2002 CHRYSLER CARAVAN timing belt

(4) Tighten the bolts to 27 N´m PLUS 1/4 turn (20
ft. lbs. PLUS 1/4 turn)Do not use a torque
wrench for last step.
(5) Using a feeler gauge, check connecting rod side
clearance (Fig. 45). Refer to clearance specifications
(Refer to 9 - ENGINE - SPECIFICATIONS).
CRANKSHAFT
DESCRIPTION
The crankshaft is made of nodular cast iron and
includes five main bearing journals and four connect-
ing rod journals (Fig. 46). The number three journal
is the location for the thrust bearing. The mains and
connecting rod journals have undercut fillet radiuses
that are rolled for added strength. To optimize bear-
ing loading, eight counterweights are used.
OPERATION
The crankshaft transfers force generated by com-
bustion within the cylinder to the flywheel or flex-
plate.
STANDARD PROCEDURE - CRANKSHAFT END
PLAY
(1) Using Dial Indicator C-3339 and Mounting
Post L-4438, attach to front of engine, locating probe
perpendicular on nose of crankshaft (Fig. 47).
(2) Move crankshaft all the way to the rear of its
travel.
(3) Zero the dial indicator.
(4) Move crankshaft all the way to the front and
read the dial indicator. Refer to Engine Specifica-
tions.
REMOVAL
NOTE: Crankshaft can not be removed when engine
is in vehicle.(1) Remove engine assembly from vehicle. (Refer to
9 - ENGINE - REMOVAL)
(2) Separate engine from transaxle.
(3) Remove flex plate and crankshaft rear oil seal.
(4) Mount engine on a repair stand.
(5) Drain engine oil and remove oil filter.
(6) Remove the oil pan. (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL)
(7) Remove engine mount support bracket.
(8) Remove the crankshaft damper and timing belt
covers. (Refer to 9 - ENGINE/VALVE TIMING/TIM-
ING BELT / CHAIN COVER(S) - REMOVAL)
(9) Remove the timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL)
Fig. 45 Connecting Rod Side Clearance
Fig. 46 Crankshaft - Typical
1 - MAIN BEARING JOURNALS
2 - COUNTER BALANCE WEIGHTS
Fig. 47 CHECKING CRANKSHAFT END PLAY
9 - 38 ENGINE 2.4LRS
CONNECTING ROD BEARINGS (Continued)
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(2) Make certain oil holes in block line up with oil
hole in bearings and bearing tabs seat in the block
tab slots.
CAUTION: Do not get oil on the bedplate mating
surface. It will affect the sealer ability to seal the
bedplate to cylinder block.
(3) Oil the bearings and journals. Install crank-
shaft.
CAUTION: Use only the specified anaerobic sealer
on the bedplate or damage may occur to the
engine.
(4) Apply 1.5 to 2.0 mm (0.059 to 0.078 in.) bead of
MopartBed Plate Sealant to cylinder block as shown
in (Fig. 51).
(5) Install lower main bearings into main bearing
cap/bedplate. Make certain the bearing tabs are
seated into the bedplate slots. Install the main bear-
ing/bedplate into engine block.
(6) Before installing the bolts the threads should
be oiled with clean engine oil, wipe off any excess oil.(7) Install main bearing bedplate to engine block
bolts 11, 17, and 20 finger tight. Tighten these bolts
down together until the bedplate contacts the cylin-
der block.
(8) To ensure correct thrust bearing alignment,
perform the following steps:
²Step 1: Rotate crankshaft until number 4 piston
is at TDC.
²Step 2: Move crankshaft rearward to limits of
travel.
²Step 3: Then, move crankshaft forward to limits
of travel.
²Step 4: Wedge an appropriate tool between the
rear of the cylinder block(NOT BED PLATE)and
the rear crankshaft counterweight. This will hold the
crankshaft in it's furthest forward position.
²Step 5: Install and tighten bolts (1±10) in
sequence shown in (Fig. 52) to 41 N´m (30 ft. lbs.).
²Step 6: Remove wedge tool used to hold crank-
shaft.
(9) Tighten bolts (1±10) again to 41 N´m (30 ft.
lbs.) in sequence shown in (Fig. 52).
CAUTION: Do Not use a torque wrench for the fol-
lowing step.
(10) Turn bolts (1±10) an additional 1/4 turn in
sequence shown in (Fig. 52).
