2002 CHRYSLER CARAVAN wheel bolts

(6) Install screws attaching upper evaporator
housing to lower evaporator housing.
(7) Install fasteners attaching HVAC unit to inner
quarter panel.
(8) Install air duct.
(9) Install bracket around HVAC unit.
(10) Route seat belt webbing and turning loop
through access hole in quarter trim.
(11) Install quarter trim panel as necessary to gain
access to HVAC unit.
(12) Install quarter trim bolster.(13) Install D-pillar trim panel.
(14) Position turning loop to extension bracket.
(15) Install bolt attaching turning loop to exten-
sion bracket above quarter glass. Tightening seat belt
bolt to 39 N´m (29 ft. lbs.) torque.
(16) Pull upper turning loop extension cover
upward over anchor bolt.
(17) Install lower anchor shoulder-nut. Tightening
seat belt bolt to 39 N´m (29 ft. lbs.) torque.
(18) Slide lower anchor cover over anchor shoul-
der-nut.
(19) Install second row seat from vehicle. Refer to
Owner's Manual for proper procedures.
SEAT BELT SECOND ROW
OUTBOARD - SWB
REMOVAL
(1) Remove second row seat from vehicle. Refer to
Owner's Manual for proper procedures.
(2) Slide lower anchor cover from over the anchor
shoulder-nut.
(3) Remove lower anchor shoulder-nut.
(4) Remove lower anchor from wheelhouse (Fig. 9).
(5) Remove D-pillar trim panel.
(6) Route seat belt webbing and turning loop
through access hole in quarter trim.
(7) Remove bolts attaching seat belt guide loop to
inner quarter panel.
(8) Remove anchor bolt attaching retractor to
inner quarter panel.
(9) Remove second row seat belt retractor from
vehicle (Fig. 9).
INSTALLATION
(1) Place second row seat belt retractor into posi-
tion.
(2) Install anchor bolt attaching retractor to inner
quarter panel. Tighten all seat belts to 39 N´m (29 ft.
lbs.) torque.
(3) Install bolts attaching seat belt guide loop to
inner quarter panel.
(4) Route seat belt webbing and turning loop
through access hole in quarter trim.
(5) Install D-pillar trim panel.
(6) Install lower anchor to the wheelhouse.
(7) Install lower anchor shoulder-nut. Tighten all
seat belts to 39 N´m (29 ft. lbs.) torque.
(8) Slide lower anchor cover over the anchor shoul-
der-nut.
Fig. 7 LOWER HEATER DUCT
1 - LOWER HEAT DUCT MOUNTING
Fig. 8 REAR HVAC MOUNTING
1 - REAR HVAC MODULE MOUNTING
2 - REAR EVAPORATOR LOWER HOUSING
3 - REAR EVAPORATOR UPPER HOUSING
8O - 12 RESTRAINTSRS
SEAT BELT SECOND RIGHT ROW OUTBOARD - LBW WITH REAR HVAC (Continued)
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(4) The coil ground terminal (85) is connected to
the electromagnet in the relay. It receives battery
feed to energize the accessory relay when the ignition
switch is in the Accessory or On positions. Turn the
ignition switch to the On position. Check for battery
voltage at the fused ignition switch output (acc/run)
circuit cavity for relay terminal 85 in the IPM recep-
tacle for the accessory relay. If OK, go to Step 5. If
not OK, repair the open fused ignition switch output
(acc/run) circuit to the ignition switch as required.
(5) The coil battery terminal (86) is connected to
the electromagnet in the relay. The IPM cavity for
this terminal should have continuity to ground at all
times. If not OK, repair the open ground circuit to
ground as required.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the Integrated Power Module (IPM)
cover from the IPM.
(3) Remove the accessory relay from the IPM.
Refer to the IPM cover for relay location.
INSTALLATION
(1) Position the accessory relay in the proper
receptacle in the Integrated Power Module (IPM).
(2) Push in firmly on the accessory relay until the
terminals are fully seated in the terminal cavities in
the IPM receptacle.
(3) Install the IPM cover.
(4) Reconnect the battery negative cable.
