mm
(0.079 in.)
Service LimitÐExhaust 2.5 mm
(0.098 in.)
Valve Guide
Diameter I.D. 5.975±6.000 mm
(0.235±0.236 in.)
Guide Bore Diameter 11.0±11.02 mm
(0.4330±0.4338 in.)
Guide Height (spring seat
to guide tip)13.25±13.75 mm
(0.521±0.541 in.)
Valves
Face AngleÐIntake and
Exhaust44.5Ð45É
Head DiameterÐIntake 34.67±34.93 mm
1.364±1.375 in.)
9 - 18 ENGINE 2.4LRS
ENGINE 2.4L (Continued)
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Page 1198 of 2177
DESCRIPTION SPECIFICATION
Head DiameterÐExhaust 28.32±28.52 mm
(1.114±1.122 in.)
Valve Length (Overall)
ÐIntake 112.76±113.32 mm
(4.439±4.461 in.)
ÐExhaust 110.89±111.69 mm
(4.365±4.397 in.)
Valve Stem Diameter
ÐIntake 5.934±5.952 mm
(0.2337±0.2344 in.)
ÐExhaust 5.906±5.924 mm
(0.2326±0.2333 in.)
Valve Margin
Intake 1.2±1.7 mm
(0.047±0.066 in.)
Service Limit 0.95 mm
(1/32 in.)
Exhaust 0.985±1.315 mm
(0.038±0.051 in.)
Service Limit 1.05 mm
(3/64 in.)
Valve Stem Tip Height
Intake 48.04 mm
(1.891 in.)
Exhaust 47.99 mm
(1.889 in.)
Valve Stem to Guide Clearance
Intake 0.048±0.066 mm
(0.0018±0.0025 in.)
Max. Allowable 0.076 mm
(0.003 in.)
Service Limit 0.25 mm
(0.010 in.)
Exhaust 0.0736±0.094 mm
(0.0029±0.0037 in.)
Max. Allowable 0.101 mm
(0.004 in.)
Service Limit 0.25 mm
(0.010 in.)DESCRIPTION SPECIFICATION
Valve Springs
Free Length (Approx.) 48.4 mm
(1.905 in.)
Nominal Force (Valve
Closed)338 N @ 38.0 mm
(75.98 lbs. @ 1.496 in.)
Nominal Force (Valve
Open)607 N @ 29.75 mm
(136 lbs. @ 1.172 in.)
Installed Height 38.00 mm
(1.496 in.)
Number of Coils 7.82
Wire Diameter 3.86 mm
(1.496 in.)
Oil Pump
Clearance Over Rotors
(Max.)0.10 mm
(0.004 in.)
Cover Out-of-Flat (Max.) 0.025 mm
(0.001 in.)
Inner Rotor Thickness
(Min.)9.40 mm
(0.370 in.)
Outer Rotor Thickness
(Min.)9.40 mm
(0.370 in.)
Outer Rotor Clearance
(Max.)0.039 mm
(0.015 in.)
Outer Rotor Diameter
(Min.)79.95 mm
(3.148 in.)
Tip Clearance Between
Rotors (Max.)0.20 mm
(0.008 in.)
Oil Pressure
At Curb Idle Speed* 25 kPa
(4 psi)
At 3000 rpm 170±550 kPa
(25±80 psi)
CAUTION:
*If pressure is ZERO at curb idle, DO NOT run engine
at 3000 rpm.
RSENGINE 2.4L9-19
ENGINE 2.4L (Continued)
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Page 1213 of 2177
HYDRAULIC LASH
ADJUSTERS
DIAGNOSIS AND TESTING - HYDRAULIC LASH
ADJUSTER NOISE DIAGNOSIS
A tappet-like noise may be produced from several
items. Check the following items.
(1) Engine oil level too high or too low. This may
cause aerated oil to enter the adjusters and cause
them to be spongy.
(2) Insufficient running time after rebuilding cylin-
der head. Low speed running up to 1 hour may be
required.
(3) During this time, turn engine off and let set for
a few minutes before restarting. Repeat this several
times after engine has reached normal operating
temperature.
(4) Low oil pressure.
(5) The oil restrictor (integral to the head gasket)
in the vertical oil passage to the cylinder head is
plugged with debris.
(6) Air ingested into oil due to broken or cracked
oil pump pick up.
(7) Worn valve guides.
(8) Rocker arm ears contacting valve spring
retainer.
(9) Rocker arm loose, adjuster stuck or at maxi-
mum extension and still leaves lash in the system.
(10) Faulty lash adjuster.
²Check lash adjusters for sponginess while
installed in cylinder head. Depress part of rocker
arm over adjuster. Normal adjusters should feel very
firm. Spongy adjusters can be bottomed out easily.