(11) Install main bearing bedplate to engine block
bolts (11±20), and torque each bolt to 28 N´m (250 in.
lbs.) in sequence shown in (Fig. 52).
(12) Tighten bolts (11±20) again to 28 N´m (250 in.
lbs.) in sequence shown in (Fig. 52).
(13) After the main bearing bedplate is installed,
check the crankshaft turning torque. The turning
torque should not exceed 5.6 N´m (50 in. lbs.).
(14) Install connecting rod bearings and caps.Do
Not Reuse Connecting Rod Bolts.Torque connect-
ing rod bolts to 27 N´m (20 ft. lbs.) plus 1/4 turn.
(15) Install balance shafts and housing assembly.
(Refer to 9 - ENGINE/VALVE TIMING/BALANCE
SHAFT - INSTALLATION)
(16) Install the oil pump. (Refer to 9 - ENGINE/
LUBRICATION/OIL PUMP - INSTALLATION)
(17) Install cylinder head if it was removed (Refer
to 9 - ENGINE/CYLINDER HEAD - INSTALLA-
TION).
(18) Install the timing belt rear cover. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION)
(19) Install crankshaft sprocket (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - INSTALLATION).
(20) Install the timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION)
Fig. 51 Bedplate Sealing
Fig. 52 Bedplate Bolt Torque Sequence
9 - 40 ENGINE 2.4LRS
CRANKSHAFT (Continued)
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(21) Install the timing belt front covers. (Refer to 9
- ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION)
(22) Install engine mount support bracket.
(23) Install the oil pan. (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - INSTALLATION)
(24) Install the oil filter.
(25) Install crankshaft rear oil seal. (Refer to 9 -
ENGINE/ENGINE BLOCK/CRANKSHAFT OIL
SEAL - REAR - INSTALLATION)
(26) Install flex plate. Apply MopartLock & Seal
Adhesive to bolt threads and tighten to 95 N´m (70
ft. lbs.).
(27) Attach transaxle to engine. Tighten attaching
bolts to 101 N´m (75 ft. lbs.).
(28) Install the engine assembly. (Refer to 9 -
ENGINE - INSTALLATION)
CRANKSHAFT MAIN
BEARINGS
STANDARD PROCEDURE - MAIN BEARING -
FITTING
For crankshaft specifications (Refer to 9 - ENGINE
- SPECIFICATIONS).
CRANKSHAFT MAIN BEARINGS
The crankshaft is supported in five main bearings.
All upper and lower bearing shells in the crankcase
have oil grooves. Crankshaft end play is controlled by
a flanged bearing on the number three main bearing
journal (Fig. 53).
Upper and lower Number 3 bearing halves are
flanged to carry the crankshaft thrust loads and are
NOT interchangeable with any other bearing halves
in the engine (Fig. 53). All bearing cap bolts removed
during service procedures are to be cleaned and oiled
before installation. Bearing shells are available in
standard and the following undersized: 0.025 mm
(0.001 in.) and 0.250 mm (0.010 in.). Never install an
undersize bearing that will reduce clearance below
specifications. Replace or machine the crankshaft as
necessary to obtain proper bearing clearances.
MAIN BEARING INSTALLATION
(1) Install the main bearing shells with the lubri-
cation groove in the cylinder block (Fig. 54).
(2) Make certain oil holes in block line up with oil
holes in bearings. Bearing tabs must seat in the
block tab slots.
CAUTION: Do not get oil on the bedplate mating
surface. It will may effect the sealer ability to seal
the bedplate to cylinder block.(3) Oil the bearings and journals and install
crankshaft.
CAUTION: Use only the specified anaerobic sealer
on the bedplate or damage may occur to the
engine. Ensure that both cylinder block and bed-
plate surfaces are clean.
(4) Apply 1.5 to 2.0 mm (0.059 to 0.078 in.) bead
of anaerobic sealer MopartBed Plate Sealant to cyl-
inder block as shown in (Fig. 55).
(5) Install lower main bearings into main bearing
cap/bedplate. Make certain the bearing tabs are
seated into the bedplate slots.
Fig. 53 Main Bearing Identification
1 - OIL GROOVE
2 - MAIN BEARINGS
3 - OIL HOLE
Fig. 54 Installing Main Bearing Upper Shell
1 - LUBRICATION GROOVES
2 - OIL HOLES
RSENGINE 2.4L9-41
CRANKSHAFT (Continued)
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(6) Position the main bearing/bedplate onto the
engine block.