INTEGRATED POWER MODULE
DESCRIPTION
The Integrated Power Module (IPM) is a combina-
tion of the Power Distribution Center (PDC) and the
Front Control Module (FCM). The IPM is located in
the engine compartment, next to the battery on this
model (Fig. 2). The power distribution center mates
directly with the Front Control Module (FCM) to
form the IPM Fuse and Relay Center. The power dis-
tribution center (PDC) is a printed circuit board
based module that contains fuses and relays, while
the front control module contains the electronics con-
trolling the IPM and other functions. This IPM con-
nects directly to the battery positive via a four pin
connector. The ground connection is via two other
connectors. The IPM provides the primary means of
voltage distribution and protection for the entire
vehicle.
The molded plastic IPM housing includes a base
and cover. The IPM cover is easily opened or removed
for service access by squeezing the two marked coverlatches and has a fuse and relay layout map integral
to the inside surface of the cover. This IPM housing
base and cover are secured in place by an IPM
mounting bracket. This mounting bracket is designed
to allow the IPM to rotate counter-clockwise once the
locking tab is disengaged. The IPM mounting bracket
is secured in place by bolts threaded into the left
front wheel house.
Replaceable components of the IPM assembly are
broken down into the following components: the
Power Distribution Center (PDC) (without fuses or
relays), the IPM cover, the Front Control Module
(FCM), the IPM mounting bracket, IPM bracket
retaining clips and the IPM assembly which includes
the power distribution center, the cover and FCM.
Refer to the Front Control Module in the Elec-
tronic Control Module sectionof this service
manual for information on the FCM.
OPERATION
All of the current from the battery and the gener-
ator output enters the Integrated Power Module
(IPM) via a four- pin connector on the bottom of the
module. The IPM cover is unlatched and opened or
removed to access the fuses or relays. Internal con-
nections of all of the power distribution center cir-
cuits is accomplished by a combination of bus bars
and a printed circuit board. Refer to the Wiring sec-
Fig. 2 BATTERY THERMAL GUARD
1 - BATTERY THERMAL GUARD
2 - INTEGRATED POWER MODULE
3 - FRONT CONTROL MODULE
RS8W-97 POWER DISTRIBUTION SYSTEM8W-97-3
ACCESSORY RELAY (Continued)
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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.
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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(4) Tighten the bolts to 27 N´m PLUS 1/4 turn (20
ft. lbs. PLUS 1/4 turn)Do not use a torque
wrench for last step.
(5) Using a feeler gauge, check connecting rod side
clearance (Fig. 45). Refer to clearance specifications
(Refer to 9 - ENGINE - SPECIFICATIONS).
CRANKSHAFT
DESCRIPTION
The crankshaft is made of nodular cast iron and
includes five main bearing journals and four connect-
ing rod journals (Fig. 46). The number three journal
is the location for the thrust bearing. The mains and
connecting rod journals have undercut fillet radiuses
that are rolled for added strength. To optimize bear-
ing loading, eight counterweights are used.
OPERATION
The crankshaft transfers force generated by com-
bustion within the cylinder to the flywheel or flex-
plate.
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. 47).
(2) Move crankshaft all the way to the rear of its
travel.
(3) Zero the dial indicator.
(4) Move crankshaft all the way to the front and
read the dial indicator. Refer to Engine Specifica-
tions.
REMOVAL
NOTE: Crankshaft can not be removed when engine
is in vehicle.(1) Remove engine assembly from vehicle. (Refer to
9 - ENGINE - REMOVAL)
(2) Separate engine from transaxle.
(3) Remove flex plate and crankshaft rear oil seal.
(4) Mount engine on a repair stand.
(5) Drain engine oil and remove oil filter.
(6) Remove the oil pan. (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL)
(7) Remove engine mount support bracket.
(8) Remove the crankshaft damper and timing belt
covers. (Refer to 9 - ENGINE/VALVE TIMING/TIM-
ING BELT / CHAIN COVER(S) - REMOVAL)
(9) Remove the timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL)
Fig. 45 Connecting Rod Side Clearance
Fig. 46 Crankshaft - Typical
1 - MAIN BEARING JOURNALS
2 - COUNTER BALANCE WEIGHTS
Fig. 47 CHECKING CRANKSHAFT END PLAY
9 - 38 ENGINE 2.4LRS
CONNECTING ROD BEARINGS (Continued)
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INSTALLATION
(1) Install the front mount bracket to engine, if
removed (Fig. 79).
