2002 CHRYSLER CARAVAN fuel

CYLINDER HEAD COVER(S)
DESCRIPTION
The cylinder head cover is made of cast aluminum
and is also the intake manifold on this engine (Fig.
22).
REMOVAL
CAUTION: Before removing the cylinder head cover/
intake manifold 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)
(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) Rotate engine until 90É after TDC is reached.
Install both camshaft locking pins and the crankshaft
locking pin. (Refer to 9 - ENGINE/VALVE TIMING -
STANDARD PROCEDURE)
(6) Remove air cleaner housing assembly.
(7) Remove power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).(8) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(9) Remove generator (Refer to 8 - ELECTRICAL/
CHARGING/GENERATOR - REMOVAL).
(10) Support engine and remove right engine
mount (Refer to 9 - ENGINE/ENGINE MOUNTING/
RIGHT MOUNT - REMOVAL).
(11) Remove outer timing belt cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(12) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL).
(13) Remove inner timing belt cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(14) Disconnect camshaft position sensor, boost
pressure/intake air temperature sensor, EGR sole-
noid, and fuel pressure sensor electrical connectors
(Fig. 23).
Fig. 22 CYLINDER HEAD COVER/INTAKE
MANIFOLD
Fig. 23 ENGINE COMPONENT LOCATIONS
1 - FUEL INJECTOR RETURN LINE
2 - FUEL INJECTOR SUPPLY LINE
3 - OIL SEPARATOR
4 - FUEL INJECTOR
5 - CAMSHAFT POSITION SENSOR
6 - BOOST PRESSURE/INTAKE AIR TEMPERATURE SENSOR
7 - EGR SOLENOID
8 - FUEL PRESSURE SENSOR
9 - CYLINDER HEAD COVER/INTAKE MANIFOL
10 - FUEL RAIL
11 - WIRING HARNESS RETAINING CLIPS
9a - 24 ENGINERG
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(15) Disconnect vacuum lines at EGR solenoid.
(16) Position electrical harness out of way.
(17) Remove fuel injectors (Refer to 14 - FUEL
SYSTEM/FUEL INJECTION/FUEL INJECTOR -
REMOVAL).
(18) Remove fuel rail (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/FUEL RAIL - REMOVAL).
(19) Remove power steering pump reservoir from
bracket.
(20) Remove oil dipstick tube retaining bolt at
intake manifold inlet.
(21) Disconnect oil separator outlet hose at separa-
tor.
(22) Remove turbo inlet tube retaining bolt at
intake manifold.
(23) Disconnect EGR tube at intake manifold inlet
tube.
(24) Remove cylinder head cover/intake manifold
retaining bolts (Fig. 24).
(25) Lift cylinder head cover/intake manifold from
cylinder head (Fig. 24).
NOTE: When removing rocker arm and lifter assem-
blies, be sure to keep them in order as they were
removed from the cylinder head. Always keep liftersin an upright position when removed from cylinder
head.
(26) Remove rocker arm and lifter assemblies from
cylinder head (Fig. 25).
(27) Remove cylinder head cover/intake manifold
gasket from cylinder head.
INSTALLATION
(1) Clean and inspect sealing surfaces.
(2) Install new gasket on cylinder head.
NOTE: Apply a small amount of grease on each
valve stem. This will help hold the rocker arm in
position during the cylinder head cover installation.
(3) Install rocker arm and lifter assemblies in cyl-
inder head (Fig. 25).Be sure to put rocker arm
and lifter assemblies in same location as
removed.
(4) Install cylinder head cover/intake manifold
alignment studs in cylinder head (Fig. 26).
(5) Install cylinder head cover/intake manifold
over alignment stud.
Fig. 24 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)
Fig. 25 CYLINDER HEAD COVER/INTAKE
MANIFOLD GASKET LOCATION
1 - THERMOSTAT HOUSING
2 - ROCKER ARM AND LIFTER ASSEMBLY
3 - CYLINDER HEAD COVER/INTAKE MANIFOLD
4 - CYLINDER HEAD
RGENGINE9a-25
CYLINDER HEAD COVER(S) (Continued)
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NOTE: Be sure to lubricate cylinder head cover/in-
take manifold retaining bolts with engine oil before
assembly. If new bolts are being installed, DO NOT
lubricate before assembly.
(6) Install two cylinder head cover/intake manifold
retaining bolts and tighten finger tight.
(7) Remove alignment studs and install remaining
retaining bolts (Fig. 24). Tighten retaining bolts fin-
ger tight.
(8) Torque cylinder head cover/intake manifold
retaining bolts following procedure below.
