2002 CHRYSLER CARAVAN oil dipstick

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 - 82 ENGINE 3.3/3.8LRS
ENGINE 3.3/3.8L (Continued)
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REMOVAL - ENGINE ASSEMBLY
(1) Perform fuel pressure release procedure (Refer
to 14 - FUEL SYSTEM/FUEL DELIVERY - STAN-
DARD PROCEDURE).
(2) Disconnect negative battery cable.
(3) Remove air cleaner and hoses.
(4) Disconnect the fuel line from fuel rail (Refer to
14 - FUEL SYSTEM/FUEL DELIVERY/QUICK
CONNECT FITTING - STANDARD PROCEDURE).
(5) Remove the wiper module (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
REMOVAL).
(6) Block off heater hoses to the rear heater sys-
tem using pinch-off pliers (if equipped).
(7) Drain the cooling system (Refer to 7 - COOL-
ING - STANDARD PROCEDURE).
(8) Disconnect the heater hoses.
(9) Remove the radiator upper support crossmem-
ber (Refer to 23 - BODY/EXTERIOR/GRILLE OPEN-
ING REINFORCEMENT - REMOVAL).
(10) Remove the radiator fans (Refer to 7 - COOL-
ING/ENGINE/RADIATOR FAN - REMOVAL).
(11) Disconnect the throttle cables from the throt-
tle body.
(12) Disconnect the MAP, IAC, and TPS electrical
connectors.
(13) Disconnect the EGR transducer electrical con-
nector (if equipped).
(14) Disconnect the vacuum hoses from throttle
body.
(15) Disconnect the brake booster and speed con-
trol vacuum hoses.
(16) Disengage wire harness clip from the right
side engine mount.
(17) Remove the power steering reservoir from
mounting position and set aside.Do notdisconnect
hose.
(18) Disconnect ground strap from rear of cylinder
head.
(19) Disconnect engine coolant temperature (ECT)
sensor and ignition coil electrical connectors.
(20) Disconnect the fuel injector electrical harness
connector and disengage clip from support bracket.
(21) Disconnect camshaft and crankshaft position
sensor electrical connectors.
(22) Evacuate air conditioning system. Refer to 24
- HEATING & AIR CONDITIONING.
(23) Disconnect A/C compressor electrical connec-
tor.(24) Disconnect the A/C lines from compressor.
Cover and seal all openings of hoses and compressor.
(25) Remove the radiator upper hose.
(26) Disengage electrical harness clip at transaxle
dipstick tube.
(27) Remove transaxle dipstick tube. Seal opening
using a suitable plug.
NOTE: When the transaxle cooler lines are removed
from the rolled-groove type fittings at the transaxle,
damage to the inner wall of the hose will occur. To
prevent prevent potential leakage, the cooler hoses
must be cut off flush at the transaxle fitting, and a
service cooler hose splice kit must be installed
upon reassembly.
(28) Using a blade or suitable hose cutter, cut
transaxle oil cooler lines off flush with fittings. Plug
cooler lines and fittings to prevent debris from enter-
ing transaxle or cooler circuit. A service splice kit will
be installed upon reassembly.
(29) Disconnect transaxle shift linkage and electri-
cal connectors.
(30) Raise vehicle on hoist and drain the engine
oil.
(31) Remove the axle shafts. (Refer to 3 - DIFFER-
ENTIAL & DRIVELINE/HALF SHAFT - REMOVAL)
(32) Remove crossmember cradle plate (Fig. 6).
Fig. 6 Crossmember Cradle Plate
1 - CRADLE PLATE
RSENGINE 3.3/3.8L9-87
ENGINE 3.3/3.8L (Continued)
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(48) Remove the water pump pulley attaching
bolts and position pulley between pump hub and
housing.
(49) Disconnect the oil pressure switch electrical
connector.
(50) Disconnect wiring harness support clip from
engine oil dipstick tube.
(51) Install Special Tools 6912 and 8444 Adapters
on the right side (rear) of engine block (Fig. 9).
(52) Lower the vehicle.
(53) Remove the power steering pump and set
aside.
(54) Raise vehicle enough to allow engine dolly
Special Tool 6135 and cradle Special Tool 6710 with
post Special Tool 6848 and adaptor Special Tool 6909
to be installed under vehicle (Fig. 12).