(2) Install the insulator mount assembly (Fig. 79).
(3) Install the front engine mount through bolt to
the insulator (Fig. 79).
(4) Lower the vehicle.
LEFT MOUNT
REMOVAL
(1) Raise the vehicle on hoist.
(2) Remove the left front wheel.
(3) Remove the left mount through bolt access
cover.
(4) Support the transaxle with a suitable jack.
(5) Remove the engine front mount through bolt to
allow left mount removal clearance (Fig. 79).
(6) Remove the left mount through frame rail bolt
(Fig. 80).
(7) Lower transaxle for access to horizontal bolts.
(8) Remove the horizontal bolts from the mount to
the transaxle (Fig. 81) or (Fig. 82).NOTE: To remove mount, additional lowering of
transaxle may be required.
(9) Remove left mount.
INSTALLATION
(1) Install left mount on transaxle (Fig. 81) or (Fig.
82).
Fig. 79 Front Mount and Bracket
1 - BRACKET - FRONT MOUNT
2 - NUT - 68 N´m (50 ft. lbs.)
3 - BOLT - 54 N´m (40 ft. lbs.)
4 - MOUNT - FRONT INSULATOR
5 - BOLT - 68 N´m (50 ft. lbs.)
6 - BOLT - 68 N´m (50 ft. lbs.)
7 - FRONT CROSSMEMBER
Fig. 80 LEFT MOUNT TO BRACKET
1 - BOLT - BRACKET TO FRAME RAIL 68 N´m (50 ft. lbs.)
2 - BOLT - MOUNT TO RAIL THRU 75 N´m (55 ft. lbs.)
3 - BOLT - LEFT MOUNT TO TRANSAXLE 54 N´m (40 ft. lbs.)
4 - TRANSAXLE
5 - MOUNT - LEFT
6 - BRACKET - LEFT MOUNT
Fig. 81 LEFT MOUNT - 31TH
1 - LEFT MOUNT ASEMBLY
2 - BOLT - 54 N´m (40 ft. lbs.)
3 - TRANSAXLE - 31TH
9 - 50 ENGINE 2.4LRS
FRONT MOUNT (Continued)
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(2) Raise transaxle with jack until left mount is in
position.
(3) Install left mount through bolt (Fig. 80).
(4) Install left mount through bolt access cover.
(5) Install front mount through bolt (Fig. 79).
(6) Install left front wheel.
(7) Lower vehicle.
REAR MOUNT
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove the rear mount heat shield (Fig. 83).
(3) Remove the through bolt from the mount and
rear mount bracket (Fig. 84).
(4) Remove the mount bolts (Fig. 84).
(5) Remove the rear mount (Fig. 84).
(6) For rear mount bracket removal, remove the
bolts attaching bracket to transaxle (Fig. 85).
(7) Remove rear mount bracket.
INSTALLATION
(1) Install rear mount bracket, if removed (Fig.
85).
(2) Install the rear mount and bolts (Fig. 84).
Tighten bolts to 54 N´m (40 ft. lbs.).
(3) Install the mount through bolt to the mount
and bracket (Fig. 84). Tighten through bolt to 54 N´m
(40 ft. lbs.).
(4) Install the rear mount heat shield (Fig. 83).
(5) Lower vehicle on hoist.
Fig. 82 UNDER CONSTRUCTION
1 - LEFT MOUNT ASSEMBLY
2 - BOLT - 54 N´m (40 ft. lbs.)
3 - TRANSAXLE - 41TE
Fig. 83 REAR MOUNT HEAT SHIELD
1 - BOLT - HEAT SHIELD 11 N´m (100 in. lbs.)
2 - HEAT SHIELD
3 - CLIP
4 - REAR MOUNT
Fig. 84 REAR MOUNT
1 - BOLT 54 N´m (40 ft. lbs.)
2 - REAR MOUNT BRACKET
3 - THRU-BOLT 54 N´m (40 ft. lbs.)
4 - REAR MOUNT
RSENGINE 2.4L9-51
LEFT MOUNT (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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(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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