2002 CHRYSLER CARAVAN shaft

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
C325 BK Right Sliding Door 27
C326 YL At Driver Side Airbag N/S
C327 YL At Passenger Side Airbag N/S
C329 (Diesel) BK Left Rear Engine Compartment N/S
C330 (Diesel) LTGY Left Rear Engine Compartment N/S
C331 (Diesel) BK Left Rear Engine Compartment N/S
Cabin Heater Assist C1 (Diesel) BK Top of Engine 11, 12
Cabin Heater Assist C2 (Diesel) BK Top of Engine 11, 12
Camshaft Position Sensor (Gas) BK Rear of Cylinder Head
Right Side of EngineN/S
Camshaft Position Sensor (Diesel) BK Rear of Cylinder Head 11, 12
CD Changer Behind CD Changer N/S
Center Dome Lamp GY At Lamp N/S
Center High Mounted Stop Lamp BK At Lamp 42
Clockspring - C1 WT Steering Column 15, 16, 17, 18, 26
Clockspring - C2 YL Steering Column 15, 16, 17, 18, 26
Clockspring - C3 BK Steering Column N/S
Clockspring - C4 BK Steering Column N/S
Clockspring - C5 YL Steering Column N/S
Clutch Pedal Interlock Switch
(Diesel)RD At Switch/Driver Side 36
Clutch Pedal Upstop Switch
(Diesel)BK At Switch/Driver Side 36
Controller Anti-Lock Brake BK Right Side of Engine Compartment 9, 10, 12, 13, 14
Crank Case Ventilation Heater
(Diesel)BK Top of Cylinder Head 11
Crankshaft Position Sensor (Diesel) BK Rear of Engine 12
Crankshaft Position Sensor (Gas) BK Rear of Engine 9, 13
Data Link Connector WT Lower Instrument Panel Near Steering
Column35, 36
Diagnostic Junction Port BK Lower Instrument Panel Near Steering
Column35, 36
Dosing Pump BK Top of Engine N/S
Driver Airbag C1 BN Steering Column N/S
Driver Airbag C2 BK Steering Column N/S
Driver Blend Actuator (ATC) GY On HVAC N/S
Driver Blend Actuator (MTC) GY On HVAC N/S
Driver Door Courtesy Lamp GY At Lamp N/S
Driver Door Lock Switch BK At Switch N/S
Driver Heated Seat Back GN At Seat N/S
Driver Heated Seat Cushion BK At Seat N/S
Driver Heated Seat Module C1 GY Driver Heated Seat N/S
Driver Heated Seat Module C2 GY Driver Heated Seat Back N/S
Driver Heated Seat Module C3 GN At Seat N/S
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-3
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
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GROUNDS
GROUND NUMBER LOCATION FIG.
G100 Body Ground Near Powertrain Control Module N/S
G101 Above Starter 10
G102 Left Headlamp Area 1
G103 Above Starter 10
G200 Right Side of Instrument Panel 15, 19, 24
G201 Right Side of Instrument Panel 15, 19, 24
G202 Near Radio N/S
G300 Left B Pillar 27
G301 Right B Pillar 28, 33
G302 Left Rear Quarter N/S
G400 Liftgate Ground N/S
SPLICES
SPLICE NUMBER LOCATION FIG.