(55) Loosen cradle/post mounts to allow movement
for positioning posts into locating holes on the engine
(Fig. 10) and (Fig. 11). Slowly lower vehicle and posi-
tion cradle/post mounts until the engine is resting on
posts. Tighten all cradle/post mounts to cradle frame.
This will keep mounts from moving when removing
or installing engine and transmission.(56) Lower vehicle so the weight ofONLY THE
ENGINE AND TRANSMISSIONis on the cradle.
(57) Install and secure the safety straps to the cra-
dle fixture and around the engine (Fig. 12).
(58) Remove the engine right side mount to engine
attaching bolts (Fig. 13).
(59) Remove the left mount through bolt (Fig. 14).
(60) Raise vehicle slowly. It is necessary to move
the engine/transmission assembly with the dolly to
allow for removal around body flanges.
Fig. 9 ADAPTER TOOLS MOUNTED ON BLOCK
1 - SPECIAL TOOL 6912
2 - SPECIAL TOOL 8444
Fig. 10 Positioning Special Tool 6848 for use with
Adapters 8444 & 6912
1 - SLOTS
2 - SPECIAL TOOLS 6848
Fig. 11 Special Tools 6848 with Adapters 6909
1 - OIL FILTER
2 - SPECIAL TOOLS 6909
3 - OIL PAN
4 - SPECIAL TOOLS 6848
RSENGINE 3.3/3.8L9-89
ENGINE 3.3/3.8L (Continued)
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INSTALLATION - ENGINE ASSEMBLY
(1) Position engine and transmission assembly
under vehicle. Slowly lower the vehicle down over the
engine and transmission. It is necessary to move the
engine/transmission assembly with the dolly for
clearance around body flanges.
(2) Align engine and transmission mounts to
attaching points. Install mounting bolts at the right
engine mount (Fig. 13) and left transmission mount
(Fig. 14).
(3) Remove the safety straps from around engine.
(4) Slowly raise vehicle enough to remove the
engine dolly and cradle Special Tools 6135, 6710,
6848 and 6909 (Fig. 12).
(5) Remove Special Tools 6912 and 8444 (Fig. 9).
(6) Lower the vehicle.
(7) Install power steering pump and pressure line
support.(8) Install the generator and wiring harness (Refer
to 8 - ELECTRICAL/CHARGING/GENERATOR -
INSTALLATION).
(9) Raise vehicle.
(10) Attach wiring harness support clip to the
engine oil dipstick tube.
(11)
Connect oil pressure switch electrical connector.
(12) Install the A/C compressor.
(13) Install the water pump pulley.
(14) Connect the radiator lower hose.
(15) Install the accessory drive belt and splash
shield (Refer to 7 - COOLING/ACCESSORY DRIVE/
DRIVE BELTS - INSTALLATION).
(16) Connect the engine block heater electrical con-
nector (if equipped).
(17) Connect the knock sensor electrical connector
(3.8L only).
(18) Install the torque converter to flex plate bolts.
(19) Install the transaxle case cover (Fig. 8).
Fig. 12 Positioning Engine Cradle Support Post Mounts
1 - SPECIAL TOOL 8444
2 - SPECIAL TOOLS 6848
3 - SPECIAL TOOL 6912
4 - SPECIAL TOOLS 6135 & 67105 - SPECIAL TOOLS 6848
6 - SAFETY STRAPS
7 - SPECIAL TOOLS 6909
9 - 90 ENGINE 3.3/3.8LRS
ENGINE 3.3/3.8L (Continued)
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(20) Install the powertrain struts (Fig. 8).
(21) Install the engine rear mount bracket.
(22) Install the engine front mount and bracket
assembly.
(23)AWD equipped;Install the power transfer
unit (PTU) (Refer to 21 - TRANSMISSION/TRANS-
AXLE/POWER TRANSFER UNIT - INSTALLA-
TION).
(24) Install the axle shafts (Refer to 3 - DIFFER-
ENTIAL & DRIVELINE/HALF SHAFT - INSTALLA-
TION).(25) Connect exhaust pipe to manifold (Fig. 7).
(26) Install crossmember cradle plate (Fig. 6).
(27) Lower vehicle.
(28) Connect transaxle shift linkage.
(29) Connect transaxle electrical connectors.
(30) Remove plugs from transmission cooler hoses
and install transaxle oil cooler line service splice kit.
Refer to instructions included with kit.
(31) Install transaxle dipstick tube and attach
electrical harness clip.
(32) Connect the A/C lines to compressor.
(33)
Connect the A/C compressor electrical connector.
