2002 CHRYSLER CARAVAN cooling

INSTALLATION
INSTALLATION.......................47
INSTALLATION.......................48
OIL PRESSURE SENSOR/SWITCH
DESCRIPTION.........................48
REMOVAL.............................48
INSTALLATION.........................48
OIL TEMPERATURE SENSOR
DESCRIPTION.........................48
REMOVAL.............................48
INSTALLATION.........................48
OIL PRESSURE RELIEF VALVE
DESCRIPTION.........................49
REMOVAL.............................49
INSTALLATION.........................49
OIL COOLER & LINES
REMOVAL.............................50
INSTALLATION.........................50
OIL FILTER
DESCRIPTION.........................51
REMOVAL.............................51
INSTALLATION.........................51
OIL JET
DESCRIPTION.........................52
REMOVAL.............................52
INSTALLATION.........................52
INTAKE MANIFOLD
DESCRIPTION.........................52
REMOVAL.............................52INSTALLATION.........................52
VALVE TIMING
STANDARD PROCEDURE - LOCKING ENGINE
90É AFTER TDC.......................53
BALANCE SHAFT
DESCRIPTION.........................54
OPERATION...........................54
REMOVAL.............................55
INSTALLATION.........................55
TIMING BELT / CHAIN COVER(S)
REMOVAL
REMOVAL - TIMING BELT OUTER COVER . . 56
REMOVAL - TIMING BELT INNER COVER . . . 56
INSTALLATION
INSTALLATION - TIMING BELT OUTER
COVER.............................56
INSTALLATION - TIMING BELT INNER
COVER.............................57
TIMING BELT IDLER PULLEY
REMOVAL.............................58
INSTALLATION.........................58
TMNG BELT/CHAIN TENSIONER
REMOVAL.............................59
INSTALLATION.........................59
ADJUSTMENTS
ADJUSTMENT - TIMING BELT TENSIONER . 60
TIMING BELT/CHAIN AND SPROCKETS
REMOVAL.............................60
INSTALLATION.........................61
ENGINE 2.5L TURBO DIESEL
DESCRIPTION
DESCRIPTION - 2.5L COMMON RAIL DIESEL
ENGINE
This 2.5 Liter (2500cc) four-cylinder ªcommon railº
direct injection engine is an in-line overhead valve
diesel engine. This engine utilizes a cast iron cylin-
der block and an aluminum cylinder head. The
engine is turbocharged and intercooled. The engine
also has four valves per cylinder and dual overhead
camshafts (Fig. 1).
DESCRIPTION SPECIFICATION
Displacement 2.5L (2499 cc)
Bore 92.00
Stroke 94.00
Compression Ratio 17.5:1
Vacuum at Idle 685.8 mm/Hg (27.0
In/Hg)
Belt Tension Automatic Belt Tensioner
DESCRIPTION SPECIFICATION
Thermostat Opening 80ÉC   2ÉC
Generator Rating Denso 12V-95A
Cooling System Capacity 13.8 Liters W/O Auxiliary
Heater
16.6 Liters With Auxiliary
Heater
Engine Oil Capacity 6.0L W/Filter Change
Timing System Belt Driven Camshafts In
Cylinder Head Cover
Air Intake Dry Filter
Fuel Feed Vane Pump Incorporated
In Injection Pump
Fuel System Direct Fuel Injection
Combustion Cycle 4 Stroke
Cooling System Water Cooling
Injection Pump Rotary Pump and
Electronically Managed
Lubrication Pressure Lubricated By
Rotary Pump
Engine Rotation Clockwise Viewed From
Front Cover
9a - 2 ENGINERG
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DESCRIPTION - ENGINE COVER
The engine cover is a black plastic cover used to
cover the top of the engine (Fig. 10). It is used to iso-
late engine noises.
REMOVAL
REMOVAL - 2.5L DIESEL ENGINE
(1) Disconnect negative battery cable.
(2) Remove engine cover (Fig. 2). (Refer to 9 -
ENGINE - REMOVAL)
(3) Remove air cleaner housing, MAF sensor, and
air intake tube assembly (Fig. 3).
(4) Remove coolant pressure tank pressure cap.
(5) Raise vehicle on hoist.
(6) Drain cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(7) Remove lower splash shield.