(7) Before installing bolts, lubricate the threads
with clean engine oil, wipe off any excess oil.
(8) Install main bearing bedplate to engine block
bolts 11, 17 and 20 finger tight. Tighten these bolts
down together until the bedplate contacts the cylin-
der block.
(9) To ensure correct thrust bearing alignment,
perform the following steps:
²Step 1: Rotate crankshaft until number 4 piston
is at TDC.
²Step 2: Move crankshaft rearward to limits of
travel.
²Step 3: Then, move crankshaft forward to limits
of travel.
²Step 4: Wedge an appropriate tool between the
rear of the cylinder block(NOT BED PLATE)and
the rear crankshaft counterweight. This will hold the
crankshaft in it's furthest forward position.
²Step 5: Install and tighten bolts (1±10) in
sequence shown in (Fig. 56) to 41 N´m (30 ft. lbs.).²Step 6: Remove wedge tool used to hold crank-
shaft.
(10) Tighten bolts (1±10) again to 41 N´m (30 ft.
lbs.) in sequence shown in (Fig. 56).
CAUTION: Do Not use a torque wrench for the fol-
lowing step.
(11) Turn bolts (1±10) an additional 1/4 turn in
sequence shown in (Fig. 56).
(12) Install main bearing bedplate to engine block
bolts (11±20), and torque each bolt to 28 N´m (250 in.
lbs.) in sequence shown in (Fig. 56).
(13) Tighten bolts (11±20) again to 28 N´m (250 in.
lbs.) in sequence shown in (Fig. 56).
(14) After the main bearing bedplate is installed,
check the crankshaft turning torque. The turning
torque should not exceed 5.6 N´m (50 in. lbs.).
CRANKSHAFT OIL SEAL -
FRONT
REMOVAL
(1) Remove the crankshaft vibration damper.
(Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL)
(2) Remove timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL)
(3) Remove crankshaft sprocket using Special Tool
6793 and insert C-4685-C2 (Fig. 57).
CAUTION: Do not nick shaft seal surface or seal
bore.
Fig. 55 Main Bearing Caps/Bedplate Sealing
Fig. 56 Main Bearing Caps/Bedplate Tightening
Sequence
Fig. 57 Crankshaft Sprocket - Removal
1 - SPECIAL TOOL 6793
2 - CRANKSHAFT SPROCKET
9 - 42 ENGINE 2.4LRS
CRANKSHAFT MAIN BEARINGS (Continued)
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(4) Using Tool 6771 to remove front crankshaft oil
seal (Fig. 58). Be careful not to damage the seal sur-
face of cover.
INSTALLATION
(1) Install new seal by using Special Tool 6780
(Fig. 59).
(2) Place seal into opening with seal spring
towards the inside of engine. Install seal until flush
with cover.
(3) Install crankshaft sprocket using Special Tool
6792 (Fig. 60).
(4) Install timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION)
(5) Install crankshaft vibration damper. (Refer to 9
- ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
INSTALLATION)
CRANKSHAFT OIL SEAL -
REAR
REMOVAL
(1) Remove transaxle. Refer to TRANSMISSION/
TRANSAXLE - REMOVAL for procedure.
(2) Remove flex plate.
(3) Insert a 3/16 flat bladed screwdriver between
the dust lip and the metal case of the crankshaft
seal. Angle the screwdriver (Fig. 61)through the dust
lip against metal case of the seal. Pry out seal.
CAUTION: Do not permit the screwdriver blade to
contact crankshaft seal surface. Contact of the
screwdriver blade against crankshaft edge (cham-
fer) is permitted.
Fig. 58 Front Crankshaft Oil Seal - Removal
1 - SPECIAL TOOL 6771
2 - REAR TIMING BELT COVER
Fig. 59 Crankshaft Front Oil Seal - Installation
1 - PROTECTOR
2 - SEAL
3 - SPECIAL TOOL 6780
Fig. 60 Crankshaft Sprocket - Installation
1 - SPECIAL TOOL 6792
2 - TIGHTEN NUT TO INSTALL
RSENGINE 2.4L9-43
CRANKSHAFT OIL SEAL - FRONT (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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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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(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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