S101 800mm from T/O for G102 1
S102 500mm from T/O for G102 1
S103 (2.5L) Between T/O for Battery Temperature Sensor and T/O
for C10211
S103 (3.3L/3.8L) Near T/O for C100 N/S
S104 Near T/O for G102 1
S105 (3.3L/3.8L) Near T/O for Battery (+) N/S
S106 (2.4L) 40mm from T/O for Torque Converter Clutch Solenoid 10
S106 (2.5L) Near T/O for Battery Temperature Sensor 11
S106 (3.3L/3.8L) Near T/O for G103 14
S107 (2.4L) In T/O for EGR Solenoid 10
S107 (2.5L) Between T/O for Engine Starter Motor and T/O for
Engine Control Module C112
S107 (3.3L/3.8L) In T/O for EGR Solenoid 14
S108 (3.3L/3.8L) Near T/O for Powertrain Control Module N/S
S109 (3.3L/3.8L) Near T/O for Camshaft Position Sensor N/S
S110 Near T/O to G102 N/S
S111 (2.4L) Near T/O for C101 N/S
S111 (2.5L) Near T/O for Battery (-) N/S
S111 (3.3L/3.8L) Near T/O for Powertrain Control Module N/S
S112 Near T/O for Intelligent Power Module - C3 N/S
S113 (2.4L) Near T/O for Park/Neutral Position Switch N/S
S114 (3.3L/3.8L) In T/O to Transmission Control Module N/S
S115 (3.3L/3.8L) In T/O to Transmission Control Module N/S
S116 (2.4L) 180mm from T/O for Torque Converter Clutch Solenoid 10
S116 (2.5L) Near T/O for Mass Air Flow Sensor 12
S116 (3.3L/3.8L) Near T/O for Ignition Coil Pack 14
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-11
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
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ENGINE
TABLE OF CONTENTS
page page
ENGINE 2.4L.............................. 1ENGINE 3.3/3.8L......................... 74
ENGINE 2.4L
TABLE OF CONTENTS
page page
ENGINE 2.4L
DESCRIPTION..........................3
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION............3
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - PERFORMANCE............4
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - MECHANICAL..............6
DIAGNOSIS AND TESTING - ENGINE OIL
LEAK INSPECTION.....................8
DIAGNOSIS AND TESTING - CYLINDER
COMPRESSION PRESSURE TEST.........9
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE
TEST................................9
STANDARD PROCEDURE
STANDARD PROCEDURE - ENGINE CORE
AND OIL GALLERY PLUGS..............10
STANDARD PROCEDURE - REPAIR OF
DAMAGED OR WORN THREADS.........10
STANDARD PROCEDURE - HYDROSTATIC
LOCKED ENGINE.....................10
STANDARD PROCEDURE - FORM-IN-
PLACE GASKETS AND SEALERS.........11
STANDARD PROCEDURE - ENGINE
GASKET SURFACE PREPARATION........11
STANDARD PROCEDURE - MEASURING
BEARING CLEARANCE USING
PLASTIGAGE........................12
REMOVAL - ENGINE ASSEMBLY...........12
INSTALLATION - ENGINE ASSEMBLY........16
SPECIFICATIONS
SPECIFICATIONS - 2.4L ENGINE.........17
SPECIFICATIONS - TORQUE............20
SPECIAL TOOLS
2.4L ENGINE.........................21AIR CLEANER ELEMENT
REMOVAL.............................24
INSTALLATION.........................24
AIR CLEANER HOUSING
REMOVAL.............................24
INSTALLATION.........................24
CYLINDER HEAD
DESCRIPTION.........................24
OPERATION...........................24
DIAGNOSIS AND TESTINGÐCYLINDER HEAD
GASKET............................24
REMOVAL - CYLINDER HEAD.............25
CLEANING............................26
INSPECTION..........................26
INSTALLATION - CYLINDER HEAD..........26
CAMSHAFT OIL SEAL(S)
REMOVAL.............................28
INSTALLATION.........................28
CAMSHAFT(S)
DESCRIPTION.........................29
OPERATION...........................29
STANDARD PROCEDURE - MEASURING
CAMSHAFT END PLAY.................29
REMOVAL.............................29
CLEANING............................29
INSPECTION..........................30
INSTALLATION.........................30
CYLINDER HEAD COVER
REMOVAL.............................31
CLEANING............................31
INSPECTION..........................31
INSTALLATION.........................31
INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION.........................32
CLEANING............................32
RSENGINE9-1
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VALVE SPRINGS & SEALS
REMOVAL
REMOVAL - CYLINDER HEAD ON.........32
REMOVAL - CYLINDER HEAD OFF........33
INSPECTION..........................33
INSTALLATION
INSTALLATION - CYLINDER HEAD ON.....33
INSTALLATION - CYLINDER HEAD OFF....33
HYDRAULIC LASH ADJUSTERS
DIAGNOSIS AND TESTING - HYDRAULIC
LASH ADJUSTER NOISE DIAGNOSIS......34
REMOVAL.............................34
INSTALLATION.........................34
ROCKER ARMS
REMOVAL.............................35
INSPECTION..........................35