CYLINDER HEAD COVER/INTAKE MANIFOLD
TIGHTENING PROCEDURE
(1) Coat all bolts being reused with clean engine
oil.
(2) Install the M8x35 bolts into holes 1,2,3,4,5, and
12. Install the M8x85 bolts into holes
6,7,8,9,10,11,13,14,15, and 16. Tighten all bolthand
tight.
(3) Alternate between bolts #11 and #16 to seat
cylinder head cover/intake manifold on cylinder head
(Fig. 27). Torque bolts to 7 N´m.
(4) Torque all cylinder head cover/intake manifold
retaining bolts to 25 N´m in numerical order starting
with #1 and ending with #16 (Fig. 27).(9) Connect EGR tube at intake manifold inlet
tube. Torque clamp to 10.8 N´m.
(10) Install turbo inlet tube retaining bolt at
intake manifold. Torque bolt to 27.5 N´m.
(11) Connect oil separator outlet hose at separator.
(12) Install oil dipstick tube retaining bolt at
intake manifold inlet. Torque bolt to 10 N´m.
(13) Install power steering pump reservoir in
bracket.
(14) Install fuel rail (Refer to 14 - FUEL SYSTEM/
FUEL DELIVERY/FUEL RAIL - INSTALLATION).
(15) Install fuel injectors and fuel injector supply
lines (Refer to 14 - FUEL SYSTEM/FUEL INJEC-
TION/FUEL INJECTOR - INSTALLATION).
(16) Connect vacuum lines at EGR solenoid.
(17) Clip wiring harness retainers on studs on fuel
rail (Fig. 23).
(18) Connect camshaft position sensor, boost pres-
sure/intake air temperature sensor, EGR solenoid,
and fuel pressure sensor electrical connectors (Fig.
23).
(19) Install inner timing belt cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(20) Install timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION) .
(21) Install outer timing belt cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
Fig. 26 CYLINDER HEAD COVER/INTAKE
MANIFOLD ALIGNMENT STUDS VM.1066
1 - CYLINDER HEAD COVER/INTAKE MANIFOLD ALIGNMENT
STUDS VM.1066
2 - CYLINDER HEAD
Fig. 27 CYLINDER HEAD COVER/INTAKE
MANIFOLD TIGHTENING SEQUENCE
9a - 26 ENGINERG
CYLINDER HEAD COVER(S) (Continued)
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(9) Remove plug in cylinder head cover/intake
manifold and insert VM.1052 to lock intake camshaft
in position (Fig. 87).
(10) At this point the timing belt can be removed
for service.
(11) After engine service is completed and timing
belt reinstalled, remove both camshaft locking pins
from cylinder head cover/intake manifold.
(12) Install both camshaft access plugs.
(13) Remove 90É after TDC engine locking pin.
(14) Install starter motor (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - INSTALLA-
TION).
(15) Install generator (Refer to 8 - ELECTRICAL/
CHARGING/GENERATOR - INSTALLATION).
(16) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
(17) Install front wiper unit (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
INSTALLATION).
(18) Connect negative battery cable.BALANCE SHAFT
DESCRIPTION
The 2.5L Common Rail Diesel engine is equipped
with two nodular cast iron balance shafts in a cast
aluminum carrier. The balance shaft assembly is
mounted to the engine block (Fig. 88).
OPERATION
The balance shaft is driven by the crankshaft. The
balance shafts are connected by heelical gears. The
dual-counter rotating shafts decrease second order
vertical shaking forces caused by component move-
ment.
Fig. 87 INTAKE CAMSHAFT LOCKING PIN VM.1052
1 - TIMING BELT INNER COVER
2 - GLOW PLUG ELECTRICAL CONNECTOR
3 - CYLINDER HEAD COVER/INTAKE MANIFOLD
4 - FUEL RAIL
5 - INTAKE CAMSHAFT LOCKING PIN VM.1052
Fig. 88 BALANCE SHAFT ASSEMBLY
1 - BALANCE SHAFT
2 - OIL JET RETAINING BOLT
3 - OIL JET
4 - ENGINE BLOCK
5 - CRANKSHAFT
6 - BALANCE SHAFT RETAINING BOLTS
7 - OIL DIPSTICK TUBE RETAINER
8 - RUBBER BUSHING
9 - RETAINING BOLT
9a - 54 ENGINERG
VALVE TIMING (Continued)
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(3) Install balance shaft assembly and retaining
bolts (Fig. 89). Torque bolts to 32.4N´m.
(4) Install oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION).
(5) Refill engine oil to proper level.
(6) Connect negative battery cable.
TIMING BELT / CHAIN
COVER(S)
REMOVAL
REMOVAL - TIMING BELT OUTER COVER
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(3) Remove air cleaner housing.
