2002 CHRYSLER CARAVAN wheel torque

Component Page
Mid Reading Lamps.................... 8W-44
Mode Door Actuator.................... 8W-42
Multi- Function Switch........... 8W-50, 52, 53
Output Speed Sensor................... 8W-31
Overhead Console..................... 8W-49
Oxygen Sensor 1/1 Upstream............. 8W-30
Oxygen Sensor 1/2 Downstream.......... 8W-30
Park Lamp Relay...................... 8W-10
Park Lamps.......................... 8W-50
Park/Turn Signal Lamps................ 8W-50
Parking Brake Switch.................. 8W-40
Passenger Airbag...................... 8W-43
Positive Temperature Coefficients......... 8W-10
Power Liftgate Module.................. 8W-61
Power Liftgate Motor................... 8W-61
Power Mirror Switch................... 8W-62
Power Mirrors........................ 8W-62
Power Outlet......................... 8W-41
Power Seat Circuit Breaker.............. 8W-10
Power Seat Front Riser Motors........... 8W-63
Power Seat Horizontal Motors............ 8W-63
Power Seat Horizontal Position Sensors.... 8W-63
Power Seat Rear Riser Motors............ 8W-63
Power Seat Rear Riser Position Sensors.... 8W-63
Power Seat Recliner Motors.............. 8W-63
Power Seat Switches................... 8W-63
Power Window Circuit Breaker........... 8W-10
Power Window Motors.................. 8W-60
Power Window Switches................ 8W-60
Powertrain Control Module.............. 8W-30
Radiator Fan Relays................... 8W-42
Radiator Fans........................ 8W-42
Radio Choke.......................... 8W-47
Radio............................... 8W-47
Reading Lamps....................... 8W-44
Rear A/C-Heater Unit.................. 8W-42
Rear Auto Temp Control Switch........... 8W-42
Rear Blower Front Control Switch......... 8W-42
Rear Blower Motor Power Module......... 8W-42
Rear Blower Motor Relay................ 8W-42
Rear Blower Motor..................... 8W-42
Rear Blower Rear Control Switch......... 8W-42
Rear Intrusion Sensor.................. 8W-39Component Page
Rear Lamp Assemblies.................. 8W-51
Rear Mode Motor...................... 8W-42
Rear Power Outlet..................... 8W-41
Rear Temperature Motor................ 8W-42
Rear Washer Pump Motor............... 8W-53
Rear Window Defogger Grid............. 8W-48
Recirculation Door Actuator.............. 8W-42
Remote Keyless Entry Antenna........... 8W-61
Remote Radio Switches................. 8W-47
Repeater Lamps....................... 8W-52
Seat Airbag.......................... 8W-43
Seat Belt Tensioners................... 8W-43
Sentry Key Immobilizer Module.......... 8W-39
Side Impact Airbag Control Modules....... 8W-43
Siren............................... 8W-39
Sliding Door Control Modules............ 8W-61
Sliding Door Latch Sensing Switches....... 8W-61
Sliding Door Lock Motor/Ajar Switches..... 8W-61
Sliding Door Lock Motors............... 8W-61
Sliding Door Motors.................... 8W-61
Solenoid/Pressure Switch Assy............ 8W-31
Speakers............................ 8W-47
Speed Control Servo................... 8W-33
Speed Control Switches................. 8W-33
Splice Information..................... 8W-70
Starter Motor Relay.................... 8W-21
Starter Motor......................... 8W-21
Stop/Turn Signal Relays................ 8W-54
Thatcham Alarm Module................ 8W-39
Throttle Position Sensor................ 8W-30
Torque Converter Clutch Solenoid......... 8W-31
Traction Control Switch................. 8W-35
Trailer Tow Connector.................. 8W-54
Transmission Control Module............ 8W-31
Transmission Range Sensor.............. 8W-31
Turn Signal Lamps.................... 8W-52
TXV Solenoid......................... 8W-42
Vehicle Speed Sensor................... 8W-30
Vent Motors.......................... 8W-60
Visor/Vanity Lamps.................... 8W-44
Washer Fluid Level Switch.............. 8W-53
Water In Fuel Sensor................... 8W-30
Wheel Speed Sensors................... 8W-35
8W - 02 - 2 8W-02 COMPONENT INDEXRS
ProCarManuals.com

