2002 CHRYSLER CARAVAN cooling

(6) Install the accessory drive belt. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION)
(7) Install inner splash shield and right front
wheel.
(8) Connect negative cable to battery.
ENGINE MOUNTING
DESCRIPTION
The engine mounting system consist of four
mounts; right and a left side support the powertrain,
and a front and a rear mount control powertrain
torque. The right side mount is a hydro-type (Fig.
91), all others are of molded rubber material.
FRONT MOUNT
REMOVAL
(1) Support the engine and transmission assembly
with a floor jack so it will not rotate.
(2) Remove the front engine mount through bolt
from the insulator and front crossmember mounting
bracket (Fig. 92).
(3) Remove six screws from air dam to allow
access to the front mount screws.
(4) Remove the front engine mount screws and
remove the insulator assembly (Fig. 92).
(5) Remove the front mounting bracket, if neces-
sary (Fig. 92).
INSTALLATION
(1) Install the front mounting bracket, if removed
(Fig. 92).
(2) Install the front engine mount through bolt
from the insulator and front crossmember mounting
bracket (Fig. 92).
(3) Install the insulator assembly and mounting
screws (Fig. 92).
Fig. 90 Vibration Damper - Installation
1 - FORCING SCREW / NUT FROM SPECIAL TOOL 8452
2 - VIBRATION DAMPER
3 - THRUST BEARING / WASHER
Fig. 91 Engine Hydro-type Mount - Right Side
1 - BOLT
2 - BOLT
3 - FRAME RAIL
4 - RIGHT MOUNT - 2.4L ENGINE
5 - RIGHT MOUNT - 3.3/3.8L ENGINE
RSENGINE 3.3/3.8L9 - 133
VIBRATION DAMPER (Continued)
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OIL COOLER & LINES
DESCRIPTION
An engine oil cooler is used on 3.3/3.8L engines
(Heavy Duty Cooling Only) (Fig. 104). The cooler is a
coolant-to-oil type and mounted between the oil filter
and engine block.
OPERATION
Engine oil travels from the oil filter and into the
oil cooler. Engine oil then exits the cooler into the
main gallery. Engine coolant flows into the cooler
from the heater return tube and exits into the water
pump inlet.
REMOVAL
(1) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE - COOLING SYSTEM
DRAINING).
(2) Disconnect oil cooler inlet and outlet hoses
(Fig. 103).
(3) Remove oil filter.
(4) Remove oil cooler attachment fitting (Fig. 104).
(5) Remove oil cooler.
INSTALLATION
(1) Lubricate seal and position oil cooler to connec-
tor fitting on oil filter adapter (Fig. 104).
NOTE: Position the flat side of oil cooler parallel to
oil pan rail.(2) Install oil cooler attachment fitting and tighten
to 27 N´m (20 ft. lbs.) (Fig. 104).
(3) Install oil filter.
(4) Connect oil cooler inlet and outlet hoses (Fig.
103).
(5) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE - COOLING SYSTEM
FILLING).
OIL FILTER
REMOVAL
CAUTION: When servicing the oil filter avoid
deforming the filter can by installing the remove/in-
stall tool band strap against the can-to-base lock
seam. The lock seam joining the can to the base is
reinforced by the base plate.
(1) Using suitable oil filter wrench, turn filter
counterclockwise to remove from oil filter adapter
(Fig. 105). Properly discard used oil filter.
INSTALLATION
(1) Wipe oil filter adapter base clean and inspect
gasket contact surface.
(2) Lubricate gasket of new filter with clean
engine oil.
(3) Install new filter until gasket contacts base
(Fig. 105). Tighten filter 1 turn or 20 N´m (15 ft.
lbs.). Use filter wrench if necessary.
(4) Start engine and check for leaks.
Fig. 103 Engine Oil Cooler Hoses
1 - OIL COOLER INLET TUBE
2 - INLET HOSE
3 - OIL COOLER OUTLET TUBE
4 - OUTLET HOSE
5 - WATER PUMP INLET TUBE
Fig. 104 Engine Oil Cooler - 3.3/3.8L (Heavy Duty
Cooling)
1 - OIL FILTER ADAPTER
2 - CONNECTOR
3 - ENGINE OIL COOLER
4 - OIL COOLER ATTACHMENT FITTING
5 - OIL FILTER
9 - 140 ENGINE 3.3/3.8LRS
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(11) Install air cleaner and air inlet hose assembly.
(12) Connect the inlet air temperature (IAT) sen-
sor electrical connector.
(13) Connect battery negative cable.
