2002 CHRYSLER CARAVAN shaft

(3) Install upper side rail first and then the lower
side rail.
(4) Install No. 2 piston ring and then No. 1 piston
ring.
(5) Position piston ring end gaps as shown in (Fig.
74).
(6) Position oil ring expander gap at least 45É
from the side rail gaps butnoton the piston pin cen-
ter or on the thrust direction. Staggering ring gap is
important for oil control.VIBRATION DAMPER
REMOVAL
(1) Remove accesory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)
(2) Remove crankshaft damper bolt.
(3) Remove damper using Special Tool 3-Jaw
Puller 1026 and Insert 6827±A (Fig. 75).
INSTALLATION
(1) Install crankshaft vibration damper using M12
1.75 x 150 mm bolt, washer, thrust bearing and nut
from Special Tool 6792 (Fig. 76).
(2) Install crankshaft vibration damper bolt and
tighten to 142 N´m (105 ft. lbs.).
(3) Install accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION)
Fig. 73 Installing Side Rail
1 - SIDE RAIL END
Fig. 74 Piston
1 - GAP OF LOWER SIDE RAIL
2 - NO. 1 RING GAP
3 - GAP OF UPPER SIDE RAIL
4 - NO. 2 RING GAP AND SPACER EXPANDER GAP
Fig. 75 Crankshaft Vibration Damper - Removal
1 - SPECIAL TOOL 1026 3-JAW PULLER
2 - SPECIAL TOOL 6827±A INSERT
Fig. 76 Crankshaft Vibration Damper - Installation
1 - M12±1.75 ý 150 MM BOLT, WASHER AND THRUST BEARING
FROM SPECIAL TOOL 6792
9 - 48 ENGINE 2.4LRS
PISTON RINGS (Continued)
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LUBRICATION
DESCRIPTION
The lubrication system is a full-flow filtration,
pressure feed type. The oil pump is mounted in the
front engine cover and driven by the crankshaft.
OPERATION
Engine oil drawn up through the pickup tube and
is pressurized by the oil pump and routed through
the full-flow filter to the main oil gallery running the
length of the cylinder block. A diagonal hole in each
bulkhead feeds oil to each main bearing. Drilled pas-
sages within the crankshaft route oil from main bear-
ing journals to connecting rod journals. Balance shaft
lubrication is provided through an oil passage from
the number one main bearing cap through the bal-
ance shaft carrier support leg. This passage directly
supplies oil to the front bearings and internal
machined passages in the shafts that routes oil from
front to the rear shaft bearing journals. A vertical
hole at the number five bulkhead routes pressurized
oil through a restrictor (integral to the cylinder head
gasket) up past a cylinder head bolt to an oil galleryrunning the length of the cylinder head. The cam-
shaft journals are partially slotted to allow a prede-
termined amount of pressurized oil to pass into the
bearing cap cavities. Lubrication of the camshaft
lobes are provided by small holes in the camshaft
bearing caps that are directed towards each lobe. Oil
returning to the pan from pressurized components
supplies lubrication to the valve stems. Cylinder
bores and wrist pins are splash lubricated from
directed slots on the connecting rod thrust collars.
DIAGNOSIS AND TESTING - CHECKING
ENGINE OIL PRESSURE
(1) Disconnect and remove oil pressure switch.
(Refer to 9 - ENGINE/LUBRICATION/OIL PRES-
SURE SENSOR/SWITCH - REMOVAL)
(2) Install Special Tools C-3292 Gauge with 8406
Adaptor fitting.
(3) Start engine and record oil pressure. Refer to
Specifications for correct oil pressure requirements.
(Refer to 9 - ENGINE - SPECIFICATIONS)
CAUTION: If oil pressure is 0 at idle, do not perform
the 3000 RPM test
(4) If oil pressure is 0 at idle. Shut off engine,
check for pressure relief valve stuck open, a clogged
oil pick-up screen or a damaged oil pick-up tube
O-ring.