INSTALLATION.........................35
ENGINE BLOCK
DESCRIPTION.........................35
STANDARD PROCEDURE
STANDARD PROCEDURE - PISTON TO
CYLINDER BORE FITTING..............36
STANDARD PROCEDURE - CYLINDER
BORE HONING.......................36
CLEANING............................37
INSPECTION..........................37
CONNECTING ROD BEARINGS
STANDARD PROCEDURE
CONNECTING ROD - FITTING...........37
CRANKSHAFT
DESCRIPTION.........................38
OPERATION...........................38
STANDARD PROCEDURE - CRANKSHAFT
ENDPLAY ...........................38
REMOVAL.............................38
INSPECTION..........................39
INSTALLATION.........................39
CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDURE - MAIN BEARING -
FITTING.............................41
CRANKSHAFT OIL SEAL - FRONT
REMOVAL.............................42
INSTALLATION.........................43
CRANKSHAFT OIL SEAL - REAR
REMOVAL.............................43
INSTALLATION.........................44
PISTON & CONNECTING ROD
DESCRIPTION.........................45
OPERATION...........................45
REMOVAL.............................45
INSTALLATION.........................46
PISTON RINGS
STANDARD PROCEDURE
PISTON RING - FITTING................47
VIBRATION DAMPER
REMOVAL.............................48
INSTALLATION.........................48STRUCTURAL COLLAR
REMOVAL.............................49
INSTALLATION.........................49
ENGINE MOUNTING
DESCRIPTION.........................49
FRONT MOUNT
REMOVAL.............................49
INSTALLATION.........................50
LEFT MOUNT
REMOVAL.............................50
INSTALLATION.........................50
REAR MOUNT
REMOVAL.............................51
INSTALLATION.........................51
RIGHT MOUNT
REMOVAL.............................52
INSTALLATION.........................52
LUBRICATION
DESCRIPTION.........................53
OPERATION...........................53
DIAGNOSIS AND TESTING - CHECKING
ENGINE OIL PRESSURE................53
OIL
STANDARD PROCEDURE
ENGINE OIL LEVEL CHECK.............53
STANDARD PROCEDURE - ENGINE OIL
AND FILTER CHANGE..................54
OIL FILTER
DESCRIPTION.........................54
REMOVAL.............................54
INSTALLATION.........................55
OIL PAN
REMOVAL.............................55
INSTALLATION.........................55
OIL PRESSURE SWITCH
REMOVAL.............................55
INSTALLATION.........................55
OIL PUMP
REMOVAL.............................55
DISASSEMBLY.........................56
CLEANING............................57
INSPECTION..........................57
ASSEMBLY............................58
INSTALLATION.........................58
INTAKE MANIFOLD
DESCRIPTION.........................59
OPERATION...........................59
DIAGNOSIS AND TESTING - INTAKE
MANIFOLD LEAKS.....................59
INTAKE MANIFOLD - UPPER
REMOVAL.............................60
INSPECTION..........................61
INSTALLATION.........................61
INTAKE MANIFOLD - LOWER
REMOVAL.............................61
INSPECTION..........................61
INSTALLATION.........................61
9 - 2 ENGINE 2.4LRS
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EXHAUST MANIFOLD
DESCRIPTION.........................62
OPERATION...........................62
REMOVAL.............................62
CLEANING............................62
INSPECTION..........................62
INSTALLATION.........................62
TIMING BELT COVER(S)
REMOVAL.............................63
INSTALLATION.........................63
TIMING BELT AND SPROCKET(S)
REMOVAL
REMOVAL - TIMING BELT...............64REMOVAL - CRANKSHAFT SPROCKET....66
CLEANING............................66
INSTALLATION
INSTALLATION - CRANKSHAFT SPROCKET . 66
INSTALLATION - TIMING BELT...........67
TIMING BELT TENSIONER & PULLEY
REMOVAL.............................68
INSTALLATION.........................69
BALANCE SHAFTS AND CARRIER ASSEMBLY
DESCRIPTION.........................69
OPERATION...........................70
REMOVAL.............................70
INSTALLATION.........................71
ENGINE 2.4L
DESCRIPTION
The 2.4 Liter (148 cu. in.) in-line four cylinder
engine is a double over head camshaft with hydraulic
lash adjusters and four valve per cylinder design.
The engine is free-wheeling; meaning it has provi-
sions for piston-to-valve clearance. However valve-to-
valve interference can occur, if camshafts are rotated
independently.
The cylinders are numbered from front of the
engine to the rear. The firing order is 1±3±4±2.
