2002 CHRYSLER CARAVAN belt

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Passenger Heated Seat Module C2 GY At Heated Seat Back N/S
Passenger Heated Seat Module C3 GN At Heated Seat N/S
Passenger Power Seat Front Riser
MotorRD Under Seat N/S
Passenger Power Seat Horizontal
MotorBK Under Seat N/S
Passenger Power Seat Rear Riser
MotorRD Under Seat N/S
Passenger Power Seat Recliner
MotorGN Under Seat N/S
Passenger Power Seat Switch GN At Switch N/S
Passenger Power Window Motor RD At Motor 37
Passenger Power Window Switch BK At Switch 37
Passenger Seatbelt Switch On Seat Harness N/S
Passenger Seatbelt Tensioner On Seat Harness N/S
Pedal Adjust Module At Module N/S
Pedal Adjust Switch At Switch N/S
Power Folding Mirror Switch BK Near Steering Column 26
Power Liftgate Module C1 BK Left Quarter 39, 40
Power Liftgate Module C2 BK/RD Left Quarter 39, 40
Power Liftgate Motor BK Left Quarter 40
Power Mirror Switch BK Rear of Switch 25
Power Outlet NAT Instrument Panel 15, 18, 20
Power Seat Circuit Breaker GY Under Seat N/S
Powertrain Control Module C1 GY/BK LT Fender Side Shield N/S
Powertrain Control Module C2 GY LT Fender Side Shield N/S
Power Window Circuit Breaker GY Left Side Kick Panel 35 36
Radiator Fan No.1 BK Left Side At Motor 1
Radiator Fan No.1 (Diesel) GY Left Side At Motor 2
Radiator Fan No.2 BK Right Side At Motor 1
Radiator Fan No.2 (Diesel) GY Right Side At Motor N/S
Radiator Fan Relay BK Top of Left Front Frame Rail 1
Radiator Fan Relay No. 1 (Diesel) BL Left Front Engine Compartment 2
Radiator Fan Relay No. 2 (Diesel) BL Left Front Engine Compartment 2
Radiator Fan Relay No. 3 (Diesel) BL Left Front Engine Compartment 2
Radio C1 GY Rear of Radio 15
Radio C2 BK Rear of Radio 15
Rear A/C-Heater Unit LT/GN Right Quarter Panel N/S
Rear Automatic Temperature
Control Switch (ATC)BK Rear of Switch 34
Rear Blower Front Control Switch BK Rear of Switch N/S
Rear Blower Motor Power Module
C1Right Quarter N/S
8W - 91 - 8 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
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EXHAUST MANIFOLD
DESCRIPTION.........................62
OPERATION...........................62
REMOVAL.............................62
CLEANING............................62
INSPECTION..........................62
INSTALLATION.........................62
TIMING BELT COVER(S)
REMOVAL.............................63
INSTALLATION.........................63
TIMING BELT AND SPROCKET(S)
REMOVAL
REMOVAL - TIMING BELT...............64REMOVAL - CRANKSHAFT SPROCKET....66
CLEANING............................66
INSTALLATION
INSTALLATION - CRANKSHAFT SPROCKET . 66
INSTALLATION - TIMING BELT...........67
TIMING BELT TENSIONER & PULLEY
REMOVAL.............................68
INSTALLATION.........................69
BALANCE SHAFTS AND CARRIER ASSEMBLY
DESCRIPTION.........................69
OPERATION...........................70
REMOVAL.............................70
INSTALLATION.........................71
ENGINE 2.4L
DESCRIPTION
The 2.4 Liter (148 cu. in.) in-line four cylinder
engine is a double over head camshaft with hydraulic
lash adjusters and four valve per cylinder design.
The engine is free-wheeling; meaning it has provi-
sions for piston-to-valve clearance. However valve-to-
valve interference can occur, if camshafts are rotated
independently.
The cylinders are numbered from front of the
engine to the rear. The firing order is 1±3±4±2.
The engine identification number is located on the
rear of the cylinder block (Fig. 1).
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION
Engine diagnosis is helpful in determining the
causes of malfunctions not detected and remedied by
routine maintenance.