(5) After test is complete, remove test gauge and
fitting.
(6) Install oil pressure switch and connector. (Refer
to 9 - ENGINE/LUBRICATION/OIL PRESSURE
SENSOR/SWITCH - INSTALLATION)
OIL
STANDARD PROCEDURE
ENGINE OIL LEVEL CHECK
The best time to check engine oil level is after it
has sat overnight, or if the engine has been running,
allow the engine to be shut off for at least 5 minutes
before checking oil level.
Checking the oil while the vehicle is on level
ground will improve the accuracy of the oil level
reading. Remove dipstick and observe oil level. Add
oil only when the level is at or below the ADD mark
(Fig. 87).
Fig. 86 RIGHT MOUNT TO RAIL AND ENGINE
1 - BOLT - MOUNT TO RAIL 68 N´m (50 ft. lbs.)
2 - BOLT - MOUNT TO ENGINE 54 N´m (40 ft. lbs.)
3 - BOLT - MOUNT TO RAIL (HORIZONTAL) 68 N´m (50 ft. lbs.)
4 - RIGHT ENGINE MOUNT
5 - RIGHT FRAME RAIL
RSENGINE 2.4L9-53
RIGHT MOUNT (Continued)
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INSTALLATION
(1) Clean and check filter mounting surface. The
surface must be smooth, flat and free of debris or
pieces of gasket.
(2) Lubricate new oil filter gasket with clean
engine oil.
(3) Screw oil filter (Fig. 88) on until the gasket
contacts base. Tighten to 12 N´m (105 in. lbs.).
OIL PAN
REMOVAL
(1) Raise vehicle on hoist and drain engine oil.
(2) Remove structural collar. (Refer to 9 -
ENGINE/ENGINE BLOCK/STRUCTURAL COVER -
REMOVAL)
(3) Remove air conditioning compressor bracket to
oil pan bolt.
(4) Remove bolts attaching oil pan.
(5) Remove oil pan.
(6) Clean oil pan and all gasket surfaces.
INSTALLATION
(1) Apply MopartEngine RTV GEN II at the oil
pump to engine block parting line (Fig. 89).
(2) Install the oil pan gasket to the block.
(3) Install pan and tighten the screws to 12 N´m
(105 in. lbs.).
(4) Install air conditioning compressor bracket to
oil pan bolt.
(5) Install structural collar. (Refer to 9 - ENGINE/
ENGINE BLOCK/STRUCTURAL COVER - INSTAL-
LATION)
(6) Lower vehicle and fill engine crankcase with
proper oil to correct level.
OIL PRESSURE SWITCH
REMOVAL
(1) Raise vehicle.
(2) Position oil collecting container under pressure
switch location.
(3) Disconnect oil pressure switch electrical con-
nector and remove switch (Fig. 90).
INSTALLATION
(1) Install oil pressure switch. Torque switch to 21
N´m (190 in. lbs.) (Fig. 90).
(2) Connect electrical connector
(3) Lower vehicle.
(4) Start engine and allow to run a minimum of 2
minutes.
(5) Shut engine off and check engine oil level.
Adjust level as necessary.
OIL PUMP
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
REMOVAL).
(3) Remove timing belt rear cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT COVER(S)
- REMOVAL).
(4) Remove oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - REMOVAL).
(5) Remove crankshaft sprocket using Special
Tools 6793 and C-4685-C2 (Fig. 91).
(6) Remove crankshaft key (Fig. 92).
(7) Remove oil pick-up tube.
(8) Remove oil pump (Fig. 93) and front crankshaft
seal.
Fig. 89 Oil Pan Sealing - Typical
1 - SEALER LOCATIONS
Fig. 90 Engine Oil Pressure Switch
RSENGINE 2.4L9-55
OIL FILTER (Continued)
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DISASSEMBLY
(1) To remove the relief valve, proceed as follows:
(a) Remove the threaded plug and gasket from
the oil pump (Fig. 94) .
(b) Remove spring and relief valve (Fig. 94) .