The engine identification number is located on the
rear of the cylinder block (Fig. 1).
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION
Engine diagnosis is helpful in determining the
causes of malfunctions not detected and remedied by
routine maintenance.
These malfunctions may be classified as either
mechanical (e.g., a strange noise), or performance
(e.g., engine idles rough and stalls).
Refer to the Engine Mechanical and the Engine
Performance diagnostic charts, for possible causes
and corrections of malfunctions (Refer to 9 - ENGINE
- DIAGNOSIS AND TESTING - MECHANICAL)
(Refer to 9 - ENGINE - DIAGNOSIS AND TESTING
- PERFORMANCE).
For fuel system diagnosis, (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY - DIAGNOSIS AND
TESTING).
Additional tests and diagnostic procedures may be
necessary for specific engine malfunctions that can-
not be isolated with the Service Diagnosis charts.
Information concerning additional tests and diagno-
sis is provided within the following:
²Cylinder Compression Pressure Test
²Cylinder Combustion Pressure Leakage Test
²Engine Cylinder Head Gasket Failure Diagnosis
²Intake Manifold Leakage Diagnosis
²Hydraulic Lash Adjuster Noise Diagnosis
²Engine Oil Leak Inspection
Fig. 1 Engine Identification
1 - ENGINE IDENTIFICATION LOCATION
RSENGINE 2.4L9-3
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DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - MECHANICAL
CONDITION POSSIBLE CAUSES CORRECTION
NOISY VALVES 1. High or low oil level in
crankcase.1. Check and correct engine oil
level.
2. Thin or diluted oil. 2. Change oil to correct viscosity.
3. Thick oil 3. (a) Change engine oil and filter.
(b) Run engine to operating
temperature.
(c) Change engine oil and filter
again.
4. Low oil pressure. 4. Check and correct engine oil
pressure problem.
5. Dirt in hydraulic lifters/lash
adjusters.5. Replace hydraulic lifters/lash
adjusters.
6. Worn rocker arms. 6. Inspect oil supply to rocker arms.
7. Worn hydraulic lifters/lash
adjusters.7. Replace hydraulic lifters/lash
adjusters.
8. Worn valve guides. 8. Replace cylinder head assembly.
9. Excessive runout of valve seats
on valve faces.9. Grind valve seats and valves.
CONNECTING ROD NOISE 1. Insufficient oil supply. 1. Check engine oil level.
2. Low oil pressure. 2. Check engine oil level. Inspect oil
pump relief valve and spring.
3. Thin or diluted oil. 3. Change oil to correct viscosity.
4. Thick oil 4. (a) Change engine oil and filter.
(b) Run engine to operating
temperature.
(c) Change engine oil and filter
again.
5. Excessive bearing clearance. 5. Measure bearings for correct
clearance. Repair as necessary.
6. Connecting rod journal
out-of-round.6. Replace crankshaft or grind
surface.
7. Misaligned connecting rods. 7. Replace bent connecting rods.
9 - 6 ENGINE 2.4LRS
ENGINE 2.4L (Continued)
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CONDITION POSSIBLE CAUSES CORRECTION
MAIN BEARING NOISE 1. Insufficient oil supply. 1. Check engine oil level.
2. Low oil pressure. 2. Check engine oil level. Inspect oil
pump relief valve and spring.
3. Thin or diluted oil. 3. Change oil to correct viscosity.
4. Thick oil 4. (a) Change engine oil and filter.
(b) Run engine to operating
temperature.
(c) Change engine oil and filter
again.
5. Excessive bearing clearance. 5. Measure bearings for correct
clearance. Repair as necessary.
6. Excessive end play. 6. Check thrust bearing for wear on
flanges.
7. Crankshaft journal out-of-round
or worn.7. Replace crankshaft or grind
journals.
8. Loose flywheel or torque
converter.8. Tighten to correct torque.
OIL PRESSURE DROP 1. Low oil level. 1. Check engine oil level.
2. Faulty oil pressure sensor/switch. 2. Replace oil pressure sensor/
switch.
3. Low oil pressure. 3. Check oil pressure sensor/switch
and main bearing oil clearance.
4. Clogged oil filter. 4. Install new oil filter.
5. Worn parts in oil pump. 5. Replace worn parts or pump.
6. Thin or diluted oil. 6. Change oil to correct viscosity.
7. Oil pump relief valve stuck. 7. Remove valve and inspect, clean,
or replace.
