timing belt CHRYSLER CARAVAN 2003 Owner's Manual

(4) Move crankshaft all the way to the front and
read the dial indicator. Refer to Engine Specifica-
tions.
REMOVAL - CRANKSHAFT
NOTE: Crankshaft can not be removed when engine
is in vehicle.
(1) Remove engine assembly from vehicle (Refer to
9 - ENGINE - REMOVAL).
(2) Separate transaxle from engine.
(3) Remove drive plate/flex plate.
(4) Remove crankshaft rear oil seal (Refer to 9 -
ENGINE/ENGINE BLOCK/CRANKSHAFT OIL
SEAL - REAR - REMOVAL).
(5) Mount engine on a suitable repair stand.
(6) Drain engine oil and remove oil filter.
(7) Remove crankshaft vibration damper (Refer to
9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL).
(8) Remove engine mount support bracket.
(9) Remove front timing belt covers (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT COVER(S)
- REMOVAL).
(10) Remove the timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
REMOVAL).
(11) Remove the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL).
(12) Remove oil pump pick-up tube.
(13) Remove the crankshaft sprocket and oil pump
(Refer to 9 - ENGINE/LUBRICATION/OIL PUMP -
REMOVAL).
(14) Remove balance shafts and housing assembly
(Refer to 9 - ENGINE/VALVE TIMING/BALANCE
SHAFT - REMOVAL).
(15) Remove crankshaft position sensor.NOTE: If piston/connecting rod replacement is nec-
essary, remove cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
(16) Using a permanent ink or paint marker, iden-
tify cylinder number on each connecting rod cap (Fig.
44).
CAUTION: DO NOT use a number stamp or a punch
to mark connecting rods. Damage to connecting
rod could occur.
(17) Remove all connecting rod bolts and caps.
Care should be taken not to damage the fracture rod
and cap surfaces.
NOTE: Do not reuse connecting rod bolts.
(18) Remove all bedplate bolts from the engine
block (Fig. 45).
(19) Using a mallet gently tap the bedplate loose
from the engine block dowel pins.
CAUTION: Do not pry up on one side of the bed-
plate. Damage may occur to cylinder block to bed-
plate alignment and thrust bearing.
(20) Bedplate should be removed evenly from the
cylinder block dowel pins to prevent damage to the
dowel pins and thrust bearing.
CAUTION: Use extreme care when handling crank-
shaft. Tone wheel damage can occur if crankshaft is
mis-handled.
(21) Lift out crankshaft from cylinder block. Do
not damage the main bearings or journals when
removing the crankshaft.
INSPECTION
For crankshaft specifications (Refer to 9 - ENGINE
- SPECIFICATIONS).
Fig. 43 CHECKING CRANKSHAFT END PLAY
Fig. 44 Identify Connecting Rod to Cylinder
RSENGINE 2.4L9-37
CRANKSHAFT (Continued)
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(13) After the main bearing bedplate is installed,
check the crankshaft turning torque. The turning
torque should not exceed 5.6 N´m (50 in. lbs.).
(14) Check crankshaft end play (Refer to 9 -
ENGINE/ENGINE BLOCK/CRANKSHAFT - STAN-
DARD PROCEDURE).
(15) Install connecting rod bearings and caps.Do
Not Reuse Connecting Rod Bolts.Torque connect-
ing rod bolts to 27 N´m (20 ft. lbs.) plus 1/4 turn.
(16) Install balance shafts and housing assembly
(Refer to 9 - ENGINE/VALVE TIMING/BALANCE
SHAFT - INSTALLATION).
(17) Install the oil pump (Refer to 9 - ENGINE/
LUBRICATION/OIL PUMP - INSTALLATION).
(18) Install oil pump pick-up tube. Torque fastener
to 28 N´m (20 ft.. lbs.).
(19) Install the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - INSTALLATION).
(20) Install crankshaft position sensor.
(21) Install cylinder head if it was removed (Refer
to 9 - ENGINE/CYLINDER HEAD - INSTALLA-
TION).
(22) Install the timing belt rear cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT COVER(S)
- INSTALLATION).
(23) Install crankshaft sprocket (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT AND
SPROCKETS - INSTALLATION).
(24) Install the timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
INSTALLATION).
(25) Install the timing belt front covers (Refer to 9
- ENGINE/VALVE TIMING/TIMING BELT COV-
ER(S) - INSTALLATION).
(26) Install engine mount support bracket.