²Remove suspected lash adjusters, and replace as
necessary.
REMOVAL
NOTE: This procedure is for in-vehicle service with
camshafts installed.
(1) Remove cylinder head cover. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL)
(2) Remove rocker arm. (Refer to 9 - ENGINE/
CYLINDER HEAD/ROCKER ARMS - REMOVAL)
(3) Remove hydraulic lash adjuster (Fig. 37).
(4) Repeat removal procedure for each hydraulic
lash adjuster.
(5) If reusing, mark each hydraulic lash adjuster
for reassembly in original position. Lash adjusters
are serviced as an assembly.
INSTALLATION
(1) Install hydraulic lash adjuster (Fig. 37).
Ensure the lash adjusters are at least partially full of
engine oil. This is indicated by little or no plunger
travel when the lifter is depressed.
(2) Install rocker arm. (Refer to 9 - ENGINE/CYL-
INDER HEAD/ROCKER ARMS - INSTALLATION)
(3) Repeat installation procedure for each hydrau-
lic lash adjuster.
(4) Install cylinder head cover. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION)
ROCKER ARMS
REMOVAL
NOTE: This procedure is for in-vehicle service with
camshafts installed.
(1) Remove cylinder head cover. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL)
(2) Remove spark plugs.
(3) Rotate engine until the camshaft lobe, on the
follower being removed, is positioned on its base cir-
cle (heel). Also, the piston should be a minimum of
6.3 mm (0.25 in) below TDC position.
CAUTION: If cam follower assemblies are to be
reused, always mark position for reassembly in
their original positions.
(4) Using Special Tools 8215A and 8436 slowly
depress valve assembly until rocker arm can be
removed (Fig. 38).
(5) Repeat removal procedure for each rocker arm.
Fig. 37 Hydraulic Lash Adjuster
9 - 34 ENGINE 2.4LRS
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Page 1214 of 2177
INSPECTION
Inspect the rocker arm for wear or damage (Fig.
39). Replace as necessary.
INSTALLATION
(1) Lubricate rocker arm with clean engine oil.
(2) Using Special Tools 8215A and 8436 slowly
depress valve assembly until rocker arm can be
installed on the hydraulic lifter and valve stem (Fig.
38).
(3) Repeat installation procedure for each rocker
arm.
(4) Install spark plugs.(5) Install cylinder head cover. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION)
ENGINE BLOCK
DESCRIPTION
The cast iron cylinder block is a two-piece assem-
bly, consisting of the cylinder block and bedplate (Fig.
40). The bedplate incorporates the main bearing caps
and bolts to the cylinder block. This design offers a
much stronger lower end and increased cylinder
block rigidity. The rear oil seal retainer is integral
with the block. The bedplate and block are serviced
as an assembly.
STANDARD PROCEDURE - CYLINDER BORE
HONING
(1)Used carefully, the cylinder bore resizing hone,
recommended tool C-823 or equivalent, equipped with
220 grit stones, is the best tool for this honing proce-
dure. In addition to deglazing, it will reduce taper and
out-of-round as well as removing light scuffing, scoring
or scratches. Usually a few strokes will clean up a bore
and maintain the required limits.
(2) Deglazing of the cylinder walls may be done
using a cylinder surfacing hone, recommended tool
C-3501 or equivalent, equipped with 280 grit stones,
if the cylinder bore is straight and round. 20±60
strokes depending on the bore condition, will be suf-
ficient to provide a satisfactory surface. Use a light
honing oil.Do not use engine or transmission oil,
mineral spirits or kerosene.Inspect cylinder walls
after each 20 strokes.
(3) Honing should be done by moving the hone up
and down fast enough to get a cross-hatch pattern.
When hone marksintersectat 40-60 degrees, the
cross hatch angle is most satisfactory for proper seat-
ing of rings (Fig. 41).
Fig. 38 Rocker Arm - Removal/Installation
1 - SPECIAL TOOL 8215A
2 - SPECIAL TOOL 8436
3 - 3/89DRIVE RACHET
Fig. 39 Rocker Arm
1 - TIP
2 - LASH ADJUSTER POCKET
3 - ROLLER
Fig. 40 Cylinder Block and Bedplate
1 - CYLINDER BLOCK
2 - BEDPLATE
RSENGINE 2.4L9-35
ROCKER ARMS (Continued)
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Page 1215 of 2177
(4) A controlled hone motor speed between
200±300 RPM is necessary to obtain the proper cross-
hatch angle. The number of up and down strokes per
minute can be regulated to get the desired 40±60
degree angle. Faster up and down strokes increase
the cross-hatch angle.