Component Page
Right Rear Lamp Assembly........... 8W-80-107
Right Rear Pillar Speaker............ 8W-80-107
Right Rear Reading Lamp (Luxury).... 8W-80-107
Right Rear Speaker................. 8W-80-107
Right Rear Vent Motor.............. 8W-80-107
Right Rear Wheel Speed Sensor....... 8W-80-108
Right Remote Radio Switch........... 8W-80-108
Right Repeater Lamp
(Built-Up-Export)................ 8W-80-108
Right Seat Airbag.................. 8W-80-108
Right Side Impact Airbag
Control Module.................. 8W-80-108
Right Sliding Door Control Module C1
(Power Sliding Door).............. 8W-80-109
Right Sliding Door Control Module C2
(Power Sliding Door).............. 8W-80-109
Right Sliding Door Latch Sensing Switch
(Power Sliding Door).............. 8W-80-109
Right Sliding Door Lock Motor
(Power Sliding Door).............. 8W-80-110
Right Sliding Door Lock Motor/Ajar Switch
(Manual Sliding Door)............. 8W-80-110
Right Sliding Door Motor
(Power Sliding Door).............. 8W-80-110
Right Speed Control Switch.......... 8W-80-110
Right Stop/Turn Signal Relay
(Trailer Tow).................... 8W-80-110Component Page
Right Turn Signal Lamp
(Built-Up-Export)................. 8W-80-111
Right Visor/Vanity Lamp
(Premium/Luxury)................ 8W-80-111
Sentry Key Immobilizer Module....... 8W-80-111
Siren (United Kingdom).............. 8W-80-111
Solenoid/Pressure Switch Assy (EATX) . . 8W-80-111
Speed Control Servo (Gas)............ 8W-80-112
Thatcham Alarm Module C1
(United Kingdom)................ 8W-80-112
Thatcham Alarm Module C2
(United Kingdom)................ 8W-80-112
Throttle Position Sensor (Gas)......... 8W-80-112
Torque Converter Clutch Solenoid
(ATX).......................... 8W-80-113
Traction Control Switch.............. 8W-80-113
Trailer Tow Connector
(Except Built-Up-Export)........... 8W-80-113
Transmission Control Module (EATX) . . . 8W-80-114
Transmission Range Sensor (EATX).... 8W-80-115
TXV Solenoid (ATC)................ 8W-80-115
Vehicle Speed Sensor (MTX/ATX)...... 8W-80-115
Washer Fluid Level Switch........... 8W-80-115
Water In Fuel Sensor (Diesel)......... 8W-80-116
Wiper Module..................... 8W-80-116
RS8W-80 CONNECTOR PIN-OUTS8W-80-5
ProCarManuals.com

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Right Seat Airbag YL At Passenger Seat N/S
Right Side Impact Airbag Control
ModuleYL/RD Right B Pillar 33
Right Sliding Door Control Module
C1BK Rear of Door 38, 39
Right Sliding Door Control Module
C2BK/RD Rear of Door 38, 39
Right Sliding Door Latch Sensing
SwitchBK At Sliding Door 38
Right Sliding Door Lock Motor BK Rear of Door 38
Right Sliding Door Lock Motor/Ajar
SwitchBK At Latch N/S
Right Sliding Door Motor BK At Sliding Door 38
Right Speed Control Switch BK At Steering Wheel N/S
Right Stop/Turn Signal Relay BK LT Quarter Panel N/S
Right Turn Signal Lamp OR At Lamp N/S
Right Visor/Vanity Lamp BK At Lamp N/S
Sentry Key Immobilizer Module BK At Steering Column 15, 16, 17, 18, 26
Siren (United Kingdom) BK Left Front Body N/S
Solenoid/Pressure Switch
Assembly (EATX)BK Side of Transmission N/S
Speed Control Servo BK Near Controller Antilock Brake 14
Thatcham Alarm Module C1 BK Top Right Side of Instrument Panel
Near SpeakerN/S
Thatcham Alarm Module C1 WT Top Right Side of Instrument Panel
Near SpeakerN/S
Throttle Position Sensor GY On Throttle Body 9, 13
Torque Converter Clutch Solenoid BK Front of Transmission 10
Traction Control Switch BK Rear of Swtich 16, 17, 26
Trailer Tow Connector BK Left Quarter Panel N/S
Transmission Control Module BK Top of Transmission 14
Transmission Range Sensor GY Top of Transmission 14
Vehicle Speed Sensor BK Rear of Transmission 9, 12
Washer Fluid Level Switch BK Bottom of Reservoir 3
Water in Fuel Sensor (Diesel) Left Rear Engine Compartment N/S
Wiper Module BK Left Side Cowl 6
8W - 91 - 10 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
ProCarManuals.com

