2002 CHRYSLER CARAVAN steering

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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(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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INTERNAL VACUUM PUMP
DESCRIPTION
The diesel engine uses a internal vacuum pump.
This vacuum pump is mounted in the front of the
engine block under the engine front cover (Fig. 45).
The vacuum pump is driven by a sprocket on the
crankshaft.
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove air cleaner housing.
(3) Remove power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(4) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(5) Support engine and remove right engine mount
(Refer to 9 - ENGINE/ENGINE MOUNTING/RIGHT
MOUNT - REMOVAL).
(6) Remove vibration damper/crankshaft pulley
(Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL).
(7) Remove outer timing belt cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(8) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL).
(9) Remove timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
NOTE: Crankshaft hub has LHD thread.
(10) Remove crankshaft hub.
(11) Remove front engine cover (Refer to 9 -
ENGINE/ENGINE BLOCK/ENGINE COVER -
REMOVAL).
(12) Remove crankshaft sprocket (Fig. 46).
(13) Remove vacuum pump (Fig. 46).
INSTALLATION
(1) Lubricate vacuum pump blades and install in
vacuum pump body as shown (Fig. 47).
(2) Install vacuum pump in engine block (Fig. 46).
Torque bolts to 10.8N´m.
(3) Install crankshaft sprocket (Fig. 46). Torque
bolts to 10.8N´m.
(4) Install front engine cover (Refer to 9 -
ENGINE/ENGINE BLOCK/ENGINE COVER -
INSTALLATION).
(5) Install front crankshaft hub. Torque bolt to
304N´m.
(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 vibration damper/crankshaft pulley.
Fig. 45 VACUUM PUMP
Fig. 46 OIL PUMP AND VACUUM PUMP
1 - VACUUM PUMP
2 - CRANKSHAFT SPROCKET
3 - OIL PUMP
4 - ENGINE BLOCK
5 - CRANKSHAFT
RGENGINE9a-35
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(10) Install right engine mount (Refer to 9 -
ENGINE/ENGINE MOUNTING/RIGHT MOUNT -
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) Connect negative battery cable.
PISTON & CONNECTING ROD
DESCRIPTION
The pistons are of a free floating design. Oil jets in
the engine block lubricate and cool the piston and pin
assembly. The connecting rods have a pressed in
place wrist pin bushing which is lubricated by the oil
jets (Fig. 48).
STANDARD PROCEDURE - PISTON RING
FITTING
(1) Wipe cylinder bore clean. Insert ring and push
down with piston to ensure it is square in bore. The
ring gap measurement must be made with the ring
positioning at least 12 mm (0.50 in.) from bottom of
cylinder bore (Fig. 49). Check gap with feeler gauge.
Top compression ring gap .30 to .45mm (.0118 to
.0177 in.). Second compression ring gap .30 to .45mm(.0118 to .0177 in.). Oil control ring gap .25 to .50mm
(.0098 to .0196 in.).
(2) If ring gaps exceed dimension given, new rings
or cylinder liners must be fitted. Keep piston rings in
piston sets.
(3) Check piston ring to groove clearance (Fig. 50).
Top compression ring gap .080 to .130mm (.0031 to
.0051 in.). Second compression ring gap .070 to
.110mm (.0027 to .0043 in.). Oil control ring gap .040
to .080mm (.0015 to .0031 in.).
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
Fig. 47 VACUUM PUMP COMPONENTS
1 - VACUUM PUMP BODY
2 - VACUUM PUMP BLADE TAPERED EDGE
3 - VACUUM PUMP BLADE
Fig. 48 PISTON AND CONNECTING ROD ASSEMBLY
1 - PISTON PIN
2 - PISTON
3 - SNAP RING
4 - CONNECTING ROD ALIGNMENT NUMBERS
5 - CONNECTING ROD BOLT
6 - CONNECTING ROD BEARING
7 - CONNECTING ROD
8 - SNAP RING
9a - 36 ENGINERG
INTERNAL VACUUM PUMP (Continued)
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CRANKSHAFT OIL SEAL -
FRONT
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove air cleaner housing.
(3) Support engine and remove right engine mount
(Refer to 9 - ENGINE/ENGINE MOUNTING/RIGHT
MOUNT - REMOVAL).
(4) Remove power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(5) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(6) Remove vibration damper/crankshaft pulley
(Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL).
(7) Remove outer timing belt cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(8) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL).
(9) Remove timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
NOTE: Crankshaft hub retaining bolt has LHD
thread.
(10) Remove crankshaft hub.
(11) Remove front engine cover (Fig. 59) (Refer to
9 - ENGINE/ENGINE BLOCK/ENGINE COVER -
REMOVAL).
(12) With cover on work bench, pry out old seal.
INSTALLATION
(1) Clean engine block and front engine cover seal-
ing surfaces.
(2) Install crankshaft oil seal on VM.1061 (Fig.
60).
(3) Place sleeve for VM.1061 on workbench as
shown (Fig. 60).
Fig. 59 ENGINE COVER - FRONT
1 - CRANKSHAFT HUB RETAINING BOLT
2 - FRONT ENGINE COVER RETAINING BOLTS
3 - ENGINE BLOCK
4 - FRONT ENGINE COVER ALIGNMENT DOWELS
5 - FRONT ENGINE COVER
6 - CRANKSHAFT HUB
Fig. 60 VM.1061 PLACEMENT
1 - VM.1061
2 - FRONT ENGINE COVER
3 - WORK BENCH
4 - SLEEVE FROM VM.1061
RGENGINE9a-41
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(4) Using hammer, install new seal into front
engine cover (Fig. 61).