(5) After honing, it is necessary that the block be
cleaned again to remove all traces of abrasive.
CAUTION: Ensure all abrasives are removed from
engine parts after honing. It is recommended that a
solution of soap and hot water be used with a
brush and the parts then thoroughly dried. The bore
can be considered clean when it can be wiped
clean with a white cloth and cloth remains clean.
Oil the bores after cleaning to prevent rusting.
CLEANING
Clean cylinder block thoroughly using a suitable
cleaning solvent.
INSPECTION
ENGINE BLOCK
(1) Clean cylinder block thoroughly and check all
core hole plugs for evidence of leaking.
(2) If new core plugs are to be installed, (Refer to 9
- ENGINE - STANDARD PROCEDURE - ENGINE
CORE AND OIL GALLERY PLUGS).
(3) Examine block and cylinder bores for cracks or
fractures.(4) Check block deck surfaces for flatness. Deck
surface must be within service limit of 0.1 mm (0.004
in.).
CYLINDER BORE
NOTE: The cylinder bores should be measured at
normal room temperature, 21ÉC (70ÉF).
The cylinder walls should be checked for out-of-
round and taper with Tool C119 or equivalent (Fig.
42) (Refer to 9 - ENGINE - SPECIFICATIONS). If
the cylinder walls are badly scuffed or scored, the
cylinder block should be replaced, and new pistons
and rings fitted.
Measure the cylinder bore at three levels in direc-
tions A and B (Fig. 42). Top measurement should be
10 mm (3/8 in.) down and bottom measurement
should be 10 mm (3/8 in.) up from bottom of bore.
(Refer to 9 - ENGINE - SPECIFICATIONS).
CRANKSHAFT
STANDARD PROCEDURE - CRANKSHAFT END
PLAY
(1) Using Dial Indicator C-3339 and Mounting
Post L-4438, attach to front of engine, locating probe
perpendicular on nose of crankshaft (Fig. 43).
(2) Move crankshaft all the way to the rear of its
travel.
(3) Zero the dial indicator.
Fig. 41 Cylinder Bore Cross-Hatch Pattern
1 - CROSS-HATCH PATTERN
2 - 40ɱ60É
Fig. 42 Checking Cylinder Bore Size
9 - 36 ENGINE 2.4LRS
ENGINE BLOCK (Continued)
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Page 1217 of 2177
The crankshaft journals should be checked for
excessive wear, taper and scoring (Fig. 46). Limits of
taper or out of round on any crankshaft journals
should be held to 0.025 mm (0.001 in.). Journal
grinding should not exceed 0.305 mm (0.012 in.)
under the standard journal diameter. DO NOT grind
thrust faces of No. 3 main bearing. DO NOT nick
crank pin or bearing fillets. After grinding, remove
rough edges from crankshaft oil holes and clean out
all passages.
CAUTION: With the nodular cast iron crankshafts, it
is important that the final paper or cloth polish be
in the same direction as normal rotation in the
engine.
The crankshaft is supported in five main bearings.
All upper and lower bearing shells in the crankcase
have oil grooves. Crankshaft end play is controlled by
a flanged bearing on the number three main bearing
journal (Fig. 47).
Upper and lower Number 3 bearing halves are
flanged to carry the crankshaft thrust loads and are
NOTinterchangeable with any other bearing halves
in the engine (Fig. 47). All bearing cap bolts removedduring service procedures are to be cleaned and oiled
before installation. Bearing shells are available in
standard and the following undersized: 0.025 mm
(0.001 in.) and 0.250 mm (0.010 in.). Never install an
undersize bearing that will reduce clearance below
specifications. Replace or machine the crankshaft as
necessary to obtain proper bearing clearances.
INSTALLATION - CRANKSHAFT
CRANKSHAFT MAIN BEARING LOCATION
The crankshaft is supported in five main bearings.
All upper and lower bearing shells in the crankcase
have oil grooves and holes (Fig. 48). Crankshaft end
play is controlled by a flanged bearing on the number
three main bearing journal.
Fig. 45 Bedplate Bolt Tightenening Sequence
Fig. 46 Crankshaft Journal Measurements
Fig. 47 Main Bearing Identification
1 - OIL GROOVE
2 - MAIN BEARINGS
3 - OIL HOLE
Fig. 48 Main Bearing Identification
1 - OIL GROOVE
2 - MAIN BEARINGS
3 - OIL HOLE
9 - 38 ENGINE 2.4LRS
CRANKSHAFT (Continued)
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Page 1223 of 2177
(6) Pistons and connecting rods must be removed
from top of cylinder block. Rotate crankshaft so that
each connecting rod is centered in cylinder bore.