These malfunctions may be classified as either
mechanical (e.g., a strange noise), or performance
(e.g., engine idles rough and stalls).
Refer to the Engine Mechanical and the Engine
Performance diagnostic charts, for possible causes
and corrections of malfunctions (Refer to 9 - ENGINE
- DIAGNOSIS AND TESTING - MECHANICAL)
(Refer to 9 - ENGINE - DIAGNOSIS AND TESTING
- PERFORMANCE).
For fuel system diagnosis, (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY - DIAGNOSIS AND
TESTING).
Additional tests and diagnostic procedures may be
necessary for specific engine malfunctions that can-
not be isolated with the Service Diagnosis charts.
Information concerning additional tests and diagno-
sis is provided within the following:
²Cylinder Compression Pressure Test
²Cylinder Combustion Pressure Leakage Test
²Engine Cylinder Head Gasket Failure Diagnosis
²Intake Manifold Leakage Diagnosis
²Hydraulic Lash Adjuster Noise Diagnosis
²Engine Oil Leak Inspection
Fig. 1 Engine Identification
1 - ENGINE IDENTIFICATION LOCATION
RSENGINE 2.4L9-3
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DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - PERFORMANCE
CONDITION POSSIBLE CAUSE CORRECTION
ENGINE WILL NOT START 1. Weak battery. 1. Test battery. Charge or replace
as necessary. (Refer to 8 -
ELECTRICAL/BATTERY SYSTEM -
DIAGNOSIS AND TESTING)
2. Corroded or loose battery
connections.2. Clean and tighten battery
connections. Apply a coat of light
mineral grease to terminals.
3. Faulty starter. 3. Test starting system. (Refer to 8 -
ELECTRICAL/STARTING -
DIAGNOSIS AND TESTING)
4. Faulty coil(s) or control unit. 4. Test and replace as needed.
(Refer to Appropriate Diagnostic
Information)
5. Incorrect spark plug gap. 5. Set gap. (Refer to 8 -
ELECTRICAL/IGNITION CONTROL
- SPECIFICATIONS)
6. Contamination in fuel system. 6. Clean system and replace fuel
filter.
7. Faulty fuel pump. 7. Test fuel pump and replace as
needed. (Refer to Appropriate
Diagnostic Information)
8. Incorrect engine timing. 8. Check for a skipped timing
belt/chain.
ENGINE STALLS OR IDLES
ROUGH1. Idle speed too low. 1. Test minimum air flow. (Refer to
Appropriate Diagnostic Information)
2. Incorrect fuel mixture. 2. (Refer to Appropriate Diagnostic
Information)
3. Intake manifold leakage. 3. Inspect intake manifold, manifold
gasket, and vacuum hoses.
4. Faulty ignition coil(s). 4. Test and replace as necessary.
(Refer to Appropriate Diagnostic
Information)
9 - 4 ENGINE 2.4LRS
ENGINE 2.4L (Continued)
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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)
(18) Remove axle shafts. (Refer to 3 - DIFFEREN-
TIAL & DRIVELINE/HALF SHAFT - REMOVAL)
(19) Drain engine oil and remove oil filter. (Refer
to 9 - ENGINE/LUBRICATION/OIL - STANDARD
PROCEDURE)
(20) Remove crossmember cradle plate (Fig. 6).
(21) Disconnect exhaust pipe from manifold (Fig.
7).
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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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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SPECIFICATIONS - TORQUE
DESCRIPTION N´mFt.
Lbs.In.
Lbs.
Balance Shaft Carrier to
BlockÐBolts54 40 Ð
Balance Shaft Gear
CoverÐDouble Ended
Fastener12 Ð 105
Balance Shaft SprocketÐ
Bolt28 Ð 250
Balance Shaft Chain
TensionerÐBolts12 Ð 105
Balance Shaft Carrier
CoverÐBolts12 Ð 105
Camshaft SprocketÐBolt 101 75 Ð
Connecting Rod
CapÐBolts27 +
1¤4
turn20
+1¤4
turnÐ
Crankshaft Main Bearing
Cap/Bedplate
ÐM8 Bolts 28 250
ÐM11 Bolts 41 +
1¤4
Turn30
+1¤4
TurnÐ
Crankshaft Damper 136 100 Ð
Cylinder HeadÐBolts (Refer to 9 - ENGINE/
CYLINDER HEAD -
INSTALLATION)
Cylinder Head CoverÐ
Bolts12 Ð 105
Flex Plate to Crankshaft 95 70 Ð
Engine Mount Bracket
RightÐBolts61 45 Ð
Engine MountingÐBolts (Refer to 9 ENGINE/
ENGINE MOUNTING)
DESCRIPTION N´mFt.