(8) Remove splash shield side panels.
Fig. 1 2.5L COMMON RAIL DIESEL ENGINE
Fig. 2 ENGINE COVER
1 - ENGINE COVER MOUNTING BOLTS
2 - ENGINE COVER
Fig. 3 MASS AIR FLOW (MAF) SENSOR LOCATION
1 - MAF SENSOR ELECTRICAL CONNECTOR
2 - RETAINING CLAMPS
3 - MASS AIR FLOW (MAF) SENSOR
4 - AIR CLEANER HOUSING
RGENGINE9a-3
ENGINE 2.5L TURBO DIESEL (Continued)
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(9) Remove power steering reservoir hose from
power steering pump and drain power steering fluid
(Fig. 4).
(10) Disconnect high pressure line at pump (Fig.
4).
(11) Disconnect power steering pump return hose
clamp (Fig. 4).
(12) Remove power steering return line retaining
clamp (Fig. 4).
(13) Remove power steering line clamps from oil
pan (Fig. 4).
(14) Remove power steering pump reservoir and
bracket (Fig. 4).(15) Drain coolant system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(16) Remove coolant pressure tank (Fig. 5).
Fig. 4 RESERVOIR AND HOSES - 2.5L DIESEL
1 - POWER STEERING FLUID RESERVOIR
2 - RESERVOIR BRACKET
3 - SUPPLY HOSE BRACKET
4 - RETURN HOSE FROM GEAR
5 - ROUTING CLIP
6 - PRESSURE HOSE TO GEAR
7 - SUPPLY HOSE (PUMP END)
8 - PRESSURE HOSE (PUMP END)
9 - SUPPLY HOSE
10 - RETURN HOSE
Fig. 5 COOLANT RECOVERY PRESSURE
CONTAINER LOCATION
1 - PRESSURE/VENT CAP
2 - BRAKE MASTER CYLINDER
3 - BATTERY
4 - BATTERY SHIELD
5 - COOLANT RECOVERY PRESSURE CONTAINER RETAING
CLIP
6 - ENGINE COVER
7 - COOLANT RECOVERY PRESSURE CONTAINER
9a - 4 ENGINERG
ENGINE 2.5L TURBO DIESEL (Continued)
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(17) Remove battery shield.
(18) Remove charge air cooler outlet hose.
(19) Remove charge air cooler inlet hose (Fig. 6).
(20) Disconnect upper radiator hose at engine (Fig.
7).
(21) Disconnect lower radiator hose at engine (Fig.
7).
(22) Disconnet brake booster vacuum supply hose.
(23) Disconnect heater core return hose at engine.
(24) Disconnect egr solenoid vacuum line at brake
booster check valve.
(25) Disconnect fuel injector, cam sensor, boost
pressure/intake air temp sensor, fuel rail high pres-
sure, and egr solenoid connectors (Fig. 8).
(26) Disconnect generator electrical connectors.
(27) Disconnect coolant temp sensor and glow plug
electrical connectors.
(28) Disconnect injection pump and A/C compres-
sor electrical connectors.
(29) Disconnect starter electrical connectors.
(30) Disconnect ground wires at engine block.
(31) Raise vehicle on hoist.
(32) Disconnect oil temp sensor, oil pressure sen-
sor, engine speed sensor, and vehicle speed sensor
electrical connector (Fig. 9).(33) Remove front wheels.
(34) Remove the suspension cradle assembly (Refer
to 13 - FRAME & BUMPERS/FRAME/ENGINE
CRADLE CROSSMEMBER - REMOVAL).
(35) Remove both axle shaft assemblies (Refer to 3
- DIFFERENTIAL & DRIVELINE/HALF SHAFT -
REMOVAL).
(36) Disconnect the clutch slave cylinder quick dis-
connect line (RHD only)(Refer to 6 - CLUTCH/SLAVE
CYLINDER - REMOVAL).
(37) Disconnect reverse lamp connector.
(38) Disconnect shifter cables at the tranmission
(Refer to 21 - TRANSMISSION/TRANSAXLE/MAN-
UAL/GEAR SHIFT CABLE - REMOVAL).
(39) Disconnect exhaust pipe from the turbo-
charger downpipe and reposition to right side of vehi-
cle.
