2002 CHRYSLER CARAVAN ABS

POWERTRAIN CONTROL MODULE C2 (GAS) - GRAY/GRAY 40 WAY
CAV CIRCUIT FUNCTION
41 V37 18VT SPEED CONTROL SWITCH SIGNAL
42 C18 18LB/BR A/C PRESSURE SENSOR SIGNAL
43 K900 18DB/DG SENSOR GROUND
44 F888 18BR/PK 8 VOLT SUPPLY
45 - -
46 A109 18OR/RD FUSED B(+)
47 - -
48 K40 18BR/LG (2.4L) IDLE AIR CONTROL NO. 3 DRIVER
49 K60 18VT/LG (2.4L) IDLE AIR CONTROL NO. 2 DRIVER
49 K39 18VT/DG (3.3L/3.8L) IDLE AIR CONTROL NO. 1 DRIVER
50 Z131 18BK/DG GROUND
51 K141 18DB/YL OXYGEN SENSOR 1/2 SIGNAL
52 - -
53 - -
54 - -
55 - -
56 V36 18VT/YL SPEED CONTROL VACUUM SOLENOID CONTROL
57 K39 18VT/DG (2.4L) IDLE AIR CONTROL NO. 1 DRIVER
57 K60 18VT/LG (3.3L/3.8L) IDLE AIR CONTROL NO. 2 DRIVER
58 K59 18BR/DG (2.4L) IDLE AIR CONTROL NO. 4 DRIVER
59 D25 18WT/VT PCI BUS
60 - -
61 F855 18PK/YL 5 VOLT SUPPLY
62 B29 18DG/WT SECONDARY BRAKE SWITCH SIGNAL
63 T10 18DG/LG (EATX) TORQUE MANAGEMENT REQUEST SENSE
64 C13 18LB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL
65 D21 18WT/BR SCI TRANSMIT
66 N7 18DB/OR VEHICLE SPEED SENSOR SIGNAL
67 K51 18BR/WT AUTOMATIC SHUT DOWN RELAY CONTROL
68 K52 18DB/WT EVAPORATIVE EMISSION SOLENOID CONTROL
69 - -
70 K70 18DB/BR EVAPORATIVE EMISSION SOLENOID SENSE
71 - -
72 K107 18VT/WT (EXCEPT
BUILT-UP-EXPORT)LEAK DETECTION PUMP SWITCH SENSE
73 K173 18BR/VT RADIATOR FAN RELAY CONTROL
74 K31 18BR FUEL PUMP RELAY CONTROL
75 D20 18WT/LG SCI RECEIVE
76 T41 18YL/DB PARK/NEUTRAL POSITION SWITCH SENSE (TRS T41)
77 K106 18VT/WT (EXCEPT
BUILT-UP-EXPORT) (2.4L EATX W/ABS)LEAK DETECTION PUMP SOLENOID CONTROL
77 K106 18VT/LB (EXCEPT
BUILT-UP-EXPORT) (EXCEPT 2.4L EATX
W/ABS)LEAK DETECTION PUMP SOLENOID CONTROL
78 K54 18DB/WT (ATX) TORQUE CONVERTER CLUTCH SOLENOID CONTROL
79 - -
80 V35 18VT/OR SPEED CONTROL VENT SOLENOID CONTROL
RS8W-80 CONNECTOR PIN-OUTS8W-80-95
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CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Liftgate Ajar Switch (Manual
Release)BK At Latch 42
Liftgate Ajar Switch (Power
Release)BK Lower Liftgate 42
Liftgate Cinch/Release Motor BL Liftgate N/S
Liftgate Cylinder Lock Switch BK At Switch 42
Liftgate Left Pinch Sensor BK Left Side of Liftgate N/S
Liftgate Right Pinch Sensor BK Right Side of Liftgate N/S
Low Note Horn BK Left Frame Rail 5
Manifold Absolute Pressure Sensor BK On Intake 10
Mass Air Flow Sensor (Diesel) OR Top of Engine 11, 12
Memory Seat/Mirror Module C1 GY Under Driver Seat N/S
Memory Seat/Mirror Module C2 GY Under Driver Seat N/S
Memory Seat/Mirror Module C3 WT Under Driver Seat N/S
Memory Seat/Mirror Module C4 GY Under Driver Seat N/S
Memory Seat Front Vertical Motor RD Under Seat N/S
Memory Seat Front Vertical
Position SensorBK Under Seat N/S
Memory Seat Horizontal Motor BK Under Seat N/S
Memory Seat Horizontal Position
SensorBK Under Seat N/S
Memory Seat Rear Vertical Motor RD Under Seat N/S
Memory Seat Rear Vertical Position
SensorBK Under Seat N/S
Memory Seat Recliner Motor GN Under Seat N/S
Memory Seat Recliner Position
SensorBK Under Seat N/S
Memory Seat Switch BK At Switch Driver Door N/S
Message Center WT Rear of Message Center 15, 16, 23
Mode Door Actuator GY Left Side of HVAC N/S
Multi Function Switch BK At Steering Column 15, 16, 17, 18, 26