INTAKE MANIFOLD - LOWER
REMOVAL - LOWER INTAKE MANIFOLD
(1) Perform fuel system pressure release procedure
(before attempting any repairs).(Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY - STANDARD
PROCEDURE)
(2) Drain the cooling system. (Refer to 7 - COOL-
ING - STANDARD PROCEDURE)
(3) Remove the upper intake manifold. (Refer to 9
- ENGINE/MANIFOLDS/INTAKE MANIFOLD -
REMOVAL)
(4) Remove the fuel line. (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/FUEL LINES - STANDARD
PROCEDURE) (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY/QUICK CONNECT FITTING - STAN-
DARD PROCEDURE)
(5) Remove ignition coil and bracket (Fig. 125).
(6) Disconnect heater supply hose and engine cool-
ant temperature sensor (Fig. 126).
(7) Disconnect the fuel injector wire harness.
(8) Remove the fuel injectors and rail assembly
(Fig. 125).
(9) Remove radiator upper hose.
(10) Remove the intake manifold bolts.
(11) Remove lower intake manifold (Fig. 127).
WARNING: INTAKE MANIFOLD GASKET IS MADE
OF VERY THIN METAL AND MAY CAUSE PER-
SONAL INJURY, HANDLE WITH CARE.
(12) Remove intake manifold seal retainers screws
(Fig. 127). Remove intake manifold gasket.
(13) Inspect and clean manifold. (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSPECTION) (Refer to 9 - ENGINE/MANIFOLDS/
INTAKE MANIFOLD - CLEANING)
CLEANING
(1) Discard gasket(s).
(2) Clean all sealing surfaces.
INSPECTION
Check for:
²Damage and cracks of each section.
²Clogged water passages in end cross-overs (if
equipped).
²Check for cylinder head mounting surface distor-
tion using a straightedge and thickness gauge. (Refer
to 9 - ENGINE/CYLINDER HEAD - INSPECTION)
INSTALLATION - LOWER INTAKE MANIFOLD
(1) Place a bead (approximately 1/4 in. diameter)
of MopartEngine RTV GEN II onto each of thefour
manifold to cylinder head gasket corners (Fig. 128).
(2) Carefully install the new intake manifold gas-
ket (Fig. 127). Tighten end seal retainer screws to 12
N´m (105 in. lbs.).
(3) Install lower intake manifold (Fig. 127). Install
the bolts and torque to 1 N´m (10 in. lbs.). Then
torque bolts to 22 N´m (200 in. lbs.) in sequence
shown in (Fig. 129). Then torque again to 22 N´m
(200 in. lbs.). After intake manifold is in place,
inspect to make sure seals are in place.
(4) Install the fuel injectors and rail assembly.
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/
FUEL RAIL - INSTALLATION)
(5) Connect fuel injector electrical harness.
Fig. 125 FUEL RAIL AND IGNITION COIL &
BRACKET
1 - FUEL RAIL
2 - BOLT - FUEL RAIL
3 - NUT - IGNITION COIL
4 - BOLT - IGNITION COIL
5 - IGNITION COIL
6 - BRACKET - IGNITION COIL
7 - STUD - IGNITION COIL
8 - SEPARATOR - SPARK PLUG CABLE
9 - BRACKET - SPARK PLUG CABLE SEPARATOR
10 - BOLT - SEPARATOR BRACKET
11 - BRACKET - SPARK PLUG CABLE SEPARATOR
9 - 150 ENGINE 3.3/3.8LRS
INTAKE MANIFOLD - UPPER (Continued)
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(6) Connect the engine coolant temperature sensor
(Fig. 126).
(7) Connect the heater supply (Fig. 126) and radi-
ator upper hoses to manifold.
(8) Connect the fuel line. (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/QUICK CONNECT FIT-
TING - STANDARD PROCEDURE)
(9) Install the upper intake manifold. (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSTALLATION)
(10) Connect negative battery cable.
(11) Fill the cooling system. (Refer to 7 - COOL-
ING - STANDARD PROCEDURE)
Fig. 126 ECT SENSOR & HEATER SUPPLY
1 - ENGINE COOLANT TEMPERATURE SENSOR
2 - CONNECTOR - ENGINE COOLANT SENSOR
3 - FITTING - HEATER SUPPLY
Fig. 127 INTAKE MANIFOLD - LOWER
1 - INTAKE MANIFOLD - LOWER
2 - BOLT - GASKET END SEAL RETAINER
3 - GASKET
4 - BOLT - LOWER INTAKE MANIFOLD
Fig. 128 Intake Manifold Gasket Sealing
1 - SEALER LOCATIONS
RSENGINE 3.3/3.8L9 - 151
INTAKE MANIFOLD - LOWER (Continued)
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(3) Position heat shield on manifold (Fig. 136).
