2002 CHRYSLER CARAVAN Service Manual

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Page 1377 of 2399

CHRYSLER CARAVAN 2002 Service Manual VM.1072 COMPRESSION TESTER ADAPTER
VM.1073 CRANKSHAFT FRONT BEARING
REMOVER/INSTALLER
VM.1074 TIMING BELT RETAINER
VM.1075 FLYWHEEL ALIGNMENT PINS
VM.1077 POWER STEERING BELT REMOVER
VM.1078 POWER STE

Page 1378 of 2399

CHRYSLER CARAVAN 2002 Service Manual CYLINDER HEAD
STANDARD PROCEDURE
STANDARD PROCEDURE - VALVE SERVICE
This procedure is done with the engine cylinder
head removed from the block.
DISASSEMBLY
(1) Remove the engine cylinder head from th

CYLINDER HEAD
STANDARD PROCEDURE
STANDARD PROCEDURE - VALVE SERVICE
This procedure is done with the engine cylinder
head removed from the block.
DISASSEMBLY
(1) Remove the engine cylinder head from the cyl-
inder block. Refer to cylinder head removal and
installation in this section.
(2) Use Valve Spring Compressor Tool and com-
press each valve spring.
(3) Remove the valve locks, retainers, and springs.
(4) Use an Arkansas smooth stone or a jewelers
file to remove any burrs on the top of the valve stem,
especially around the groove for the locks.
(5) Remove the valves, and place them in a rack in
the same order as removed.
VALVE CLEANING
(1) Clean all carbon deposits from the combustion
chambers, valve ports, valve stems, valve stem
guides and head.
(2) Clean all grime and gasket material from the
engine cylinder head machined gasket surface.
INSPECTION
(1) Inspect for cracks in the combustion chambers
and valve ports.
(2) Inspect for cracks on the exhaust seat.
(3) Inspect for cracks in the gasket surface at each
coolant passage.
(4) Inspect valves for burned, cracked or warped
heads.
(5) Inspect for scuffed or bent valve stems.
(6) Replace valves displaying any damage.
(7) Check valve spring height (Fig. 11).
VALVE REFACING
(1) Use a valve refacing machine to reface the
intake and exhaust valves to the specified angle.
(2) After refacing, a margin of at least 4.52-4.49
mm (.178-.177 inch) must remain (Fig. 12). If the
margin is less than 4.49 mm (.177 inch), the valve
must be replaced.
VALVE SEAT REFACING
(1) Install a pilot of the correct size in the valve
guide bore. Reface the valve seat to the specified
angle with a good dressing stone. Remove only
enough metal to provide a smooth finish.
(2) Use tapered stones to obtain the specified seat
width when required.
VALVE STAND DOWN
Valve stand down is to maintain the adequate com-
pression ratio.
(1) Invert cylinder head.
(2) Fit each valve to its respective valve guide.
(3) Using a straight edge and feeler gauge, check
valve head stand down: Inlet valve head stand down
1.08 to 1.34 mm (.042 to .052 ins.) and exhaust valve
stand down .99 to 1.25 mm (.035 to .049 ins.).
(4) If valve head stand down is not in accordance
with above, discard original valves, check stand down
with new valves and recut valve seat inserts to
obtain correct stand down.
VALVE GUIDES
(1) Valve Guides height requirement.
(2) Measurement A (Fig. 13): 16.50 - 17.00 mm.
Measurment B : 14.50 - 15.00 mm.
VALVE STEM-TO-GUIDE CLEARANCE
MEASUREMENT
(1) Measure and record internal diameter of valve
guides. Valve guide internal diameter is 8.0 to 8.015
mm (.3149 to .3155 ins.).
(2) Measure valve stems and record diameters.
Intake valve stem diameter 7.94 to 7.96 mm (.3125 to
Fig. 11 VALVE SPRING CHART
LOAD Kg HEIGHT mm STATE
P1 0.00 H1 45.26 FREE LENGTH
P2 182-5
+10%H2 38.00 VALVE CLOSED
P3 395 5% H3 28.20 VALVE OPEN
RGENGINE9a-17
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Page 1379 of 2399

CHRYSLER CARAVAN 2002 Service Manual .3133 in). Exhaust valve stem diameter 7.92 to 7.94
mm (.3118 to .31215 in).
(3) Subtract diameter of valve stem from internal
diameter of its respective valve guide to obtain valve
stem clearance in

Page 1380 of 2399

CHRYSLER CARAVAN 2002 Service Manual 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 Ho

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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Page 1381 of 2399

CHRYSLER CARAVAN 2002 Service Manual (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 el

Page 1382 of 2399

CHRYSLER CARAVAN 2002 Service Manual (23) Remove cylinder head assembly from engine
block (Fig. 18).
CLEANING
Thoroughly clean the engine cylinder head and cyl-
inder block mating surfaces. Clean the intake and
exhaust manifold and engin