Output Speed Sensor GY Front of Transmission 14
Overhead Console BK Front of Console N/S
Oxygen Sensor 1/1 Upstream BK Rear of Engine 9, 10, 14
Oxygen Sensor 1/2 Downstream BK Rear of Engine 9, 10, 14
Park/Neutral Positon Switch BK Front of Transmission 10
Passenger Airbag YL Passenger Side of Instrument Panel 15, 18, 19 24
Passenger Blend Door Actuator On HVAC N/S
Passenger Door Courtesy Lamp BK At Lamp 37
Passenger Door Lock Switch BK At Switch 37
Passenger Folding Mirror Relay BL Right Kick Panel N/S
Passenger Heated Seat Back GN At Seat N/S
Passenger Heated Seat Cushion BK At Seat N/S
Passenger Heated Seat Module C1 GY At Heated Seat N/S
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-7
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
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SPLICE NUMBER LOCATION FIG.
S117 (2.4L) Neat T/O for G101 and G103 10
S117 (3.3L/3.8L) Near T/O for Output Speed Sensor 14
S118 (2.4L) Near T/O for Knock Sensor 10
S119 (2.5L) Near T/O for Engine Starter Motor 11
S120 (2.4L) Near T/O for Oxygen Sensors 9
S120 (3.3L/3.8L) Near T/O for Oxygen Sensors 14
S121 (3.3L/3.8L) Near T/O for Output Speed Sensor 14
S122 (2.4L) In T/O to Engine Starter Motor 10
S122 (3.3L/3.8L) In T/O to Engine Starter Motor 14
S123 In T/O to Low Note Horn 5
S124 (2.4L) Near T/O for Fuel Injector No.2 N/S
S124 (3.3L/3.8L) Near T/O for Fuel Injector No.5 and No.6 N/S
S125 (2.4L) In T/O for Manifold Absolute Pressure Sensor N/S
S126 In Right Headlamp Leveling Assembly N/S
S127 (2.5L) Near T/O for Engine Starter Motor N/S
S128 (2.5L) Near T/O for Engine Starter Motor 11
S129 (2.5L) Near T/O for Battery (+) N/S
S130 (2.5L) Near T/O for Battery (+) N/S
S131 (3.3L/3.8L) Near T/O for Transmission Control Module N/S
S132 (2.5L) Near T/O for Battery (+) N/S
S133 (2.5L) Near T/O for Intelligent Power Module C3 N/S
S134 Near T/O for Controller Antilock Brake N/S
S135 (2.5L) Near T/O for Glow Plug No.2 11
S136 (2.5L) Between T/O for Radiator Fan No.2 and T/O for G102 N/S
S137 (2.5L) Near T/O for A/C Compressor Clutch 11
S138 (2.5L) Between T/O for Radiator Fan No.2 and T/O for G102 N/S
S139 (2.5L) Between T/O for Engine Starter Motor and T/O for
Engine Control Module C112
S141 (2.4L) Near T/O for Powertrain Control Module N/S
S141 (2.5L) Near /t/O for G100 N/S
S141 (3.3L/3.8L) Near T/O for Powertrain Control Module N/S
S142 (3.3L/3.8L) Near T/O for A/C Compressor Clutch 14
S143 (2.5L) Near T/O for Engine Control Module C1 11
S143 (3.3L/3.8L) Near T/O for Intelligent Power Module - C3 N/S
S144 (2.5L) Between T/O for Battery Temperature Sensor and T/O
for C10311
S145 (2.5L) Near T/O for Battery (+) N/S
S148 (2.5L) Near T/O for Engine Starter Motor 11
S150 (2.5L) Between T/O for Battery Temperature Sensor and T/O
for C103N/S
S151 (2.5L) Near T/O for Radiator Fan Relay No.1 2
S152 (2.5L) Near T/O for Left Fog Lamp N/S
S157 (2.5L) Near T/O for Glow Plug No.1 11
8W - 91 - 12 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
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CAUTION: Squirt approximately one teaspoon of oil
into the cylinders, rotate engine to lubricate the cyl-
inder walls to prevent damage on restart.