Lbs.In.
Lbs.
Exhaust Manifold to
Cylinder HeadÐBolts19 Ð 170
Exhaust Manifold Heat
ShieldÐBolts12 Ð 105
Intake Manifold - Lower
ÐBolts28 Ð 250
Intake Manifold -
UpperÐBolts28 Ð 250
Oil Filter 12 Ð 105
Oil PanÐBolts 12 Ð 105
Oil Pan DrainÐPlug 27 20 Ð
Oil Pressure Switch 21 Ð 190
Oil Pump to BlockÐBolts 28 Ð 250
Oil Pump Cover
PlateÐBolts12 Ð 105
Oil Pump Pick-up
TubeÐBolt28 20 Ð
Oil Pump Relief
ValveÐCap41 30 Ð
Spark Plugs 18 13 Ð
Structural Collar (Refer to 9 - ENGINE/
ENGINE BLOCK/
STRUCTURAL COVER -
INSTALLATION)
Timing Belt Covers
- Front Covers to Rear
CoverÐBolts7Ð60
- Rear CoverÐM6 Bolts 12 Ð 105
ÐM8 Bolts 28 Ð 250
Timing Belt Tensioner
AssemblyÐBolts61 45 Ð
9 - 20 ENGINE 2.4LRS
ENGINE 2.4L (Continued)
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Possible indications of the cylinder head gasket
leaking between adjacent cylinders are:
²Loss of engine power
²Engine misfiring
²Poor fuel economy
Possible indications of the cylinder head gasket
leaking between a cylinder and an adjacent water
jacket are:
²Engine overheating
²Loss of coolant
²Excessive steam (white smoke) emitting from
exhaust
²Coolant foaming
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determine if an engine cylinder head gasket is
leaking between adjacent cylinders, follow the proce-
dures in Cylinder Compression Pressure Test (Refer
to 9 - ENGINE - DIAGNOSIS AND TESTING). An
engine cylinder head gasket leaking between adja-
cent cylinders will result in approximately a 50±70%
reduction in compression pressure.
CYLINDER-TO-WATER JACKET LEAKAGE TEST
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING WITH COOLANT PRES-
SURE CAP REMOVED.VISUAL TEST METHOD
With the engine cool, remove the coolant pressure
cap. Start the engine and allow it to warm up until
thermostat opens.
If a large combustion/compression pressure leak
exists, bubbles will be visible in the coolant.
COOLING SYSTEM TESTER METHOD
WARNING: WITH COOLING SYSTEM TESTER IN
PLACE, PRESSURE WILL BUILD UP FAST. EXCES-
SIVE PRESSURE BUILT UP, BY CONTINUOUS
ENGINE OPERATION, MUST BE RELEASED TO A
SAFE PRESSURE POINT. NEVER PERMIT PRES-
SURE TO EXCEED 138 kPa (20 psi).
Install Cooling System Tester 7700 or equivalent to
pressure cap neck. Start the engine and observe the
tester's pressure gauge. If gauge pulsates with every
power stroke of a cylinder a combustion pressure
leak is evident.
CHEMICAL TEST METHOD
Combustion leaks into the cooling system can also
be checked by using Bloc-Chek Kit C-3685-A or
equivalent. Perform test following the procedures
supplied with the tool kit.
REMOVAL - CYLINDER HEAD
(1) Perform fuel system pressure release procedure
before attempting any repairs.(Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY - SPECIFICA-
TIONS)
(2) Disconnect battery negative cable.
(3) Drain cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(4) Remove air filter housing and inlet tube.
