2002 CHRYSLER CARAVAN Service Manual

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Page 1385 of 2399

CHRYSLER CARAVAN 2002 Service Manual 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/

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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Page 1386 of 2399

CHRYSLER CARAVAN 2002 Service Manual (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 fu

(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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Page 1387 of 2399

CHRYSLER CARAVAN 2002 Service Manual 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 cy

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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Page 1388 of 2399

CHRYSLER CARAVAN 2002 Service Manual (22) Install right engine mount (Refer to 9 -
ENGINE/ENGINE MOUNTING/RIGHT MOUNT -
INSTALLATION).
(23) Install generator (Refer to 8 - ELECTRICAL/
CHARGING/GENERATOR - INSTALLATION).
(24) Install acce

(22) Install right engine mount (Refer to 9 -
ENGINE/ENGINE MOUNTING/RIGHT MOUNT -
INSTALLATION).
(23) Install generator (Refer to 8 - ELECTRICAL/
CHARGING/GENERATOR - INSTALLATION).
(24) Install accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(25) Install power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(26) Install air cleaner housing assembly.
(27) Remove crankshaft and both camshaft locking
pins (Refer to 9 - ENGINE/VALVE TIMING - STAN-
DARD PROCEDURE).
(28) Refill cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(29) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
(30) Install front wiper unit (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
INSTALLATION).
(31) Connect negative battery cable.
CAMSHAFT OIL SEAL(S)
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove air cleaner housing assembly.
(3) Support engine and remove right engine mount
(Refer to 9 - ENGINE/ENGINE MOUNTING/RIGHT
MOUNT - REMOVAL).
(4) Remove outer timing belt cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
WARNING: Before removing the 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)
(5) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL).
(6) Using VM.1055, remove both camshaft gears
(Fig. 28).
(7) Remove both camshaft oil seals.
INSTALLATION
(1) Install new camshaft oil seal using VM.1057.
(2) Install camshaft sprockets and tighten retain-
ing bolts finger tight.
(3) Install timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION) .(4) Torque camshaft sprockets to 108 N´m using
VM.1055 (Fig. 28).
(5) Install outer timing belt cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(6) Install right engine mount (Refer to 9 -
ENGINE/ENGINE MOUNTING/RIGHT MOUNT -
INSTALLATION).
(7) Install air cleaner housing assembly.
(8) Connect negative battery cable.
ROCKER ARMS
DESCRIPTION
The rocker arms are made of stamped steel (Fig.
29).
OPERATION
The rocker arms are used as a link between the
camshaft and valves. As the camshaft rotates the
lobes of the camshafts apply downward pressure on
the rocker arms. This pressure is then transmitted to
the valves which causes the valves to open.
REMOVAL
(1) Disconnect negative battery cable.
Fig. 28 CAMSHAFT GEAR REMOVAL/INSTALLATION
1 - TIMING BELT INNER COVER
2 - CAMSHAFT SPROCKET
3 - IDLER PULLEYS
4 - CAMSHAFT SPROCKET
5 - VM.1055
RGENGINE9a-27
CYLINDER HEAD COVER(S) (Continued)
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Page 1389 of 2399

CHRYSLER CARAVAN 2002 Service Manual (2) Remove front wiper unit (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
REMOVAL).
(3) Remove air cleaner housing assembly.
(4) Support engine and remove right engine mount
(Refer to 9 - E

(2) Remove front wiper unit (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
REMOVAL).
(3) Remove air cleaner housing assembly.
(4) Support engine and remove right engine mount
(Refer to 9 - ENGINE/ENGINE MOUNTING/RIGHT
MOUNT - REMOVAL).
(5) Remove outer timing belt cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(6) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL).
(7) Remove inner timing belt cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(8) Remove cylinder head cover/intake manifold
(Refer to 9 - ENGINE/CYLINDER HEAD/CYLIN-
DER HEAD COVER(S) - REMOVAL).(9) Remove rocker arm from lifter (Fig. 30).
INSTALLATION
(1) Clean and inspect gasket sealing surfaces.
(2) Install new gasket on cylinder head.
(3) Lubricate lifter ball end of lifter(s), valve(s),
and rocker arm roller(s) with MopartEngine Oil
Supplement or equivlalent.
(4) Connect rocker arm(s) to lifter and reposition
on valve(s) (Fig. 30).
(5) Install cylinder head cover/intake manifold
(Refer to 9 - ENGINE/CYLINDER HEAD/CYLIN-
DER HEAD COVER(S) - INSTALLATION).
(6) Install inner timing belt 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 outer timing belt 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 air cleaner housing assembly.
Fig. 29 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. 30 ROCKER ARM ASSEMBLY
1 - ROCKER ARM ASSEMBLY
2 - CYLINDER HEAD COVER/INTAKE MANIFOLD
3 - HYDRAULIC LIFTER
4 - CYLINDER HEAD
5 - VALVE
9a - 28 ENGINERG
ROCKER ARMS (Continued)
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Page 1390 of 2399

CHRYSLER CARAVAN 2002 Service Manual (11) Install front wiper unit (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
INSTALLATION).
(12) Connect negative battery cable.
HYDRAULIC LIFTERS
DESCRIPTION
Valve lash is controlled by hyd

Page 1391 of 2399

CHRYSLER CARAVAN 2002 Service Manual (9) Remove rocker arm and lifter assemblies from
lifter bores.
INSPECTION
Clean each lifter assembly in cleaning solvent to
remove all varnish and sludge deposits. Inspect for
indications of scuffing

Page 1392 of 2399

CHRYSLER CARAVAN 2002 Service Manual STANDARD PROCEDURE - CHECKING
CRANKSHAFT END PLAY
(1) Mount a dial indicator to a stationary point at
rear of engine. Locate the probe perpendicular
against the flywheel (Fig. 35).
(2) Move the cranks

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