(8) Install new spark plugs.
(9) Drain engine oil and remove oil filter.
(10) Install a new oil filter.
(11) Fill engine with specified amount of approved
oil.
(12) Connect negative battery cable.
(13) Start engine and check for any leaks.
STANDARD PROCEDURE - FORM-IN-PLACE
GASKETS AND SEALERS
There are numerous places where form-in-place
gaskets are used on the engine. Care must be taken
when applying form-in-place gaskets to assure
obtaining the desired results.Do not use form-in-
place gasket material unless specified.Bead size,
continuity, and location are of great importance. Too
thin a bead can result in leakage while too much can
result in spill-over which can break off and obstruct
fluid feed lines. A continuous bead of the proper
width is essential to obtain a leak-free gasket.
There are numerous types of form-in-place gasket
materials that are used in the engine area. Mopart
Engine RTV GEN II, MopartATF-RTV, and Mopart
Gasket Maker gasket materials, each have different
properties and can not be used in place of the other.
MOPARtENGINE RTV GEN IIis used to seal
components exposed to engine oil. This material is a
specially designed black silicone rubber RTV that
retains adhesion and sealing properties when
exposed to engine oil. Moisture in the air causes the
material to cure. This material is available in three
ounce tubes and has a shelf life of one year. After one
year this material will not properly cure. Always
inspect the package for the expiration date before
use.
MOPARtATF RTVis a specifically designed
black silicone rubber RTV that retains adhesion and
sealing properties to seal components exposed to
automatic transmission fluid, engine coolants, and
moisture. This material is available in three ounce
tubes and has a shelf life of one year. After one year
this material will not properly cure. Always inspect
the package for the expiration date before use.
MOPARtGASKET MAKERis an anaerobic type
gasket material. The material cures in the absence of
air when squeezed between two metallic surfaces. It
will not cure if left in the uncovered tube. The
anaerobic material is for use between two machined
surfaces. Do not use on flexible metal flanges.
MOPARtBED PLATE SEALANTis a unique
(green-in-color) anaerobic type gasket material that
is specially made to seal the area between the bed-plate and cylinder block without disturbing the bear-
ing clearance or alignment of these components. The
material cures slowly in the absence of air when
torqued between two metallic surfaces, and will rap-
idly cure when heat is applied.
MOPARtGASKET SEALANTis a slow drying,
permanently soft sealer. This material is recom-
mended for sealing threaded fittings and gaskets
against leakage of oil and coolant. Can be used on
threaded and machined parts under all tempera-
tures. This material is used on engines with multi-
layer steel (MLS) cylinder head gaskets. This
material also will prevent corrosion. MopartGasket
Sealant is available in a 13 oz. aerosol can or 4oz./16
oz. can w/applicator.
SEALER APPLICATION
MopartGasket Maker material should be applied
sparingly 1 mm (0.040 in.) diameter or less of sealant
to one gasket surface. Be certain the material sur-
rounds each mounting hole. Excess material can eas-
ily be wiped off. Components should be torqued in
place within 15 minutes. The use of a locating dowel
is recommended during assembly to prevent smear-
ing material off the location.