(4) Support engine and remove right engine mount
and bracket.
(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 vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(8) Remove timing belt outer cover retaining bolts
and remove cover (Fig. 92).
REMOVAL - TIMING BELT INNER COVER
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(3) Remove air cleaner housing.
(4) Support engine and remove right engine mount
and bracket.
(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 vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(8) Remove timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(9) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL).(10) Remove timing belt idler pulleys (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT IDLER
PULLEY - REMOVAL).
(11) Using special tool VM.1055, remove camshaft
sprockets (Fig. 93).
(12) Remove timing belt tensioner (Refer to 9 -
ENGINE/VALVE TIMING/TMNG BELT/CHAIN
TENSIONER&PULLEY - REMOVAL) .
(13) Remove injection pump sprocket (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL INJEC-
TION PUMP - REMOVAL).
(14) Remove timing belt inner cover retaining bolts
and remove cover (Fig. 94).
INSTALLATION
INSTALLATION - TIMING BELT OUTER COVER
(1) Install timing belt outer cover seal and cover
(Fig. 92). Torque 3mm bolts to 10.8N´m and 8mm
bolts to 10.8N´m.
(2) Install vibration damper (Refer to 9 - ENGINE/
ENGINE BLOCK/VIBRATION DAMPER - INSTAL-
LATION).
Fig. 92 TIMING BELT COVER (OUTER)
1 - SEAL
2 - TIMING BELT OUTER COVER
3 - RETAINING BOLTS
9a - 56 ENGINERG
BALANCE SHAFT (Continued)
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(3) Install accessory drive belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(4) Install power steering belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(5) Install right engine mount.
(6) Install air cleaner housing.
(7) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
(8) Connect negative battery cable.
INSTALLATION - TIMING BELT INNER COVER
(1) Install timing belt inner cover to engine front
cover seal (Fig. 94).
(2) Install timing belt inner cover to cylinder head
cover gaskets (Fig. 94).
(3) Install timing belt inner cover and retaining
bolts (Fig. 94). Torque 10mm bolts to 47.1N´m and
8mm bolts to 10.8N´m.
(4) Install injection pump sprocket (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL INJEC-
TION PUMP - INSTALLATION).
(5) Install camshaft sprockets (Fig. 93). Torque
bolts to 108N´m.(6) Install timing belt idler pulleys (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT IDLER
PULLEY - INSTALLATION).
(7) Install timing belt and tensioner (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - INSTALLATION) .
(8) Install timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
Fig. 93 CAMSHAFT SPROCKET REMOVAL/
INSTALLATION
1 - TIMING BELT INNER COVER
2 - CAMSHAFT SPROCKET
3 - IDLER PULLEYS
4 - CAMSHAFT SPROCKET
5 - VM.1055
Fig. 94 TIMING BELT COVER - INNER
1 - TIMING BELT COVER TO CYLINDER HEAD COVER GASKET
2 - TIMING BELT COVER TO FRONT ENGINE COVER SEAL
3 - RUBBER GROMMET
4 - BUSHING
5 - TIMING BELT COVER - INNER
6 - RETAINING BOLT
7 - RETAINING BOLT
8 - RETAINING BOLT
9 - BUSHING
10 - RUBBER GROMMET
RGENGINE9a-57
TIMING BELT / CHAIN COVER(S) (Continued)
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OPERATION
The exhaust system contains, quiets, and cleans
the exhaust gases generated by the engine.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - EXCESSIVE
EXHAUST SYSTEM NOISE
CONDITION POSSIBLE CAUSES CORRECTION
EXCESSIVE EXHAUST NOISE
(UNDER HOOD)1. Exhaust manifold cracked or
broken.1. Replace manifold.
2. Manifold to cylinder head leak. 2. Tighten manifold and/or replace
gasket.
3. EGR Valve to manifold gasket
leakage.3. Tighten fasteners or replace
gasket.
4. EGR Valve to EGR tube gasket
leakage.4. Tighten fasteners or replace
gasket.
5. EGR tube to manifold tube
leakage.5. Tighten tube nut.
6. Exhaust flex-joint to manifold
leak.6. Tighten joint fasteners and/or
replace gasket.
7. Exhaust flex-joint. 7. Replace catalytic converter
assembly.
8. Pipe and shell noise from front
exhaust pipe.8. Characteristic of single wall pipe.
EXCESSIVE EXHAUST NOISE 1. Leak at exhaust pipe joints. 1. Tighten clamps at leaking joints.
2. Burned or rusted out muffler
assembly or exhaust pipe.2. Replace muffler resonator tailpipe
assembly or exhaust pipe with
catalytic converter assembly.