(27) InstallNEWoil filter.
(28) Install crankshaft rear oil seal (Refer to 9 -
ENGINE/ENGINE BLOCK/CRANKSHAFT OIL
SEAL - REAR - INSTALLATION).
(29) Install flex plate. Apply MopartLock & Seal
Adhesive to bolt threads and tighten to 95 N´m (70
ft. lbs.).
(30) Attach transaxle to engine. Tighten attaching
bolts to 101 N´m (75 ft. lbs.).
(31) Install the engine assembly (Refer to 9 -
ENGINE - INSTALLATION).
CRANKSHAFT OIL SEAL -
FRONT
REMOVAL
(1) Remove the crankshaft vibration damper.
(Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL)(2) Remove timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL)
(3) Remove crankshaft sprocket using Special Tool
6793 and insert C-4685-C2 (Fig. 52).
CAUTION: Do not nick shaft seal surface or seal
bore.
(4) Using Tool 6771 to remove front crankshaft oil
seal (Fig. 53). Be careful not to damage the seal sur-
face of cover.
INSTALLATION
(1) Install new seal by using Special Tool 6780
(Fig. 54).
(2) Place seal into opening with seal spring
towards the inside of engine. Install seal until flush
with cover.
Fig. 52 Crankshaft Sprocket - Removal
1 - SPECIAL TOOL 6793
2 - SPECIAL TOOL C-4685±C2
3 - CRANKSHAFT SPROCKET
Fig. 53 Front Crankshaft Oil Seal - Removal
1 - SPECIAL TOOL 6771
2 - REAR TIMING BELT COVER
9 - 40 ENGINE 2.4LRS
CRANKSHAFT (Continued)
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(3) Install crankshaft sprocket using Special Tool
6792 (Fig. 55).(4) Install timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION)
(5) Install crankshaft vibration damper. (Refer to 9
- ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
INSTALLATION)
CRANKSHAFT OIL SEAL -
REAR
REMOVAL
(1) Remove transaxle. Refer to TRANSMISSION/
TRANSAXLE - REMOVAL for procedure.
(2) Remove flex plate.
(3) Insert a 3/16 flat bladed screwdriver between
the dust lip and the metal case of the crankshaft
seal. Angle the screwdriver (Fig. 56)through the dust
lip against metal case of the seal. Pry out seal.
CAUTION: Do not permit the screwdriver blade to
contact crankshaft seal surface. Contact of the
screwdriver blade against crankshaft edge (cham-
fer) is permitted.
Fig. 54 Crankshaft Front Oil Seal - Installation
1 - PROTECTOR
2 - SEAL
3 - SPECIAL TOOL 6780
Fig. 55 Crankshaft Sprocket - Installation
1 - SPECIAL TOOL 6792
2 - TIGHTEN NUT TO INSTALL
Fig. 56 Rear Crankshaft Oil Seal - Removal
1 - REAR CRANKSHAFT SEAL
2 - ENGINE BLOCK
3 - ENGINE BLOCK
4 - REAR CRANKSHAFT SEAL METAL CASE
5 - PRY IN THIS DIRECTION
6 - CRANKSHAFT
7 - SCREWDRIVER
8 - REAR CRANKSHAFT SEAL DUST LIP
9 - SCREWDRIVER
RSENGINE 2.4L9-41
CRANKSHAFT OIL SEAL - FRONT (Continued)
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OIL PUMP
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
REMOVAL).
(3) Remove timing belt rear cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT COVER(S)
- REMOVAL).
(4) Remove oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - REMOVAL).
(5) Remove crankshaft sprocket using Special
Tools 6793 and C-4685-C2 (Fig. 90).
(6) Remove crankshaft key (Fig. 91).
(7) Remove oil pick-up tube.(8) Remove oil pump (Fig. 92) and front crankshaft
seal.
DISASSEMBLY
(1) To remove the relief valve, proceed as follows:
(a) Remove the threaded plug and gasket from
the oil pump (Fig. 93) .
(b) Remove spring and relief valve (Fig. 93) .