(40) Disconnect cabin heater coolant line (Refer to
24 - HEATING & AIR CONDITIONING/CABIN
HEATER/HEATER UNIT - REMOVAL).
(41) Remove front engine mount bracket retaining
bolts from lower radiator support
(42) Lower vehicle. Evacuate the A/C system
(Refer to 24 - HEATING & AIR CONDITIONING/
Fig. 6 CHARGE AIR COOLER HOSES
1 - COOLING MODULE
2 - BYPASS HOSE
3 - UPPER RADIATOR HOSE
4 - CHARGE AIR COOLER OULET HOSE
5 - CHARGE AIR COOLER INLET HOSE
6 - LOWER RADIATOR HOSE
7 - CHARGE AIR COOLER
Fig. 7 UPPER AND LOWER RADIATOR HOSES
1 - COOLANT BYPASS HOSE
2 - RADIATOR ASSEMBLY
3 - UPPER RADIATOR HOSE
4 - COOLING FAN
5 - LOWER RADIATOR HOSE
6 - CHARGE AIR COOLER
7 - RADIATOR BRACKET
RGENGINE9a-5
ENGINE 2.5L TURBO DIESEL (Continued)
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INSTALLATION
INSTALLATION - 2.5L TURBO DIESEL ENGINE
(1) Reassembly engine and transmission assembly
and install on engine cradle.
(2) Position engine and cradle assembly under
vehicle.
(3) Slowly lower the vehicle down over the engine
and cradle assembly.
(4) Install right engine mount bolts. Torque to
54N´m (40 ft. lbs.)
(5) Install left engine mount through bolt. Torque
to 75N´m (55 ft. lbs.)
(6) Raise vehicle and engine from engine cradle.
(7) Attach front engine mount bracket to lower
radiator support. Torque to 54N´m (40 ft. lbs.)
(8) Connect cabin heater coolant hose.
(9) Connect exhaust pipe to the turbocharger
downpipe flange. Torque to 28 N´m (250 in. lbs.)
(10) Connect reverse lamp electrical connector at
transmission.
(11) Connect both shifter cables (Refer to 21 -
TRANSMISSION/TRANSAXLE/MANUAL/GEAR
SHIFT CABLE - INSTALLATION).
(12) Connect the clutch slave cylinder quick dis-
connect connector (RHD only)(Refer to 6 - CLUTCH/
SLAVE CYLINDER - INSTALLATION).
(13) Install engine harness into bracket on trans-
mission.
(14) Lower vehicle.
(15) Connect fuel supply and return lines.
(16) Connect A/C lines to A/C compressor. Torque
to 23N´m (17 ft. lbs.)
(17) Route engine wiring harnes to proper location.
(18) Connect engine harness ground cables to
engine block
(19) Connect starter solenoid electrical connector
and battery feed wire to starter. Torque to 10N´m (90
in. lbs.)
(20) Connect A/C compressor, injection pump, glow
plugs, and coolant temperature sensor electrical con-
nectors.
(21) Connect generator electrical connector. Torque
to 9N´m (75 in. lbs.)
(22) Connect the fuel injector, fuel pressure sensor,
boost pressure/intake air temp sensor, cam sensor,
and egr solenoid electrical connectors (Fig. 8).
(23) Connect egr solenoid vacuum supply line to
brake boost vacuum supply line.(24) Connect brake booster vacuum supply line.
(25) Connect heater core return hose to coolant
pipe.
(26) Connect lower radiator hose to engine (Fig. 7).
(27) Install charger air cooler inlet hose (Fig. 6).
(28) Install charge air cooler outlet hose (Fig. 6).
(29) Connect upper radiator hose to engine (Fig.
7).
(30) Install battery shield.
(31) Install coolant reserve pressure container
(Refer to 7 - COOLING/ENGINE/COOLANT RECOV-
ERY PRESS CONTAINER - INSTALLATION).
(32) Install power steering reservoir and bracket
(Fig. 4).
(33) Raise vehicle
(34) Connect oil pressure sensor, oil temperature
sensor, engine speed sensor, and vehicle speed sensor
electrical connector (Fig. 9).
(35) Install suspension cradle in vehicle (Refer to
13 - FRAME & BUMPERS/FRAME/ENGINE CRA-
DLE CROSSMEMBER - INSTALLATION).