MopartEngine RTV GEN II or ATF RTV gasket
material should be applied in a continuous bead
approximately 3 mm (0.120 in.) in diameter. All
mounting holes must be circled. For corner sealing, a
3.17 or 6.35 mm (1/8 or 1/4 in.) drop is placed in the
center of the gasket contact area. Uncured sealant
may be removed with a shop towel. Components
should be torqued in place while the sealant is still
wet to the touch (within 10 minutes). The usage of a
locating dowel is recommended during assembly to
prevent smearing material off the location.
MopartGasket Sealant in an aerosol can should be
applied using a thin, even coat sprayed completely
over both surfaces to be joined, and both sides of a
gasket. Then proceed with assembly. Material in a
can w/applicator can be brushed on evenly over the
sealing surfaces. Material in an aerosol can should be
used on engines with multi-layer steel gaskets.
STANDARD PROCEDURE - ENGINE GASKET
SURFACE PREPARATION
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.
Neveruse the following to clean gasket surfaces:
²Metal scraper
²Abrasive pad or paper to clean cylinder block
and head
²High speed power tool with an abrasive pad or a
wire brush (Fig. 3)
RSENGINE 2.4L9-11
ENGINE 2.4L (Continued)
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AIR CLEANER ELEMENT
REMOVAL
(1) Unsnap 2 clips.
(2) Lift cover and pull toward the engine and
remove cover tabs from air box.
(3) Lift cover and remove the element (Fig. 11).
INSTALLATION
(1) Install the air filter element into air box (Fig.
11).
(2) Move cover so that the tabs insert into the air
box.
(3) Push cover down and snap the 2 clips.
AIR CLEANER HOUSING
REMOVAL
(1) Disconnect the negative battery cable.
(2) Disconnect the inlet air temperature sensor
(Fig. 12).
(3) Remove the inlet hose to throttle body (Fig. 11).
(4) Remove the bolt for air box at upper radiator
cross member.
(5) Pull air box up and off over the single locating
pin.
(6) Remove air box from vehicle
INSTALLATION
(1) Install air box into vehicle and onto the locat-
ing pin.(2) Install bolt to hold air box to the upper radia-
tor cross member.
(3) Install the inlet hose to the throttle body.
(4) Connect the inlet air temperature sensor (Fig.
12).
(5) Connect the negative battery cable.
CYLINDER HEAD
DESCRIPTION
The cross flow designed, aluminum cylinder head
contains dual over-head camshafts with four valves
per cylinder (Fig. 13). The valves are arranged in two
in-line banks. The intake valves face toward the
front of the vehicle. The exhaust valves face the dash
panel. The cylinder head incorporates powdered
metal valve guides and seats. The cylinder head is
sealed to the block using a multi-layer steel head
gasket and retaining bolts.
Integral oil galleries provide lubrication passages
to the hydraulic lash adjusters, camshafts, and valve
mechanisms.
OPERATION
The cylinder head closes the combustion chamber,
allowing the pistons to compress the fuel/air mixture
for ignition. The valves are actuated by the lobe pro-
files on the camshaft to open and close at specified
duration to either allow clean air in the combustion
chamber or the exhaust gases out; depending on the
stroke of the engine.
DIAGNOSIS AND TESTINGÐCYLINDER HEAD
GASKET
A cylinder head gasket leak can be located between
adjacent cylinders or between a cylinder and the
adjacent water jacket.
Fig. 11 AIR BOX COVER
Fig. 12 IAT SENSOR 2.4L
9 - 24 ENGINE 2.4LRS
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(2) Make certain oil holes in block line up with oil
hole in bearings and bearing tabs seat in the block
tab slots.
CAUTION: Do not get oil on the bedplate mating
surface. It will affect the sealer ability to seal the
bedplate to cylinder block.
(3) Oil the bearings and journals. Install crank-
shaft.
CAUTION: Use only the specified anaerobic sealer
on the bedplate or damage may occur to the
engine.
(4) Apply 1.5 to 2.0 mm (0.059 to 0.078 in.) bead of
MopartBed Plate Sealant to cylinder block as shown
in (Fig. 51).
(5) Install lower main bearings into main bearing
cap/bedplate. Make certain the bearing tabs are
seated into the bedplate slots. Install the main bear-
ing/bedplate into engine block.