(5) Remove upper intake manifold. (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
REMOVAL)
(6) Remove heater tube support bracket from cyl-
inder head.
(7) Disconnect radiator upper and heater supply
hoses from intake manifold water outlet connections.
(8) Remove accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)
(9) Raise vehicle and remove exhaust pipe from
manifold.
(10) Remove power steering pump reservoir and
line support bracket from lower intake manifold and
set aside. Do not disconnect lines.
(11) Remove ignition coil and wires from engine.
(12) Disconnect cam sensor and fuel injector wir-
ing connectors.
Fig. 13 Cylinder Head and Camshafts
1 - CAMSHAFT BEARING CAPS
2 - PLUG
3 - CAMSHAFT
4 - CYLINDER HEAD
5 - CAMSHAFT OIL SEAL
RSENGINE 2.4L9-25
CYLINDER HEAD (Continued)
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(13) Remove timing belt and camshaft sprockets.
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT/CHAIN AND SPROCKETS - REMOVAL)
(14) Remove timing belt idler pulley and rear tim-
ing belt cover. (Refer to 9 - ENGINE/VALVE TIM-
ING/TIMING BELT / CHAIN COVER(S) -
REMOVAL)
(15) Remove cylinder head cover. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL)
(16) Remove camshafts (Refer to 9 - ENGINE/
CYLINDER HEAD/CAMSHAFT(S) - REMOVAL).
NOTE: Identify rocker arm position to ensure cor-
rect re-installation in original position, if reused.
(17) Remove rocker arms. (Refer to 9 - ENGINE/
CYLINDER HEAD/ROCKER ARMS - REMOVAL)
(18) Remove cylinder head bolts in REVERSE
sequence of tightening (Fig. 19).
(19) Remove cylinder head from engine block.
(20) Inspect and clean cylinder head. (Refer to 9 -
ENGINE/CYLINDER HEAD - INSPECTION) (Refer
to 9 - ENGINE/CYLINDER HEAD - CLEANING)
CLEANING
To ensure engine gasket sealing, proper surface
preparation must be performed, especially with the
use of aluminum engine components and multi-layer
steel cylinder head gaskets.
NOTE: Multi-Layer Steel (MLS) head gaskets require
a scratch free sealing surface.
Remove all gasket material from cylinder head and
block (Refer to 9 - ENGINE - STANDARD PROCE-
DURE). Be careful not to gouge or scratch the alumi-
num head sealing surface.
Clean all engine oil passages.
INSPECTION
(1) Cylinder head must be flat within 0.1 mm
(0.004 in.) (Fig. 14).
(2) Inspect camshaft bearing journals for scoring.
(3) Remove carbon and varnish deposits from
inside of valve guides with a reliable guide cleaner.
(4) Using a small hole gauge and a micrometer,
measure valve guides in 3 places top, middle and bot-
tom (Fig. 15). (Refer to 9 - ENGINE - SPECIFICA-
TIONS) Replace guides if they are not within
specification.
(5) Check valve guide height (Fig. 16).
INSTALLATION - CYLINDER HEAD
NOTE: The Cylinder head bolts should be examined
BEFORE reuse. If the threads are necked down, the
bolts must be replaced (Fig. 17).
Necking can be checked by holding a scale or
straight edge against the threads. If all the threads
do not contact the scale, the bolt should be replaced.
(1) Before installing the bolts, the threads should
be coated with engine oil.
(2) Position cylinder head gasket on engine block
(Fig. 18).
(3) Install cylinder head on engine block.
(4) Tighten the cylinder head bolts in the sequence
shown in (Fig. 19). Using the 4 step torque turn
method, tighten according to the following values:
²First All to 34 N´m (25 ft. lbs.)
Fig. 14 Checking Cylinder Head Flatness
1 - FEELER GAUGE
2 - STRAIGHT EDGE
Fig. 15 Checking Wear on Valve GuideÐTypical
1-TOP
2 - MIDDLE
3 - BOTTOM
4 - CUT AWAY VIEW OF VALVE GUIDE MEASUREMENT
LOCATIONS
9 - 26 ENGINE 2.4LRS
CYLINDER HEAD (Continued)
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