(36) Install both axle shaft assemblies (Refer to 3 -
DIFFERENTIAL & DRIVELINE/HALF SHAFT -
INSTALLATION).
(37) Connect the power steering supply, pressure,
and return lines to power steering pump (Fig. 4).
(38) Install the power steering line brackets on oil
pan (Fig. 4).
(39) Install lower splash shield and side panels.
(40) Install both front wheel and tire assemblies.
(41) Lower vehicle.
(42) Install air cleaner housing, MAF sensor, and
air intake tube assembly (Fig. 3).
(43) Refill transmission to proper level (Refer to 21
- TRANSMISSION/TRANSAXLE/MANUAL/FLUID -
STANDARD PROCEDURE).
(44) Refill engine coolant (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(45) Recharge A/C system (Refer to 24 - HEATING
& AIR CONDITIONING/PLUMBING/REFRIGER-
ANT - STANDARD PROCEDURE) .
(46) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION) (Fig. 2).
(47) Connect negative battery cable.
INSTALLATION - ENGINE COVER
(1) Install engine cover on engine.
(2) Install the engine cover mounting bolts (Fig.
10).
RGENGINE9a-7
ENGINE 2.5L TURBO DIESEL (Continued)
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Measure Dimension
(mm)0.49-0.60
Cylinder Head Gasket
Thickness (mm)1.32
No Holes or Notches
Piston Clearance (mm) 0.72-0.83
Measure Dimension
(mm)0.61-0.70
Cylinder Head Gasket
Thickness (mm)1.42
1 Hole or Notch
Piston Clearance (mm) 0.72-0.84
Measure Dimension
(mm)0.71-0.83
Cylinder Head Gasket
Thickness (mm)1.52
2 Holes or Notches
Piston Clearance (mm) 0.68-0.81
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove front wiper unit (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
REMOVAL).
(3) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(4) Drain cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(5) Remove power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(6) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(7) Remove generator (Refer to 8 - ELECTRICAL/
CHARGING/GENERATOR - REMOVAL).(8) Support engine and remove right engine mount
(Refer to 9 - ENGINE/ENGINE MOUNTING/RIGHT
MOUNT - REMOVAL).
CAUTION: Before removing the cylinder head cover/
intake manifold or timing belt the engine must put
at 90É after TDC. Failure to do so could result in
valve and/or piston damage during reassembly.
(Refer to 9 - ENGINE/VALVE TIMING - STANDARD
PROCEDURE)
(9) Remove timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(10) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL).
(11) Remove timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(12) Remove cylinder head cover/intake manifold
(Fig. 15)(Refer to 9 - ENGINE/CYLINDER HEAD/
CYLINDER HEAD COVER(S) - REMOVAL).
Fig. 14 MEASURING PISTON PROTRUSION
Fig. 15 CYLINDER HEAD COVER/INTAKE
MANIFOLD ASSEMBLY
1 - CYLINDER HEAD COVER/INTAKE MANIFOLD BOLTS(LONG)
2 - CYLINDER HEAD COVER/INTAKE MANIFOLD
3 - CYLINDER HEAD
4 - CYLINDER HEAD COVER/INTAKE MANIFOLD GASKET
5 - CYLINDER HEAD COVER/INTAKE MANIFOLD
BOLTS(SHORT)
RGENGINE9a-19
CYLINDER HEAD (Continued)
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(13) Remove rocker arm and lifter assemblies from
cylinder head.
(14) Remove cylinder head cover/intake manifold
gasket from cylinder head.
(15) Disconnect glow plug and engine coolant tem-
perture electrical connectors.
(16) Remove coolant recovery pressure container
(Refer to 7 - COOLING/ENGINE/COOLANT RECOV-
ERY PRESS CONTAINER - REMOVAL).
(17) Remove thermostat housing to upper radiator
hose pipe (Fig. 16).
(18) Remove turbocharger outlet to charge air
cooler pipe (Fig. 16).(19) Remove exhaust manifold heat shield (Fig.
17).
(20) Remove exhaust manifold retaining nuts (Fig.
17).
(21) Slide exhaust manifold and turbocharger off of
exhaust manifold studs (Fig. 17).
(22) Remove cylinder head bolts.