(2) Remove oil pump cover fasteners, and lift off
cover (Fig. 95) .
(3) Remove pump rotors (Fig. 95) .
(4) Wash all parts in a suitable solvent and
inspect carefully for damage or wear.
Fig. 91 Crankshaft Sprocket - Removal
1 - SPECIAL TOOL 6793
2 - SPECIAL TOOL C-4685±C2
3 - CRANKSHAFT SPROCKET
Fig. 92 Crankshaft Key
1 - CRANKSHAFT KEY
Fig. 93 Oil Pump
1 - BOLTS
2 - BOLTS
3 - OIL PUMP
Fig. 94 Oil Pressure Relief Valve
1 - PLUG
2 - OIL PUMP BODY
3 - RELIEF VALVE
4 - SPRING
5 - SEAL
9 - 56 ENGINE 2.4LRS
OIL PUMP (Continued)
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ASSEMBLY
(1) Assemble pump, using new parts as required.
Install the inner rotor with chamfer facing the
cast iron oil pump cover.
(2) Prime oil pump before installation by filling
rotor cavity with engine oil.
(3) Install cover and tighten fasteners to 12 N´m
(105 in. lbs.) (Fig. 95).
CAUTION: Oil pump pressure relief valve must be
installed as shown in (Fig. 94) or serious engine
damage may occur.
(4) Install relief valve, spring, gasket and cap as
shown in (Fig. 94). Tighten cap to 41 N´m (30 ft.
lbs.).
INSTALLATION
(1) Make sure all surfaces are clean and free of oil
and dirt.(2) Apply MopartGasket Maker to oil pump as
shown in (Fig. 100). Install O-ring into oil pump body
discharge passage.
(3) Prime oil pump with engine oil before installa-
tion.
(4) Align oil pump rotor flats with flats on crank-
shaft. Install the oil pump to the block (Fig. 93).
CAUTION: To align, the front crankshaft seal MUST
be out of pump, or damage may result.
(5) Install new front crankshaft seal using Special
Tool 6780 (Fig. 101).
(6) Install crankshaft key (Fig. 92).
CAUTION: The crankshaft sprocket is set to a pre-
determined depth from the factory for correct tim-
ing belt tracking. If removed, use of Special Tool
6792 is required to set the sprocket to original
installation depth. An incorrectly installed sprocket
will result in timing belt and engine damage.
(7) Install crankshaft sprocket using Special Tool
6792 (Fig. 102).
(8) Install oil pump pick-up tube.
(9) Install oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION).
(10) Install timing belt rear cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT COVER(S)
- INSTALLATION).
(11) Install timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
INSTALLATION).
Fig. 98 Measuring Outer Rotor Thickness
Fig. 99 Measuring Inner Rotor Thickness
Fig. 100 Oil Pump Sealing
1 - O-RING
2 - SEALER LOCATION
9 - 58 ENGINE 2.4LRS
OIL PUMP (Continued)
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INTAKE MANIFOLD
DESCRIPTION
The intake manifold is a two piece aluminum cast-
ing (Fig. 103) that attaches to the cylinder head with
fasteners. The manifold is a long branch design to
enhance low and mid-range torque
OPERATION
The intake manifold delivers air to the combustion
chambers. This air allows the fuel delivered by the
fuel injectors to ignite when the spark plugs fire.
DIAGNOSIS AND TESTING - INTAKE
MANIFOLD LEAKS
An intake manifold air leak is characterized by
lower than normal manifold vacuum. Also, one or
more cylinders may not be functioning.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
(1) Start the engine.
(2) Spray a small stream of water (Spray Bottle) at
the suspected leak area.
(3) If engine RPM'S change, the area of the sus-
pected leak has been found.
(4) Repair as required.