8. Oil pump suction tube loose. 8. Remove oil pan and install new
tube or clean, if necessary.
9. Oil pump cover warped or
cracked.9. Install new oil pump.
10. Excessive bearing clearance. 10. Measure bearings for correct
clearance.
OIL LEAKS 1. Misaligned or deteriorated
gaskets.1. Replace gasket(s).
2. Loose fastener, broken or porous
metal part.2. Tighten, repair or replace the
part.
3. Misaligned or deteriorated cup or
threaded plug.3. Replace as necessary.
RSENGINE 2.4L9-7
ENGINE 2.4L (Continued)
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CONDITION POSSIBLE CAUSES CORRECTION
OIL CONSUMPTION OR SPARK
PLUGS FOULED1. PCV system malfunction. 1. Check system and repair as
necessary. (Refer to 25 -
EMISSIONS CONTROL/
EVAPORATIVE EMISSIONS/PCV
VALVE - DIAGNOSIS AND
TESTING)
2. Worn, scuffed or broken rings. 2. Hone cylinder bores. Install new
rings.
3. Carbon in oil ring slots. 3. Install new rings.
4. Rings fitted too tightly in grooves. 4. Remove rings and check
grooves. If groove is not proper
width, replace piston.
5. Worn valve guide(s). 5. Replace cylinder head assembly.
6. Valve stem seal(s) worn or
damaged.6. Replace seal(s).
DIAGNOSIS AND TESTING - ENGINE OIL LEAK
INSPECTION
Begin with a thorough visual inspection of the
engine, particularly at the area of the suspected leak.
If an oil leak source is not readily identifiable, the
following steps should be followed:
(1) Do not clean or degrease the engine at this
time because some solvents may cause rubber to
swell, temporarily stopping the leak.
(2) Add an oil soluble dye (use as recommended by
manufacturer). Start the engine and let idle for
approximately 15 minutes. Check the oil dipstick to
make sure the dye is thoroughly mixed as indicated
with a bright yellow color under a black light.
(3) Using a black light, inspect the entire engine
for fluorescent dye, particularly at the suspected area
of oil leak. If the oil leak is found and identified,
repair as necessary.
(4) If dye is not observed, drive the vehicle at var-
ious speeds for approximately 24 km (15 miles), and
repeat inspection.
(5)If the oil leak source is not positively
identified at this time, proceed with the air leak
detection test method as follows:
²Disconnect the fresh air hose (make-up air) at
the cylinder head cover and plug or cap the nipple on
the cover.
²Remove the PCV valve hose from the cylinder
head cover. Cap or plug the PCV valve nipple on the
cover.
²Attach an air hose with pressure gauge and reg-
ulator to the dipstick tube.
CAUTION: Do not subject the engine assembly to
more than 20.6 kpa (3 PSI) of test pressure.²Gradually apply air pressure from 1 psi to 2.5
psi maximum while applying soapy water at the sus-
pected source. Adjust the regulator to the suitable
test pressure that provides the best bubbles which
will pinpoint the leak source. If the oil leak is
detected and identified, repair per service manual
procedures.
²If the leakage occurs at the crankshaft rear oil
seal area, refer to the section, Inspection for Rear
Seal Area Leak.
(6) If no leaks are detected, turn off the air supply.
Remove the air hose, all plugs, and caps. Install the
PCV valve and fresh air hose (make-up air). Proceed
to next step.
(7) Clean the oil off the suspect oil leak area using
a suitable solvent. Drive the vehicle at various
speeds approximately 24 km (15 miles). Inspect the
engine for signs of an oil leak by using a black light.
NOTE: If oil leakage is observed at the dipstick tube
to block location; remove the tube, clean and reseal
using MoparTStud & Bearing Mount (press fit tube
applications only), and for O-ring style tubes,
remove tube and replace the O-ring seal.
INSPECTION FOR REAR SEAL AREA LEAKS
Since it is sometimes difficult to determine the
source of an oil leak in the rear seal area of the
engine, a more involved inspection is necessary. The
following steps should be followed to help pinpoint
the source of the leak.
If the leakage occurs at the crankshaft rear oil seal
area:
(1) Disconnect the battery.
(2) Raise the vehicle.
9 - 8 ENGINE 2.4LRS
ENGINE 2.4L (Continued)
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