Fig. 16 TURBOCHARGER AND COOLANT PIPES
1 - TURBOCHARGER OUTLET PIPE RETAINING BOLT
2 - TURBOCHARGER OUTLET PIPE
3 - ADAPTER HOSE
4 - HEAT SHIELD
5 - HOSE CLAMPS
6 - TURBOCHARGER INLET PIPE RETAINING BOLT
7 - TURBOCHARGER INLET PIPE
8 - ADAPTER HOSE
9 - HOSE CLAMPS
10 - CLAMP
11 - EGR VALVE TO INTAKE AIR INLET PIPE
12 - CLAMP
13 - THERMOSTAT HOUSING TO UPPER RADIATOR HOSE
PIPE
Fig. 17 EXHAUST MANIFOLD AND
TURBOCHARGER
1 - TURBOCHARGER OIL SUPPLY BANJO BOLT
2 - COPPER WASHER
3 - EXHAUST MANIFOLD GASKET
4 - COPPER WASHER
5 - EXHAUST MANIFOLD HEAT SHIELD RETAINING BOLT
6 - TURBOCHARGER
7 - ENGINE LIFT HOOK
8 - ENGINE LIFT HOOK RETAINING BOLT
9 - SPACER
10 - EXHAUST MANIFOLD RETAINING NUT
11 - TURBOCHARGER OIL RETURN HOSE
12 - HOSE CLAMPS
13 - EXHAUST MANIFOLD STUDS
9a - 20 ENGINERG
CYLINDER HEAD (Continued)
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(5) Slide exhaust manifold and turbocharger on
exhaust manifold studs (Fig. 17).
(6) Install exhaust manifold retaining nuts. Torque
nuts to 32.4N´m.
(7) Install exhaust manifold heat shield (Fig. 17).
Torque bolts to 27.5N´m.
(8) Install turbocharger outlet to charge air cooler
pipe (Fig. 16).
(9) Install thermostat housing to upper radiator
hose pipe (Fig. 16). Install retaining bolt and torque
to 47.1N´m.
(10) Install coolant recovery pressure container
(Refer to 7 - COOLING/ENGINE/COOLANT RECOV-
ERY PRESS CONTAINER - INSTALLATION).
(11) Connect glow plug and coolant temperature
sensor electrical connectors.
(12) Install new cylinder head cover/intake mani-
fold gasket.
(13) Install rocker arm and lifter assemblies.Be
sure to put rocker arm and lifter assemblies in
same location as removed.
(14) Install cylinder head cover/intake manifold
(Fig. 15)(Refer to 9 - ENGINE/CYLINDER HEAD/
CYLINDER HEAD COVER(S) - INSTALLATION).
(15) Install timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(16) Install timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION) .
(17) Install timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(18)Remove crankshaft and both camshaft
locking pins at this time(Refer to 9 - ENGINE/
VALVE TIMING - STANDARD PROCEDURE).
(19) Install generator (Refer to 8 - ELECTRICAL/
CHARGING/GENERATOR - INSTALLATION).
(20) Install accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(21) Install power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(22) Install right engine mount (Refer to 9 -
ENGINE/ENGINE MOUNTING/RIGHT MOUNT -
INSTALLATION).
(23) Install air cleaner housing assembly.
(24) Refill cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(25) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
(26) Install front wiper unit (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
INSTALLATION).
(27) Connect negative battery cable.CAMSHAFT(S)
DESCRIPTION
The camshafts are made of gray cast iron with
eight machined lobes and four bearing journals (Fig.
20).
OPERATION
When the camshaft rotates the lobes actuate the
hydraulic lifters and rocker arms, forcing downward
on the rocker arms which opens the valves.
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove front wiper unit (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
REMOVAL).
(3) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(4) Drain cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(5) Remove air cleaner housing.
(6) Remove power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(7) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(8) Remove generator (Refer to 8 - ELECTRICAL/
CHARGING/GENERATOR - REMOVAL).
(9) Support engine and remove right engine mount
(Refer to 9 - ENGINE/ENGINE MOUNTING/RIGHT
MOUNT - REMOVAL).
Fig. 20 CAMSHAFTS
1 - INTAKE CAMSHAFT
2 - EXHAUST CAMSHAFT
9a - 22 ENGINERG
CYLINDER HEAD (Continued)
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