Fig. 101 Front Crankshaft Seal - Installation
1 - PROTECTOR
2 - SEAL
3 - SPECIAL TOOL 6780
Fig. 102 Crankshaft Sprocket - Installation
1 - SPECIAL TOOL 6792
2 - TIGHTEN NUT TO INSTALL
Fig. 103 Intake Manifold - Upper and Lower
1 - UPPER INTAKE MANIFOLD
2 - LOWER INTAKE MANIFOLD
RSENGINE 2.4L9-59
OIL PUMP (Continued)
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(2) Attach exhaust pipe to exhaust manifold and
tighten fasteners to 37 N´m (27 ft. lbs.).
(3) Install and connect the oxygen sensor. (Refer to
14 - FUEL SYSTEM/FUEL INJECTION/O2 SENSOR
- COMPONENT LOCATION)
TIMING BELT COVER(S)
REMOVAL
FRONT COVER
(1) Remove crankshaft vibration damper. (Refer to
9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL)
(2) Remove generator drive belt tensioner assem-
bly. (Refer to 7 - COOLING/ACCESSORY DRIVE/
BELT TENSIONERS - REMOVAL)
(3) Remove timing belt front cover bolts (Fig. 112)
and remove covers.
REAR COVER
(1) Remove front covers.
(2) Remove engine mount bracket (Fig. 113).
(3) Remove timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL)
(4) Hold camshaft sprocket with Special Tool 6847
while removing center bolt (Fig. 114).
(5) Remove timing belt idler pulley.
(6) Remove rear cover fasteners and remove cover
from engine (Fig. 115).
INSTALLATION
REAR COVER
(1) Install timing belt rear cover and bolts (Fig.
115).CAUTION: Do not use an impact wrench for tighten-
ing camshaft sprocket bolt. Damage to the timing
locating pin can occur. Hand tighten using a
wrench ONLY.
(2) Install camshaft sprockets. Hold sprockets with
Special Tool 6848 and tighten center bolt to 101 N´m
(75 ft. lbs.).
(3) Install timing belt idler pulley and tighten
mounting bolt to 61 N´m (45 ft. lbs.).
(4) Install timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION)
(5) Install engine mount bracket and tighten bolts
to 61 N´m (45 ft. lbs.) (Fig. 113).
(6) Install front covers.
FRONT COVER
(1) Install timing belt front covers (Fig. 112).
Tighten fasteners to 7 N´m (60 in. lbs.).
(2) Install generator drive belt tensioner. (Refer to
7 - COOLING/ACCESSORY DRIVE/BELT TEN-
SIONERS - INSTALLATION)
Fig. 111 Exhaust Manifold Tightening Sequence
Fig. 112 Timing Belt Front Covers
1 - BOLTS - UPPER FRONT COVER 7 N´m (60 in. lbs.)
2 - BOLTS - LOWER FRONT COVER 7 N´m (60 in. lbs.)
RSENGINE 2.4L9-63
EXHAUST MANIFOLD (Continued)
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(3) Install crankshaft vibration damper. (Refer to 9
- ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
INSTALLATION)
TIMING BELT AND
SPROCKET(S)
REMOVAL
REMOVAL - TIMING BELT
(1) Remove air cleaner upper cover, housing, and
clean air tube.
(2) Remove make-up air hose from cylinder head
cover.
(3) Raise vehicle on hoist.
(4) Remove right front wheel.
(5) Remove right inner splash shield.
(6) Remove accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/BELT TENSION-
ERS - REMOVAL)
Fig. 113 ENGINE FRONT MOUNT BRACKET
1 - ENGINE MOUNT BRACKET
2 - BOLTS - 61 N´m (45 ft. lbs.)
Fig. 114 Camshaft Sprocket - Removal/Installation
1 - SPECIAL TOOL 6847
Fig. 115 Timing Belt Rear Cover
1 - BOLTS - REAR COVER 12 N´m (105 in. lbs.)
2 - BOLTS - REAR COVER 28 N´m (250 in. lbs.)
3 - TIMING BELT TENSIONER
9 - 64 ENGINE 2.4LRS
TIMING BELT COVER(S) (Continued)
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