Fig. 90 Crankshaft Sprocket - Removal
1 - SPECIAL TOOL 6793
2 - SPECIAL TOOL C-4685±C2
3 - CRANKSHAFT SPROCKET
Fig. 91 Crankshaft Key
1 - CRANKSHAFT KEY
Fig. 92 Oil Pump
1 - BOLTS
2 - BOLTS
3 - OIL PUMP
Fig. 93 Oil Pressure Relief Valve
1 - PLUG
2 - OIL PUMP BODY
3 - RELIEF VALVE
4 - SPRING
5 - SEAL
RSENGINE 2.4L9-55
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CAUTION: Oil pump pressure relief valve must be
installed as shown in (Fig. 93) or serious engine
damage may occur.
(4) Install relief valve, spring, gasket and cap as
shown in (Fig. 93). Tighten cap to 41 N´m (30 ft.
lbs.).
INSTALLATION
(1) Make sure all surfaces are clean and free of oil
and dirt.
(2) Apply MopartGasket Maker to oil pump as
shown in (Fig. 98). Install O-ring into oil pump body
discharge passage.
(3) Prime oil pump with engine oil before installa-
tion.
(4) Align oil pump rotor flats with flats on crank-
shaft. Install the oil pump to the block (Fig. 92).
CAUTION: To align, the front crankshaft seal MUST
be out of pump, or damage may result.
(5) Install new front crankshaft seal using Special
Tool 6780 (Fig. 99).
(6) Install crankshaft key (Fig. 91).
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.
(7) Install crankshaft sprocket using Special Tool
6792 (Fig. 100).
(8) Install oil pump pick-up tube.
(9) Install oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION).(10) Install timing belt rear cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT COVER(S)
- INSTALLATION).
(11) Install timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
INSTALLATION).
Fig. 98 Oil Pump Sealing
1 - O-RING
2 - SEALER LOCATION
Fig. 99 Front Crankshaft Seal - Installation
1 - PROTECTOR
2 - SEAL
3 - SPECIAL TOOL 6780
Fig. 100 Crankshaft Sprocket - Installation
1 - SPECIAL TOOL 6792
2 - TIGHTEN NUT TO INSTALL
RSENGINE 2.4L9-57
OIL PUMP (Continued)
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EXHAUST MANIFOLD
REMOVAL
(1) Raise vehicle and disconnect exhaust pipe from
the exhaust manifold.
(2) Disconnect upstream oxygen sensor connector
at the rear of exhaust manifold.
(3) Remove the bolts attaching the manifold to the
cylinder head.
(4) Remove exhaust manifold.
(5) Inspect the manifold. (Refer to 9 - ENGINE/
MANIFOLDS/EXHAUST MANIFOLD - INSPEC-
TION)
CLEANING
(1) Discard gasket (if equipped) and clean all sur-
faces of manifold and cylinder head.
INSPECTION
(1) Inspect manifold gasket surfaces for flatness
with straight edge. Surface must be flat within 0.15
mm per 300 mm (0.006 in. per foot) of manifold
length.
(2) Inspect manifolds for cracks or distortion.
Replace manifold as necessary.
INSTALLATION
(1) Install exhaust manifold with a new gasket.
Tighten attaching nuts in the sequence shown in
(Fig. 109) to 19 N´m (170 in. lbs.).
(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 - UPPER
(1) Remove upper timing belt cover fasteners (Fig.
110) and remove cover.
FRONT COVER - LOWER
(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. 110)
and remove covers.
REAR COVER
(1) Remove front covers.
(2) Remove engine mount bracket (Fig. 111).
(3) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
REMOVAL).
Fig. 109 Exhaust Manifold Tightening Sequence
Fig. 110 Front Timing Belt Covers
1 - BOLTS - UPPER FRONT COVER 6 N´m (50 in. lbs.)
2 - BOLTS - LOWER FRONT COVER 6 N´m (50 in. lbs.)
RSENGINE 2.4L9-61
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(4) Remove camshaft sprockets. Hold camshaft
sprocket with Special Tool 6847 while removing cen-
ter bolt (Fig. 112).(5) Remove timing belt idler pulley (Fig. 113).
(6) Remove rear cover fasteners and remove cover
from engine (Fig. 114).
INSTALLATION
FRONT COVER - UPPER
(1) Install timing belt cover. Torque fasteners to 6
N´m (50 in. lbs.) (Fig. 110).
FRONT COVER - LOWER
(1) Install timing belt front covers (Fig. 110).
Tighten fasteners to 6 N´m (50 in. lbs.).
(2) Install generator drive belt tensioner (Refer to
7 - COOLING/ACCESSORY DRIVE/BELT TEN-
SIONERS - INSTALLATION).
(3) Install crankshaft vibration damper (Refer to 9
- ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
INSTALLATION).