3. Burned or rusted out resonator. 3. Replace muffler resonator tailpipe
assembly.
4. Restriction in exhaust system. 4. Perform Exhaust System
Restriction Check. Replace
component as necessary.
5. Converter material in muffler. 5. Replace muffler and converter
assemblies. Check fuel injection and
ignition systems for proper
operation.
DIAGNOSIS AND TESTING - EXHAUST SYSTEM
RESTRICTION CHECK
Exhaust system restriction can be checked by mea-
suring back pressure using the DRB IIItand PEP
module pressure tester.WARNING: THE NORMAL OPERATING TEMPERA-
TURE OF THE EXHAUST SYSTEM IS VERY HIGH.
THEREFORE, NEVER WORK AROUND OR ATTEMPT
TO SERVICE ANY PART OF THE EXHAUST SYSTEM
UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE
TAKEN WHEN WORKING NEAR THE CATALYTIC
CONVERTER. THE TEMPERATURE OF THE CON-
VERTER RISES TO A HIGH LEVEL AFTER A SHORT
PERIOD OF ENGINE OPERATION TIME.
11 - 2 EXHAUST SYSTEMRS
EXHAUST SYSTEM (Continued)
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(1) Disconnect and remove the upstream (before
catalytic converter) oxygen sensor. (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/O2 SENSOR -
REMOVAL)
(2) Install the Exhaust Back Pressure Fitting
Adaptor CH8519.
(3) Connect the Low Pressure Sensor (15 psi)
CH7063 to the back pressure fitting.
(4) Following the PEP module instruction manual,
connect all required cables to the DRB IIItand PEP
module. Select the available menu options on the
DRBIIItdisplay screen for using the digital pressure
gauge function.
(5) Apply the park brake and start the engine.
(6) With transmission in Park or Neutral, raise
engine speed to 2000 RPM. Monitor the pressure
readings on the DRBIIIt. Back pressure should not
exceed specified limit. Refer to specification in table
below EXHAUST BACK PRESSURE LIMITS .
NOTE: For applications with dual catalytic convert-
ers, repeat test on opposite converter using the
previous steps.
(7) If pressure exceeds maximum limits, inspect
exhaust system for restricted component. For further
catalytic converter inspection procedures, (Refer to 11
- EXHAUST SYSTEM/CATALYTIC CONVERTER -
INSPECTION). Replace component(s) as necessary.
EXHAUST BACK PRESSURE LIMITS
Exhaust Back Pressure Limit (Max)
Vehicle in Park/Neutral
(no load) RPM3.45 Kpa (0.5 psi)
INSPECTION
Inspect the exhaust pipes, catalytic converters,
muffler, and resonators for cracked joints, broken
welds and corrosion damage that would result in a
leaking exhaust system. Inspect the clamps, support
brackets, and insulators for cracks and corrosion
damage.
NOTE: Slip joint band clamps are spot welded to
exhaust system. If a band clamp must be replaced,
the spot weld must be ground off.
ADJUSTMENTS
A misaligned exhaust system is usually indicated
by a vibration, rattling noise, or binding of exhaust
system components. These noises are sometimes hard
to distinguish from other chassis noises. Inspect
exhaust system for broken, damaged or loose compo-
nents such as; clamps, heat shields, isolators, andhanger brackets. Replace or tighten as necessary. It
is important that exhaust system clearances and
alignment be maintained.
Perform the following procedures to align the
exhaust system:
(1) Loosen band clamp at catalytic converter pipe
to muffler/resonator assembly.
(2) Align the exhaust system by inserting pipe
inward or outward until specification is achieved as
shown in (Fig. 2).
(3) Tighten band clamp to 54 N´m (40 ft. lbs.).
SPECIFICATIONS
TORQUE
DESCRIPTION N´mFt.
Lbs.In.
Lbs.
Band Clamp 54 40 Ð
Cross-over PipeÐFastener 41 30 Ð
Exhaust Manifold FlangeÐFastener 37 Ð 325
Heat Shield (Muffler)ÐFastener 2.6 Ð 23
Heat Shield (Toe Board)ÐFastener 2.6 Ð 23
Heat Shield (Resonator Pipe)Ð
Fastener2.6 Ð 23
Insulator Mounting BracketÐBolts 28 Ð 250
Fig. 2 Exhaust System Alignment
1 - HANGER BRACKET TO BODY
2 - ISOLATOR
3 - HANGER - MUFFLER/RESONATOR SUPPORT
4-6mm(0.25 in.)
RSEXHAUST SYSTEM11-3
EXHAUST SYSTEM (Continued)
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