(7) Using a permanent ink or paint marker, iden-
tify cylinder number on each connecting rod cap (Fig.
63).
CAUTION: DO NOT use a number stamp or a punch
to mark connecting rods. Damage to connecting
rod could occur.
(8) Remove connecting rod bolts and cap. Care
should be taken not to damage the fracture rod and
cap surfaces.
NOTE: Do not reuse connecting rod bolts.
CAUTION: Care must be taken not to damage the
fractured rod and cap joint surfaces, as engine
damage many occur.
(9) To protect crankshaft journal and fractured rod
surfaces, install Special Tool 8189, connecting rod
guides onto connecting rod (Fig. 64). Carefully push
each piston and rod assembly out of cylinder bore.
(10) Remove Special Tool 8189, connecting rod
guides and re-install bearing cap on the mating rod.
NOTE: Piston and rods are serviced as an assem-
bly.
(11) Repeat procedure for each piston and connect-
ing rod assembly.
(12) Remove piston rings (Refer to 9 - ENGINE/
ENGINE BLOCK/PISTON RINGS - REMOVAL).
INSTALLATION
(1) Install piston rings on piston (Refer to 9 -
ENGINE/ENGINE BLOCK/PISTON RINGS -
INSTALLATION)
(2) Before installing pistons and connecting rod
assemblies into the bore, be sure that compression
ring gaps are staggered so that neither is in line with
oil ring rail gap (Fig. 65).(3) Before installing the ring compressor, make
sure the oil ring expander ends are butted and the
rail gaps located as shown in (Fig. 65). As viewed
from top.
(4) Immerse the piston head and rings in clean
engine oil, slide the ring compressor, over the piston
(Fig. 66).Be sure position of rings does not
change during this operation.
(5) The directional stamp on the piston should face
toward the front of the engine (Fig. 62).
(6) Rotate crankshaft so that the connecting rod
journal is on the center of the cylinder bore. Lubri-
cate connecting rod journal with clean engine oil.
Fig. 63 Identify Connecting Rod to Cylinder
Fig. 64 Connecting Rod GuidesÐTypical
1 - SPECIAL TOOL 8189 CONNECTING ROD GUIDES
Fig. 65 Piston Ring End Gap Position
1 - GAP OF LOWER SIDE RAIL
2 - NO. 1 RING GAP
3 - GAP OF UPPER SIDE RAIL
4 - NO. 2 RING GAP AND SPACER EXPANDER GAP
9 - 44 ENGINE 2.4LRS
PISTON & CONNECTING ROD (Continued)
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Page 1248 of 2177
INSTALLATION
(1) Align timing belt tensioner assembly to engine
and install lower mounting boltbut do not tighten
(Fig. 129). 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. 129).
(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.
Torque fasteners to values specified in (Fig. 128).
(4) Install timing belt idler pulley and torque
mounting bolt to 61 N´m (45 ft. lbs.) (Fig. 126).
(5) Install camshaft sprockets. Use Special Tool
6847 to hold sprockets (Fig. 127), 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. 130).
OPERATION
The balance shafts are driven by the crankshaft
via a roller chain and sprockets. The balance shafts
are connected by helical gears. The dual counter
rotating shafts decrease second order vertical shak-
ing forces caused by component movement.
REMOVAL
BALANCE SHAFTS/CHAIN/SPROCKETS
NOTE: For service procedures requiring only tem-
porary relocation of carrier assembly refer to BAL-
ANCE SHAFT CARRIER procedure below.
(1) Drain engine oil.
(2) Remove the oil pan and pick-up tube (Refer to
9 - ENGINE/LUBRICATION/OIL PAN - REMOVAL).
(3) If replacing crankshaft sprocket, remove oil
pump (Refer to 9 - ENGINE/LUBRICATION/OIL
PUMP - REMOVAL).
(4) Remove chain cover, guide and tensioner (Fig.
131).
(5) Remove screw retaining balance shaft drive
sprocket (Fig. 132). Remove chain and sprocket.
(6) Using two wide pry bars, work the crankshaft
sprocket back and forth until it is off the crankshaft-
shaft.
(7) Remove gear cover retaining stud (double
ended to also retain chain guide). Remove cover and
balance shaft gears (Fig. 133).
(8) Remove rear cover and balance shafts (Fig.
134).
(9) Remove four carrier to crankcase attaching
bolts to separate carrier from engine bedplate.
Fig. 129 Timing Belt Tensioner/Bracket Assembly
1 - BOLT
2 - TENSIONER ASSEMBLY
3 - BOLT-INSTALL FOR PROPER ALIGNMENT
RSENGINE 2.4L9-69
TIMING BELT TENSIONER & PULLEY (Continued)
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