(4) Install the remaining manifold attaching bolts.
Tighten all bolts to 23 N´m (200 in. lbs.).
(5) Install and tighten heat shield attaching nut to
12 N´m (105 in. lbs.) (Fig. 136).
(6) Connect battery negative cable.
VALVE TIMING
STANDARD PROCEDURE
STANDARD PROCEDURE - VALVE TIMING
VERIFICATION
(1) Remove front cylinder head cover and all 6
spark plugs.
(2) Rotate engine until the #2 piston is at TDC of
the compression stroke.
(3) Install a degree wheel on the crankshaft pulley.
(4) With proper adaptor, install a dial indicator
into #2 spark plug hole. Using the indicator find TDC
on the compression stroke.
(5) Position the degree wheel to zero.
(6) Remove dial indicator from spark plug hole.
(7) Place a 5.08 mm (0.200 in.) spacer between the
valve stem tip of #2 intake valve and rocker arm pad.
Allow tappet to bleed down to give a solid tappet
effect.
(8) Install a dial indicator so plunger contacts the
#2 intake valve spring retainer as nearly perpendic-
ular as possible. Zero the indicator.
(9) Rotate the engine clockwise until the intake
valve has lifted .254 mm (0.010 in.).
CAUTION: Do not turn crankshaft any further clock-
wise as intake valve might bottom and result in
serious damage.
(10) Degree wheel should read 6 degrees BTDC to
6 degrees ATDC.
STANDARD PROCEDURE - MEASURING
TIMING CHAIN WEAR
NOTE: This procedure must be performed with the
timing chain cover removed (Refer to 9 - ENGINE/
VALVE TIMING/TIMING CHAIN COVER - REMOVAL).
(1) Position a scale next to timing chain so that
any movement of chain may be measured (Fig. 138).
(2) Position a torque wrench and socket on the
camshaft sprocket attaching bolt. Apply force in the
direction of crankshaft rotation to take up slack to
the following torque:
²41 N´m (30 ft. lb.) with cylinder heads installed
²20 N´m (15 ft. lb.) with cylinder heads removedNOTE: With torque applied to the camshaft
sprocket bolt, crankshaft should not be permitted to
move. It may be necessary to block crankshaft to
prevent rotation.
(3) Holding a measuring scale along edge of chain
links (Fig. 138).
(4) Apply force in the reverse direction to the fol-
lowing torque:
²41 N´m (30 ft. lb.) with cylinder heads installed
²20 N´m (15 ft. lb.) with cylinder heads removed
(5) Measure amount of sprocket/chain movement.
(6) Install a new timing chain and sprockets if
movement exceeds 3.175 mm (1/8 in.).
TIMING CHAIN COVER
REMOVAL
(1) Disconnect negative cable from battery.
(2) Drain cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(3) Raise vehicle on hoist.
(4) Drain engine oil.
(5) Remove right wheel and inner splash shield.
(6) Remove oil pan. (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - REMOVAL)
(7) Remove oil pick-up tube (Fig. 139).
(8) Remove accessory drive belt. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)
(9) Remove A/C compressor and set aside.
(10) Remove crankshaft vibration damper. (Refer
to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL)
(11) Remove radiator lower hose.
Fig. 138 Measuring Timing Chain Wear
1 - TORQUE WRENCH
RSENGINE 3.3/3.8L9 - 155
EXHAUST MANIFOLD - LEFT (Continued)
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(12) Remove heater hose from timing chain cover
housing (Fig. 140) or water pump inlet tube (if
engine oil cooler equipped) (Fig. 141).
(13) Remove the right side engine mount. (Refer to
9 - ENGINE/ENGINE MOUNTING/RIGHT MOUNT
- REMOVAL)
(14) Remove idler pulley from engine bracket (Fig.
142).
(15) Remove the engine mount bracket (Fig. 142).
(16) Remove camshaft position sensor from timing
chain cover (Fig. 142).
(17) Remove the water pump for cover removal
clearance. (Refer to 7 - COOLING/ENGINE/WATER
PUMP - REMOVAL)
(18) Remove the bolt attaching the power steering
pump support strut to the front cover (Fig. 143).
(19) Remove the timing chain cover fasteners.
Remove timing chain cover (Fig. 144).
INSTALLATION
(1) Be sure mating surfaces of chain case cover
and cylinder block are clean and free from burrs.
Crankshaft oil seal must be removed to insure cor-
rect oil pump engagement.
NOTE: DO NOT USE SEALER ON COVER GASKET
(2) Position new gasket on timing cover (Fig. 144).