(34) Evacuate and recharge A/C system.
(35) Connect crankshaft and camshaft position
sensors.
(36) Connect the fuel injector electrical harness
connector and engage clip to support bracket.
(37) Connect engine coolant temperature (ECT)
sensor and ignition coil electrical connectors.
(38) Connect the ground strap to rear of cylinder
head.
(39) Install power steering reservoir.
(40) Engage wire harness clip to engine right side
mount.
(41) Connect the brake booster and speed control
vacuum hoses.
(42) Connect the vacuum hoses to the throttle
body.
(43) Connect the EGR transducer electrical connec-
tor (if equipped).
(44) Connect the TPS, IAC, and MAP sensor elec-
trical connectors.
(45) Connect throttle cables to throttle body.
(46) Install the radiator fans (Refer to 7 - COOL-
ING/ENGINE/RADIATOR FAN - INSTALLATION).
(47) Connect the radiator upper hose.
(48) Connect the heater hoses. Remove pinch-off
pliers from the rear heater hoses (if equipped).
(49) Install the radiator upper support crossmem-
ber (Refer to 23 - BODY/EXTERIOR/GRILLE OPEN-
ING REINFORCEMENT - INSTALLATION).
(50) Install the wiper module (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
INSTALLATION).
(51) Connect the fuel line to fuel rail (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL LINES -
STANDARD PROCEDURE).
(52) Install the air cleaner and hoses.
(53) Install new oil filter. Fill engine crankcase
with proper oil to correct level.
(54) Connect negative cable to battery.
(55) Fill the cooling system (Refer to 7 - COOLING
- STANDARD PROCEDURE).
(56) Start engine and run until operating temper-
ature is reached.
(57) Adjust transmission linkage, if necessary.
Fig. 13 Right Mount to Engine
1 - BOLT
2 - MOUNT BRACKET
3 - ENGINE RIGHT MOUNT ASSEMBLY
Fig. 14 LEFT MOUNT TO FRAME BRACKET
1 - FRAME BRACKET
2 - FRAME RAIL - LEFT
3 - BOLT
4 - TRANSAXLE MOUNT
RSENGINE 3.3/3.8L9-91
ENGINE 3.3/3.8L (Continued)
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DESCRIPTION N´mFt.
Lbs.In.
Lbs.
Exhaust Crossover
PipeÐBolts54 40 Ð
Intake Manifold -
LowerÐBolts23 Ð 200
Intake Manifold - Lower
Gasket RetainerÐBolts12 Ð 105
Intake Manifold
UpperÐBolts12 Ð 105
Lifter Yoke RetainerÐ
Bolts12 Ð 105
Oil Filter Attaching Fitting 54 40 Ð
Oil Cooler Attaching
Fitting27 20 Ð
Oil Filter 20 15 Ð
Oil Filter AdapterÐBolts 28 Ð 250
Oil Gallery Plug 27 20 Ð
Oil PanÐBolts 12 Ð 105
Oil Pan DrainÐPlug 27 20 Ð
Oil Pressure Switch 23 Ð 200
Oil Pump Cover
PlateÐScrews12 Ð 105
Oil Pump Pick-up
TubeÐBolt28 Ð 250
Oil Dipstick HousingÐ
Bolts48 35 Ð
Rocker Arm ShaftÐBolts 23 Ð 200
Spark Plug 16 12 Ð
Timing Chain Case Cover
ÐM8 Bolt 27 20 Ð
ÐM10 Bolt 54 40 Ð
Water PumpÐBolts 12 Ð 105
Water Pump PulleyÐ
Bolts28 Ð 250SPECIAL TOOLS
3.3/3.8L ENGINE
Dolly 6135
Cradle 6710A
Adapter 6909A
Adapter 8444
9 - 96 ENGINE 3.3/3.8LRS
ENGINE 3.3/3.8L (Continued)
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(4) Remove the cylinder head covers. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL)
(5) Remove the spark plugs from cylinder head.
(6) Remove the dipstick and tube (Fig. 18).
(7) Remove exhaust manifold(s). (Refer to 9 -
ENGINE/MANIFOLDS/EXHAUST MANIFOLD -
REMOVAL)
(8) Remove rocker arm and shaft assemblies.(Refer
to 9 - ENGINE/CYLINDER HEAD/ROCKER ARMS -
REMOVAL) Remove push rods andmark positions
to ensure installation in original locations.
(9) Remove the eight head bolts from each cylinder
head and remove cylinder heads (Fig. 22).