REAR COVER
(1) Install rear timing belt cover and fasteners.
Torque fasteners to specified values (Fig. 114).
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.
Fig. 111 Engine Mount Bracket
1 - ENGINE MOUNT BRACKET
2 - BOLTS - 61 N´m (45 ft. lbs.)
Fig. 112 Camshaft Sprocket - Removal/Installation
1 - SPECIAL TOOL 6847
Fig. 113 Timing Belt Idler Pulley
1 - IDLER PULLEY
2 - BOLT
9 - 62 ENGINE 2.4LRS
TIMING BELT COVER(S) (Continued)
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(2) Install camshaft sprockets. Hold sprockets with
Special Tool 6848 and tighten center bolt to 101 N´m
(75 ft. lbs.) (Fig. 112).
(3) Install timing belt idler pulley and tighten
mounting bolt to 61 N´m (45 ft. lbs.) (Fig. 113).
(4) Install timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
INSTALLATION).
(5) Install engine mount bracket and tighten bolts
to 61 N´m (45 ft. lbs.) (Fig. 111).
(6) Install front covers.
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/DRIVE BELTS -
REMOVAL).
(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 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 COVER(S) -
REMOVAL).
(12) Remove right engine mount (Refer to 9 -
ENGINE/ENGINE MOUNTING/RIGHT MOUNT -
REMOVAL).
(13) Remove engine mount bracket (Fig. 115).
Fig. 114 Rear Timing Belt Cover Fasteners
1 - M6 BOLTS - 12 N´m (105 in. lbs.)
2 - M8 BOLTS - 28 N´m (250 in. lbs.)
3 - TIMING BELT TENSIONER
Fig. 115 Engine Mount Bracket
1 - ENGINE MOUNT BRACKET
2 - BOLTS - 61 N´m (45 ft. lbs.)
RSENGINE 2.4L9-63
TIMING BELT COVER(S) (Continued)
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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. 116).
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) Loosen timing belt tensioner lock bolt (Fig.
117).
(16) Inserta6mmAllen wrench into the hexagon
opening located on the top plate of the belt tensioner
pulley (Fig. 117). Rotate the top plateCLOCKWISE
until there is enough slack in timing belt to allow for
removal.
(17) Remove timing belt.CAUTION: If timing belt was damaged due to incor-
rect tracking (alignment), the belt tensioner pulley
and bracket must be replaced as an assembly
(Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT
TENSIONER & PULLEY - REMOVAL).
REMOVAL - CAMSHAFT SPROCKETS
(1) Disconnect negative battery cable.
(2) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
REMOVAL).
(3) Hold camshaft sprockets with Special Tool 6847
while removing center bolts (Fig. 118).
REMOVAL - CRANKSHAFT SPROCKET
(1) Disconnect negative battery cable.
(2) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT 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.
Fig. 116 Crankshaft and Camshaft Timing
1 - CAMSHAFT TIMING MARKS
2 - CRANKSHAFT TDC MARKS
3 - TRAILING EDGE OF SPROCKET TOOTH
Fig. 117 Timing Belt Tensioner
1 - LOCK BOLT
2 - TOP PLATE
9 - 64 ENGINE 2.4LRS
TIMING BELT AND SPROCKET(S) (Continued)
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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)
INSTALLATION - CAMSHAFT SPROCKETS
(1) Install camshaft sprockets. Hold camshaft
sprockets with Special Tool 6847 while tightening
center bolts to 115 N´m (85 ft. lbs.) (Fig. 118).
(2) Install timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
INSTALLATION).
(3) Connect negative battery cable.
INSTALLATION - TIMING BELT
(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.
(5) Inserta6mmAllen wrench into the hexagon
opening located on the top plate of the belt tensioner
pulley. Rotate the top plateCOUNTERCLOCK-
WISE. The tensioner pulley will move against the
belt and the tensioner setting notch will eventually
start to move clockwise. Watching the movement of
the setting notch, continue rotating the top plate
counterclockwise until the setting notch is aligned
with the spring tang (Fig. 123). Using the allen
wrench to prevent the top plate from moving, torque
the tensioner lock bolt to 25 N´m (220 in. lbs.). Set-
Fig. 118 Camshaft Sprocket - Removal/Installation
1 - SPECIAL TOOL 6847
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
RSENGINE 2.4L9-65
TIMING BELT AND SPROCKET(S) (Continued)
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