Adhere new gasket to chain case cover, making sure
that the lower edge of the gasket is flush to 0.5 mm
(0.020 in.) passed the lower edge of the cover.
Fig. 139 OIL PICKUP TUBE
1 - BOLT
2 - OIL PICK-UP TUBE
3 - O-RING
Fig. 140 HEATER RETURN HOSE (Without Engine
Oil Cooler)
1 - CAP AND CLAMP (OIL COOLER EQUIPPED ONLY)
2 - HOSE ASSEMBLY - HEATER RETURN
3 - BOLT - HEATER TUBE ATTACHING
4 - BOLT - HEATER TUBE ATTACHING
Fig. 141 HEATER HOSES 3.3/3.8L (With Engine Oil
Cooler)
1 - HOSE - HEATER SUPPLY
2 - HOSE - HEATER RETURN
3 - TUBE ASSEMBLY - HEATER RETURN
4 - BOLT - TUBE ASSEMBLY
5 - BOLT - TUBE ASSEMBLY
6 - HOSE - HEATER RETURN/OIL COOLER OUTLET
9 - 156 ENGINE 3.3/3.8LRS
TIMING CHAIN COVER (Continued)
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(3) Rotate crankshaft so that the oil pump drive
flats are in the vertical position.
(4) Position oil pump inner rotor so the mating
flats are in the same position as the crankshaft drive
flats (Fig. 144).CAUTION: Make sure the oil pump is engaged on
the crankshaft correctly or severe damage may
result.
(5) Install timing cover (Fig. 144).
(6) Install timing chain cover bolts. Tighten M8
bolts to 27 N´m (20 ft. lbs.) and M10 bolts to 54 N´m
(40 ft. lbs.) (Fig. 145).
(7) Install crankshaft front oil seal. (Refer to 9 -
ENGINE/ENGINE BLOCK/CRANKSHAFT OIL
SEAL - FRONT - INSTALLATION)
(8) Install water pump and pulley. (Refer to 7 -
COOLING/ENGINE/WATER PUMP - INSTALLA-
TION)
(9) Install crankshaft vibration damper. (Refer to 9
- ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
INSTALLATION)
(10) Install engine mount bracket (Fig. 142) and
tighten M10 to 54 N´m (40 ft. lbs.), M8 bolt to 28
N´m (21 ft. lb. lbs.).
(11) Install idler pulley on engine mount bracket
(Fig. 142).
(12) Install right side engine mount. (Refer to 9 -
ENGINE/ENGINE MOUNTING/RIGHT MOUNT -
INSTALLATION)
(13) Install camshaft position sensor (Refer to 8 -
ELECTRICAL/IGNITION CONTROL/CAMSHAFT
POSITION SENSOR - INSTALLATION).
(14) Connect the heater return hose at rear of tim-
ing chain cover (Fig. 140) or at water pump inlet
tube (if engine oil cooler equipped) (Fig. 141).
(15) Connect the radiator lower hose.
(16) Install A/C compressor.
(17) Install accessory drive belt. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION)
Fig. 142 Engine Mount Bracket
1 - CAMSHAFT SENSOR
2 - BOLT - CAMSHAFT SENSOR
3 - BOLT - MOUNT BRACKET (VERTICAL)
4 - BRACKET - ENGINE MOUNT
5 - BOLT - MOUNT BRACKET (HORIZONTAL)
6 - PULLEY - IDLER
7 - BOLT - IDLER PULLEY
8 - SPACER - IDLER PULLEY BOLT
9 - BOLT - MOUNT BRACKET (HORIZONTAL)
Fig. 143 Power Steering Pump Strut
1 - BOLT - LOWER
2 - STRUT - P/S PUMP
3 - BOLT - UPPER
Fig. 144 Timing Chain Cover and Gasket
1 - GASKET
2 - TIMING CHAIN COVER
RSENGINE 3.3/3.8L9 - 157
TIMING CHAIN COVER (Continued)
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(18) Install oil pump pick-up tube with new
O-ring. Tighten attaching bolt to 28 N´m (250 in.
lbs.).
(19) Install oil pan. (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION)
(20) Install inner splash shield and right front
wheel.(21) Fill crankcase with engine oil to proper level.
(22) Fill cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(23) Connect negative cable to battery.
Fig. 145 TIMING CHAIN COVER BOLT LOCATIONS
1 - BOLT - M8 x 1.25 x 95 4 - BOLT - M8 x 1.25 x 80
2 - BOLT - M10 x 1.5 x 100 5 - BOLT - M8 x 1.25 x 45
3 - BOLT - M10 x 1.5 x 85
9 - 158 ENGINE 3.3/3.8LRS
TIMING CHAIN COVER (Continued)
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