(6) Before installing the bolts the threads should
be oiled with clean engine oil, wipe off any excess oil.(7) Install main bearing bedplate to engine block
bolts 11, 17, and 20 finger tight. Tighten these bolts
down together until the bedplate contacts the cylin-
der block.
(8) To ensure correct thrust bearing alignment,
perform the following steps:
²Step 1: Rotate crankshaft until number 4 piston
is at TDC.
²Step 2: Move crankshaft rearward to limits of
travel.
²Step 3: Then, move crankshaft forward to limits
of travel.
²Step 4: Wedge an appropriate tool between the
rear of the cylinder block(NOT BED PLATE)and
the rear crankshaft counterweight. This will hold the
crankshaft in it's furthest forward position.
²Step 5: Install and tighten bolts (1±10) in
sequence shown in (Fig. 52) to 41 N´m (30 ft. lbs.).
²Step 6: Remove wedge tool used to hold crank-
shaft.
(9) Tighten bolts (1±10) again to 41 N´m (30 ft.
lbs.) in sequence shown in (Fig. 52).
CAUTION: Do Not use a torque wrench for the fol-
lowing step.
(10) Turn bolts (1±10) an additional 1/4 turn in
sequence shown in (Fig. 52).
(11) Install main bearing bedplate to engine block
bolts (11±20), and torque each bolt to 28 N´m (250 in.
lbs.) in sequence shown in (Fig. 52).
(12) Tighten bolts (11±20) again to 28 N´m (250 in.
lbs.) in sequence shown in (Fig. 52).
(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) 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.
(15) Install balance shafts and housing assembly.
(Refer to 9 - ENGINE/VALVE TIMING/BALANCE
SHAFT - INSTALLATION)
(16) Install the oil pump. (Refer to 9 - ENGINE/
LUBRICATION/OIL PUMP - INSTALLATION)
(17) Install cylinder head if it was removed (Refer
to 9 - ENGINE/CYLINDER HEAD - INSTALLA-
TION).
(18) Install the timing belt rear cover. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION)
(19) Install crankshaft sprocket (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - INSTALLATION).
(20) Install the timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION)
Fig. 51 Bedplate Sealing
Fig. 52 Bedplate Bolt Torque Sequence
9 - 40 ENGINE 2.4LRS
CRANKSHAFT (Continued)
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(21) Install the timing belt front covers. (Refer to 9
- ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION)
(22) Install engine mount support bracket.
(23) Install the oil pan. (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - INSTALLATION)
(24) Install the oil filter.
(25) Install crankshaft rear oil seal. (Refer to 9 -
ENGINE/ENGINE BLOCK/CRANKSHAFT OIL
SEAL - REAR - INSTALLATION)
(26) Install flex plate. Apply MopartLock & Seal
Adhesive to bolt threads and tighten to 95 N´m (70
ft. lbs.).
(27) Attach transaxle to engine. Tighten attaching
bolts to 101 N´m (75 ft. lbs.).
(28) Install the engine assembly. (Refer to 9 -
ENGINE - INSTALLATION)
CRANKSHAFT MAIN
BEARINGS
STANDARD PROCEDURE - MAIN BEARING -
FITTING
For crankshaft specifications (Refer to 9 - ENGINE
- SPECIFICATIONS).
CRANKSHAFT MAIN BEARINGS
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. 53).
Upper and lower Number 3 bearing halves are
flanged to carry the crankshaft thrust loads and are
NOT interchangeable with any other bearing halves
in the engine (Fig. 53). All bearing cap bolts removed
during 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.
MAIN BEARING INSTALLATION
(1) Install the main bearing shells with the lubri-
cation groove in the cylinder block (Fig. 54).
(2) Make certain oil holes in block line up with oil
holes in bearings. Bearing tabs must seat in the
block tab slots.
CAUTION: Do not get oil on the bedplate mating
surface. It will may effect the sealer ability to seal
the bedplate to cylinder block.(3) Oil the bearings and journals and install
crankshaft.
CAUTION: Use only the specified anaerobic sealer
on the bedplate or damage may occur to the
engine. Ensure that both cylinder block and bed-
plate surfaces are clean.