(23) Remove cylinder head assembly from engine
block (Fig. 18).
CLEANING
Thoroughly clean the engine cylinder head and cyl-
inder block mating surfaces. Clean the intake and
exhaust manifold and engine cylinder head mating
surfaces. Remove all gasket material and carbon.
Check to ensure that no coolant or foreign material
has fallen into the tappet bore area.
Remove the carbon deposits from the combustion
chambers and top of the pistons.
INSPECTION
Use a straightedge and feeler gauge to check the
flatness of the engine cylinder head and block mating
surfaces.
The minimum cylinder head thickness is 89.95mm
(3.541 in.).
INSTALLATION
CAUTION: Piston protrusion must be measured to
determine cylinder head gasket thickness if one or
more cylinder liners have been replaced (Refer to 9
- ENGINE/CYLINDER HEAD - STANDARD PROCE-
DURE).
NOTE: If cylinder liner(s) have not been removed,
the same thickness head gasket that was removed
can be used.
(1) Clean and inspect gasket mating surfaces.
(2) Position correct head gasket on engine block.
(3) Place cylinder head on engine block (Fig. 18).
CAUTION: New cylinder head bolts must be used.
(4) Tighten cylinder head bolts following procedure
below.
Cylinder Head Bolt Torquing Procedure
(1) Lubricate cylinder head bolts with engine oil.
(2) Torque bolts to 30N´m in numerical starting
with bolt #1 (Fig. 19).
(3) Tighten all bolts an additional 75É, starting
with bolt #4 then 5-6-7-8-9-10-1-2-3 (Fig. 19).
(4) Tighten all bolts an additional 50É in numerical
order starting with bolt #11 then 12-13-14-15-16-
17-18 (Fig. 19).
(5) Without loosening any bolts tighten all bolts an
additional 75É in the following seguence: 4-5-6-7-8-9-
10-1-2-3-11-12-13-14-15-16-17-18.
Fig. 18 CYLINDER HEAD ASSEMBLY
1 - VALVE SPRING
2 - CYLINDER HEAD BOLT
3 - GLOW PLUG
4 - COOLANT TEMPERATURE SENSOR
5 - CYLINDER HEAD ALIGNMENT DOWEL
6 - CYLINDER BLOCK
7 - CYLINDER LINER
8 - ENGINE BLOCK DECK
9 - CYLINDER HEAD GASKET
10 - CYLINDER HEAD
11 - ROCKER ARM AND LIFTER ASSEMBLY
Fig. 19 CYLINDER HEAD TORQUE SEQUENCE
RGENGINE9a-21
CYLINDER HEAD (Continued)
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Page 1383 of 2399

CHRYSLER CARAVAN 2002 Service Manual (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

(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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Page 1384 of 2399

CHRYSLER CARAVAN 2002 Service Manual 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.
(

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)
(10) Remove timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(11) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL).
(12) Remove timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(13) Remove cylinder head cover/intake manifold
(Refer to 9 - ENGINE/CYLINDER HEAD/CYLIN-
DER HEAD COVER(S) - REMOVAL).
(14) With cylinder head cover/intake manifold on
work bench, remove plugs at rear of cylinder head
cover/intake manifold.
(15) Remove camshaft oil seals (Fig. 21).
(16) Remove snapring and thrust washer from
camshaft (Fig. 21).
(17) Slide camshaft through access hole at rear of
cylinder head cover/intake manifold.
INSTALLATION
(1) Lubricate the camshafts with MopartEngine
Oil Supplement, or equivalent.
(2) Carefully install camshafts into access holes in
rear of cylinder head cover/intake manifold.
(3) Install thrust washer, snapring, and camshaft
oil seal (Fig. 21).
CHECKING CAMSHAFT ENDPLAY
(1) After camshafts are properly installed in cylin-
der head cover check end play of camshafts with a
dial indicator. The end play should be between .10
mm ± .30 mm.
NOTE: If the camshaft endplay is not within speci-
fication, measure thickness of the camshaft spacer.
Camshaft spacer thickness should be 2.8 .02mm.
(4) Install access hole plugs and gaskets at rear of
cylinder head cover/intake manifold. Torque plugs to
80N´m.
(5) Install cylinder head cover/intake manifold on
engine block (Refer to 9 - ENGINE/CYLINDER
HEAD/CYLINDER HEAD COVER(S) - INSTALLA-
TION).
(6) Install timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).(7) Install timing belt (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).
(9) Install right engine mount (Refer to 9 -
ENGINE/ENGINE MOUNTING/RIGHT MOUNT -
INSTALLATION).
(10) Install generator (Refer to 8 - ELECTRICAL/
CHARGING/GENERATOR - INSTALLATION).
(11) Install accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(12) Install power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(13) Install air cleaner housing.
(14) Refill cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(15) Install front wiper unit (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
INSTALLATION).
(16) Connect negative battery cable.
Fig. 21 CAMSHAFT ASSEMBLY
1 - INTAKE CAMSHAFT
2 - SNAPRING
3 - CAMSHAFT OIL SEAL
4 - THRUST WASHER
5 - CYLINDER HEAD COVER/INTAKE MANIFOLD
6 - EXHAUST CAMSHAFT
RGENGINE9a-23
CAMSHAFT(S) (Continued)
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