CLEANING
To ensure engine gasket sealing, proper surface
preparation must be performed, especially with the
use of aluminum engine components and multi-layer
steel cylinder head gaskets.NOTE: Multi-Layer Steel (MLS) head gaskets require
a scratch free sealing surface.
Remove all gasket material from cylinder head and
block (Refer to 9 - ENGINE - STANDARD PROCE-
DURE). Be careful not to gouge or scratch the alumi-
num head sealing surface.
Clean all engine oil passages.
INSPECTION
(1) Before cleaning, check for leaks, damage and
cracks.
(2) Clean cylinder head and oil passages.
(3) Check cylinder head for flatness (Fig. 19).
(4) Cylinder head must be flat within:
²Standard dimension = less than 0.05 mm (0.002
inch.)
²Service Limit = 0.2 mm (0.008 inch.)
²Grinding Limit = Maximum of 0.2 mm (0.008
inch.) is permitted.
Fig. 17 Cylinder Head and Components
1 - VALVE LOCKS 5 - SPRING SEATS
2 - RETAINERS 6 - CYLINDER HEAD
3 - VALVE SPRINGS 7 - VALVE - EXHAUST
4 - VALVE STEM SEALS 8 - VALVE - INTAKE
RSENGINE 3.3/3.8L9 - 101
CYLINDER HEAD (Continued)
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²Step 2: Bolts1±8to88N´m(65ft.lbs.)
²Step 3: Bolts1±8(again) to 88 N´m (65 ft. lbs.)
²Step 4: Bolts1±8turn an additional 1/4 Turn.
(Do not use a torque wrench for this step.)
NOTE: Bolt torque after 1/4 turn should be over 122
N´m (90 ft. lbs.). If not, replace the bolt.
(6) Inspect push rods and replace worn or bent
rods.
(7) Install the push rods.
(8) Install the rocker arm and shaft assemblies.
(Refer to 9 - ENGINE/CYLINDER HEAD/ROCKER
ARMS - INSTALLATION)
(9) Install the cylinder head covers. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION)
(10) Install the exhaust manifolds. (Refer to 9 -
ENGINE/MANIFOLDS/EXHAUST MANIFOLD -
INSTALLATION)
(11) Install new O-ring on dipstick tube. Install
dipstick tube assembly (Fig. 18).
(12) Install the spark plugs.
(13) Install upper and lower intake manifolds.
(Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANI-
FOLD - INSTALLATION)
(14) Fill the cooling system. (Refer to 7 - COOL-
ING - STANDARD PROCEDURE)
(15) Connect negative cable to battery.
CYLINDER HEAD COVER(S)
DESCRIPTION
The cylinder head covers are made of stamped
steel. The covers are sealed with steel reinforced sil-
icon rubber gaskets. The cylinder head cover uses
rubber isolators at each fastener location (Fig. 23).
NOTE: Due to the tight packaging near the cylinder
head covers, which makes spill clean-up difficult, a
spill during an engine oil change may be misinter-
preted as an oil leak. When investigating an oil leak
in the location of the cylinder head covers and
intake manifold, follow the procedure found in Oil
Leak Diagnosis (Refer to 9 - ENGINE - DIAGNOSISAND TESTING) for determining the source of a
leak.
CYLINDER HEAD COVER -
RIGHT
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove the wiper module. (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
REMOVAL)
(3) Disconnect spark plug wires from plugs.
(4) Disconnect power steering pump supply hose
support clip from cylinder head cover (Fig. 24).
(5) Disconnect PCV hose from cylinder head cover
(Fig. 25).
(6) Remove cylinder head cover bolts.
(7) Remove cylinder head cover and gasket (Fig.
23).
INSTALLATION
(1) Clean cylinder head and cover mating surfaces.
Inspect cylinder head cover surface for flatness.
Replace gasket as necessary.
(2) Inspect seal on the cover bolt for wear or dam-
age (Fig. 26). Replace bolt assembly as necessary.
NOTE: The cylinder head cover bolts contain a
torque limiter sleeve and a seal (Fig. 26). The seal
and torque sleeve is replaced with the bolt.
Fig. 22 CYLINDER HEAD TIGHTENING SEQUENCE
Fig. 23 Cylinder Head Cover
1 - CYLINDER HEAD COVER
2 - BOLT
RSENGINE 3.3/3.8L9 - 103
CYLINDER HEAD (Continued)
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