(4) Apply 1.5 to 2.0 mm (0.059 to 0.078 in.) bead
of anaerobic sealer MopartBed Plate Sealant to cyl-
inder block as shown in (Fig. 55).
(5) Install lower main bearings into main bearing
cap/bedplate. Make certain the bearing tabs are
seated into the bedplate slots.
Fig. 53 Main Bearing Identification
1 - OIL GROOVE
2 - MAIN BEARINGS
3 - OIL HOLE
Fig. 54 Installing Main Bearing Upper Shell
1 - LUBRICATION GROOVES
2 - OIL HOLES
RSENGINE 2.4L9-41
CRANKSHAFT (Continued)
ProCarManuals.com

MOPARtGASKET MAKERis an anaerobic type
gasket material. The material cures in the absence of
air when squeezed between two metallic surfaces. It
will not cure if left in the uncovered tube. The
anaerobic material is for use between two machined
surfaces. Do not use on flexible metal flanges.
MOPARtBED PLATE SEALANTis a unique
(green-in-color) anaerobic type gasket material that
is specially made to seal the area between the bed-
plate and cylinder block without disturbing the bear-
ing clearance or alignment of these components. The
material cures slowly in the absence of air when
torqued between two metallic surfaces, and will rap-
idly cure when heat is applied.
MOPARtGASKET SEALANTis a slow drying,
permanently soft sealer. This material is recom-
mended for sealing threaded fittings and gaskets
against leakage of oil and coolant. Can be used on
threaded and machined parts under all tempera-
tures. This material is used on engines with multi-
layer steel (MLS) cylinder head gaskets. This
material also will prevent corrosion. MopartGasket
Sealant is available in a 13 oz. aerosol can or 4oz./16
oz. can w/applicator.
SEALER APPLICATION
MopartGasket Maker material should be applied
sparingly 1 mm (0.040 in.) diameter or less of sealant
to one gasket surface. Be certain the material sur-
rounds each mounting hole. Excess material can eas-
ily be wiped off. Components should be torqued in
place within 15 minutes. The use of a locating dowel
is recommended during assembly to prevent smear-
ing material off the location.
MopartEngine RTV GEN II or ATF RTV gasket
material should be applied in a continuous bead
approximately 3 mm (0.120 in.) in diameter. All
mounting holes must be circled. For corner sealing, a
3.17 or 6.35 mm (1/8 or 1/4 in.) drop is placed in the
center of the gasket contact area. Uncured sealant
may be removed with a shop towel. Components
should be torqued in place while the sealant is still
wet to the touch (within 10 minutes). The usage of a
locating dowel is recommended during assembly to
prevent smearing material off the location.
MopartGasket Sealant in an aerosol can should be
applied using a thin, even coat sprayed completely
over both surfaces to be joined, and both sides of a
gasket. Then proceed with assembly. Material in a
can w/applicator can be brushed on evenly over the
sealing surfaces. Material in an aerosol can should be
used on engines with multi-layer steel gaskets.
STANDARD PROCEDURE - ENGINE GASKET
SURFACE PREPARATION
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.
Neveruse the following to clean gasket surfaces:
²Metal scraper
²Abrasive pad or paper to clean cylinder block
and head
²High speed power tool with an abrasive pad or a
wire brush (Fig. 4)
NOTE: Multi-Layer Steel (MLS) head gaskets require
a scratch free sealing surface.
Only use the following for cleaning gasket surfaces:
²Solvent or a commercially available gasket
remover
²Plastic or wood scraper (Fig. 4)
²Drill motor with 3M RolocŸ Bristle Disc (white
or yellow) (Fig. 4)
CAUTION: Excessive pressure or high RPM (beyond
the recommended speed), can damage the sealing
surfaces. The mild (white, 120 grit) bristle disc is
recommended. If necessary, the medium (yellow, 80
grit) bristle disc may be used on cast iron surfaces
with care.
Fig. 4 Proper Tool Usage For Surface Preparation
1 - ABRASIVE PAD
2 - 3M ROLOCŸ BRISTLE DISC
3 - PLASTIC/WOOD SCRAPER
RSENGINE 3.3/3.8L9-85
ENGINE 3.3/3.8L (Continued)
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