CONDITION POSSIBLE CAUSES CORRECTION
MAIN BEARING NOISE 1. Insufficient oil supply. 1. Check engine oil level.
2. Low oil pressure. 2. Check engine oil level. Inspect oil
pump relief valve and spring.
3. Thin or diluted oil. 3. Change oil to correct viscosity.
4. Thick oil 4. (a) Change engine oil and filter.
(b) Run engine to operating
temperature.
(c) Change engine oil and filter
again.
5. Excessive bearing clearance. 5. Measure bearings for correct
clearance. Repair as necessary.
6. Excessive end play. 6. Check thrust bearing for wear on
flanges.
7. Crankshaft journal out-of-round
or worn.7. Replace crankshaft or grind
journals.
8. Loose flywheel or torque
converter.8. Tighten to correct torque.
OIL PRESSURE DROP 1. Low oil level. 1. Check engine oil level.
2. Faulty oil pressure sensor/switch. 2. Replace oil pressure sensor/
switch.
3. Low oil pressure. 3. Check oil pressure sensor/switch
and main bearing oil clearance.
4. Clogged oil filter. 4. Install new oil filter.
5. Worn parts in oil pump. 5. Replace worn parts or pump.
6. Thin or diluted oil. 6. Change oil to correct viscosity.
7. Oil pump relief valve stuck. 7. Remove valve and inspect, clean,
or replace.
8. Oil pump suction tube loose. 8. Remove oil pan and install new
tube or clean, if necessary.
9. Oil pump cover warped or
cracked.9. Install new oil pump.
10. Excessive bearing clearance. 10. Measure bearings for correct
clearance.
OIL LEAKS 1. Misaligned or deteriorated
gaskets.1. Replace gasket(s).
2. Loose fastener, broken or porous
metal part.2. Tighten, repair or replace the
part.
3. Misaligned or deteriorated cup or
threaded plug.3. Replace as necessary.
RSENGINE 2.4L9-7
ENGINE 2.4L (Continued)
ProCarManuals.com

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)
ProCarManuals.com

(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)
ProCarManuals.com

CONDITION POSSIBLE CAUSES CORRECTION
MAIN BEARING NOISE 1. Insufficient oil supply. 1. Check engine oil level.
2. Low oil pressure. 2. Check engine oil level. Inspect oil
pump relief valve and spring.
3. Thin or diluted oil. 3. Change oil to correct viscosity.
4. Thick oil 4. (a) Change engine oil and filter.
(b) Run engine to operating
temperature.
(c) Change engine oil and filter
again.
5. Excessive bearing clearance. 5. Measure bearings for correct
clearance. Repair as necessary.
6. Excessive end play. 6. Check thrust bearing for wear on
flanges.
7. Crankshaft journal out-of-round
or worn.7. Replace crankshaft or grind
journals.
8. Loose flywheel or torque
converter.8. Tighten to correct torque.
OIL PRESSURE DROP 1. Low oil level. 1. Check engine oil level.
2. Faulty oil pressure sensor/switch. 2. Replace oil pressure sensor/
switch.
3. Low oil pressure. 3. Check oil pressure sensor/switch
and main bearing oil clearance.
4. Clogged oil filter. 4. Install new oil filter.
5. Worn parts in oil pump. 5. Replace worn parts or pump.
6. Thin or diluted oil. 6. Change oil to correct viscosity.
7. Oil pump relief valve stuck. 7. Remove valve and inspect, clean,
or replace.
8. Oil pump suction tube loose. 8. Remove oil pan and install new
tube or clean, if necessary.
9. Oil pump cover warped or
cracked.9. Install new oil pump.
10. Excessive bearing clearance. 10. Measure bearings for correct
clearance.
OIL LEAKS 1. Misaligned or deteriorated
gaskets.1. Replace gasket(s).
2. Loose fastener, broken or porous
metal part.2. Tighten, repair or replace the
part.
3. Misaligned or deteriorated cup or
threaded plug.3. Replace as necessary.
RSENGINE 3.3/3.8L9-81
ENGINE 3.3/3.8L (Continued)
ProCarManuals.com

(4) Install No. 2 piston ring and then No. 1 piston
ring (Fig. 87).
(5) Position piston ring end gaps as shown in (Fig.
88).
(6) Position oil ring expander gap at least 45É
from the side rail gaps butnoton the piston pin cen-
ter or on the thrust direction. Staggering ring gap is
important for oil control.VIBRATION DAMPER
REMOVAL
(1) Disconnect negative cable from battery.
(2) Raise vehicle on hoist.
(3) Remove the right front wheel and inner splash
shield.
(4) Remove the accessory drive belt. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)
(5) Remove vibration damper bolt.
(6) Insert Special Tool 8450 into crankshaft nose
(Fig. 89).
(7) Position 3-jaw puller Special Tool 1026 on
damper as shown in (Fig. 89). Turn puller forcing
screw until damper releases from crankshaft.
(8) Remove the crankshaft vibration damper.
INSTALLATION
(1) Install crankshaft vibration damper using the
forcing screw, nut, and thrust bearing/washer from
Special Tool 8452 (Fig. 90).
NOTE: To minimize friction and prolong tool life,
lubricate the threads on the forcing screw of Spe-
cial Tool 8452.
(2) Position vibration damper on crankshaft.
(3) Screw Special Tool 8452 into crankshaft until
the bolt seats. Turn the nut to install damper until it
seats fully.
(4) Remove Special Tool 8452.
(5) Install vibration damper bolt. Torque bolt to 54
N´m (40 ft. lbs.).
Fig. 87 Piston Ring Installation
Fig. 88 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
Fig. 89 Vibration Damper - Removal
1 - SPECIAL TOOL 8450 - INSERT
2 - SPECIAL TOOL 1026-3JAWPULLER
9 - 132 ENGINE 3.3/3.8LRS
PISTON RINGS (Continued)
ProCarManuals.com