(5) Install front engine cover (Refer to 9 -
ENGINE/ENGINE BLOCK/ENGINE COVER -
INSTALLATION).
(6) Install crankshaft hub and retaining bolt.
Torque bolt to 304N´m.
(7) Install timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(8) Install timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION) .
(9) Install timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(10) Install vibration damper/crankshaft pulley
(Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - 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 right engine mount (Refer to 9 -
ENGINE/ENGINE MOUNTING/RIGHT MOUNT -
INSTALLATION).
(14) Install air cleaner housing.
(15) Connect negative battery cable.VIBRATION DAMPER
REMOVAL
(1) Remove power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(2) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(3) Remove vibration damper retaining bolts and
damper (Fig. 62).
INSTALLATION
(1) Install vibration damper and retaining bolts
(Fig. 62). Torque bolts to 27.5N´m.
(2) Install accessory drive belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(3) Install power steering belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
Fig. 61 CRANKSHAFT OIL SEAL INSTALLATION
WITH VM.1061
1 - VM.1061
2 - FRONT ENGINE COVER
3 - WORK BENCH
Fig. 62 VIBRATION DAMPER
1 - BELT TENSIONER RETAINING BOLT
2 - BELT TENSIONER
3 - IDLER PULLEY
4 - VIBRATION DAMPER/CRANKSHAFT PULLEY
5 - VIBRATION DAMPER/CRANKSHAFT PULLEY RETAINING
BOLTS
9a - 42 ENGINERG
CRANKSHAFT OIL SEAL - FRONT (Continued)
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ENGINE COVER - FRONT
DESCRIPTION
The front engine cover on this engine is a stamped
steel cover which covers the oil pump and vacuum
pump.
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove air cleaner housing.
(3) Support engine and remove right engine mount
(Refer to 9 - ENGINE/ENGINE MOUNTING/RIGHT
MOUNT - REMOVAL).
(4) Remove power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(5) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(6) Remove vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(7) Remove timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - 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)
(8) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL).
(9) Remove timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
NOTE: Crankshaft hub has LHD thread.
(10) Remove crankshaft hub.
(11) Remove front engine cover (Fig. 63).
INSTALLATION
(1) Clean engine block and front engine cover seal-
ing surfaces.
(2) Apply a continous 3mm bead of Silicone Sealer
to cover, install within 10 minutes (Fig. 63). Torque
bolts to 11.8N´m.
(3) Install crankshaft hub (Fig. 63). Torque bolt to
304N´m.
(4) Install timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).(5) Install timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION) .
(6) Install timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(7) Install vibration damper (Refer to 9 - ENGINE/
ENGINE BLOCK/VIBRATION DAMPER - INSTAL-
LATION).
(8) Install right engine mount (Refer to 9 -
ENGINE/ENGINE MOUNTING/RIGHT MOUNT -
INSTALLATION).
(9) Install accessory drive belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(10) Install power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(11) Install air cleaner housing.
(12) Connect negative battery cable.
Fig. 63 ENGINE COVER - FRONT
1 - CRANKSHAFT HUB RETAINING BOLT
2 - FRONT ENGINE COVER RETAINING BOLTS
3 - ENGINE BLOCK
4 - FRONT ENGINE COVER ALIGNMENT DOWELS
5 - FRONT ENGINE COVER
6 - CRANKSHAFT HUB
RGENGINE9a-43
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CRANKSHAFT OIL SEAL -
REAR
REMOVAL
This must be done with either the engine or trans-
mission removed from vehicle.
(1) Remove flywheel assembly.
(2) Pry out old crankshaft oil seal.
INSTALLATION
(1) Using special tool VM.1050, install rear crank-
shaft oil seal in rear main bearing support (Fig. 69).
(2) Install engine or tranmission in vehicle.
OIL PAN
REMOVAL
(1) Disconnect negative battery cable.
(2) Raise vehicle on hoist.
(3) Drain engine oil from engine.
(4) Remove all oil pan retaining bolts and oil pan
(Fig. 70).
INSTALLATION
(1) Clean oil pan and sealing surfaces. Inspect oil
pan and engine block.
(2) Install oil pan, gasket, and retaining bolts (Fig.
70).
(3) Be sure power steering line brackets are in
proper location (Fig. 70).
(4) Torque oil pan bolts to 11.8N´m.
(5) Lower vehicle.
(6) Refill engine oil to proper level.
(7) Connect negative battery cable.
Fig. 69 REAR CRANKSHAFT OIL SEAL
INSTALLATION USING VM.1050
1 - SPECIAL TOOL VM.1050
2 - REAR MAIN BEARING SUPPORT
3 - OIL PAN
4 - ENGINE TO TRANSMISSION ADAPTER PLATE
Fig. 70 OIL PAN AND PRESSURE RELIEF VALVE
1 - OIL PAN RETAINING BOLTS
2 - POWER STEERING LINE BRACKETS
3 - OIL PAN GASKET
4 - OIL PRESSURE SENSOR
5 - ENGINE BLOCK
6 - OIL PRESSURE RELIEF VALVE
7 - OIL PAN RETAINING BOLTS
8 - OIL PAN
9a - 46 ENGINERG
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