2002 CHRYSLER CARAVAN wheel alignment

NOTE: The main cap bolts should be examined
before reuse. Bolt stretch can be checked by hold-
ing a scale or straight edge against the threads. If
all the threads do not contact the scale the bolt
must be replaced (Fig. 63).
(5) Install each main cap and tighten bolts finger
tight.
(6) Tighten number 1, 3 and 4 main cap bolts to 41
N´m + 1/4 Turn (30 ft. lbs.+ 1/4 Turn).
(7) Rotate the crankshaft until the number 6 pis-
ton is at TDC.
(8) To ensure correct thrust bearing alignment the
following procedure must be done:
a. Move crankshaft all the way to the rear of its
travel.
b. Then, move crankshaft all the way to the front
of its travel.
c. Wedge an appropriate tool between the rear of
the cylinder block and rear crankshaft counter-
weight. This will hold the crankshaft in it's most for-
ward position.
d. Tighten the #2 Thrust Bearing cap bolts to 41
N´m + 1/4 Turn (30 ft. lbs.+ 1/4 Turn). Remove the
holding tool.
(9) Install oil pan. (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION)
(10) Fill engine crankcase with proper oil to cor-
rect level.
CRANKSHAFT OIL SEAL -
FRONT
REMOVAL
(1) Disconnect negative cable from battery.
(2) Raise vehicle on hoist. Remove right wheel and
inner splash shield.(3) Remove accessory drive belt. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)
(4) Remove crankshaft damper. (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL)
(5) Position Special Tool 6341A on crankshaft nose.
Carefully screw the tool into the seal until it engages
firmly (Fig. 64). Be careful not to damage that crank-
shaft seal surface of cover
(6) Remove oil seal by turning the forcing screw
until the seal disengages from the cover (Fig. 65).
Fig. 63 Check for Stretched (Necked) Bolts
1 - STRETCHED BOLT
2 - THREADS ARE NOT STRAIGHT ON LINE
3 - THREADS ARE STRAIGHT ON LINE
4 - UNSTRETCHED BOLT
Fig. 64 Engaging Tool into Seal
1 - SEAL
2 - SPECIAL TOOL 6341A
Fig. 65 Crankshaft Front Seal Removal
1 - SEAL
2 - SPECIAL TOOL 6341A
9 - 122 ENGINE 3.3/3.8LRS
CRANKSHAFT MAIN BEARINGS (Continued)
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VM.1064 POWER STEERING PUMP GEAR
REMOVER
VM.1065 PISTON RING COMPRESSOR
VM.1066 CYLINDER HEAD COVER ALIGNMENT
PINS
VM.1068 90 DEGREES AFTER TDC ALIGNMENT PIN
VM.1069 CRANKSHAFT REM/INSTALL SLEEVE
VM.1070 FLYWHEEL LOCKING TOOL
RGENGINE9a-15
ENGINE 2.5L TURBO DIESEL (Continued)
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VM.1072 COMPRESSION TESTER ADAPTER
VM.1073 CRANKSHAFT FRONT BEARING
REMOVER/INSTALLER
VM.1074 TIMING BELT RETAINER
VM.1075 FLYWHEEL ALIGNMENT PINS
VM.1077 POWER STEERING BELT REMOVER
VM.1078 POWER STEERING BELT INSTALLER
9a - 16 ENGINERG
ENGINE 2.5L TURBO DIESEL (Continued)
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STANDARD PROCEDURE - CHECKING
CRANKSHAFT END PLAY
(1) Mount a dial indicator to a stationary point at
rear of engine. Locate the probe perpendicular
against the flywheel (Fig. 35).
(2) Move the crankshaft all the way to the front of
its travel.
(3) Zero the dial indicator.
(4)
Move the crankshaft all the way to the rear and
read dial indicator. For crankshaft end play clearances
(Refer to 9 - ENGINE - SPECIFICATIONS).
REMOVAL
(1) Remove engine from vehicle (Refer to 9 -
ENGINE - REMOVAL).
(2) Mount engine on an engine stand.
(3) Drain engine oil and remove oil filter.
(4) Remove timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(5) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL).
(6) Remove timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(7) Remove cylinder head cover/intake manifold
(Refer to 9 - ENGINE/CYLINDER HEAD/CYLIN-
DER HEAD COVER(S) - REMOVAL).
(8) Remove cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
(9) Remove flywheel.
(10) Remove rear main bearing support/adapter
plate retaining bolts and remove adapter plate (Fig.
36).
Fig. 35 CHECKING CRANKSHAFT END PLAY
1 - DIAL INDICATOR
2 - ADAPTER PLATE
3 - REAR MAIN BEARING SUPPORT
4 - SEALING RING
5 - SEALING RING
6 - ALIGNMENT PIN
7 - CRANKSHAFT
8 - RELUCTOR WHEEL
9 - RELUCTOR WHEEL RETAINING BOLT
10 - REAR MAIN BEARING SUPPORT RETAINING BOLTS
11 - FLYWHEEL
12 - FLYWHEEL BOLTSFig. 36 REAR MAIN BEARING SUPPORT
1 - ADAPTER PLATE
2 - REAR MAIN BEARING SUPPORT
3 - CRANKSHAFT
4 - REAR MAIN BEARING SUPPORT RETAINING BOLTS
RGENGINE9a-31
CRANKSHAFT (Continued)
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VALVE TIMING
STANDARD PROCEDURE - LOCKING ENGINE
90É AFTER TDC
(1) Disconnect negative battery cable.
(2) Remove starter motor (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - REMOVAL).
(3) Rotate engine untill notch in hub is in the fol-
lowing position (Fig. 84).
(4) Special tool VM.1068 can be install in engine
block as shown at this time (Fig. 85). This will lock
the engine at 90É after TDC.
(5) Remove front wiper unit (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
REMOVAL).
(6) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(7) Remove plug in cylinder head cover/intake
manifold and insert VM.1053 to lock exhaust cam-
shaft in position (Fig. 86).
(8) Remove generator (Refer to 8 - ELECTRICAL/
CHARGING/GENERATOR - REMOVAL).
Fig. 84 CRANKSHAFT HUB ALIGNMENT
1 - VIBRATION DAMPER/CRANKSHAFT PULLEY
2 - CRANKSHAFT HUB NOTCH
3 - VIBRATION DAMPER/CRANKSHAFT PULLEY TO
CRANKSHAFT HUB BOLTS
Fig. 85 TDC AND 90 DEGREES AFTER TDC
ALIGNMENT PIN LOCATION
1 - ENGINE BLOCK
2 - VM.1051 TDC PIN OR VM.1068 90 DEGREES ATDC PIN
3 - FLYWHEEL
Fig. 86 EXHAUST CAMSHAFT LOCKING PIN
VM.1053
1 - EXHAUST MANIFOLD HEAT SHIELD
2 - EXHAUST CAMSHAFT LOCKING PIN VM.1053
3 - COOLANT TUBE FROM THERMOSTAT HOUSING TO UPPER
RADIATOR HOSE
4 - CYLINDER HEAD COVER/INTAKE MANIFOLD
RGENGINE9a-53
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REMOVAL
(1) Disconnect negative battery cable.
(2) Raise vehicle on hoist.
(3) Remove oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - REMOVAL).
(4) Remove balance shaft assembly (Fig. 89).
INSTALLATION
(1)Before installation of the balance shaft assembly,
the # 1 cylinder must be brought to TDC. Using special
tool VM.1051, roll engine over by hand until tool can be
inserted into engine block locking flywheel from turning
(Fig. 90). Once the # 1 cylinder is brought to TDC, the
balance shaft assembly can be installed.
(2) With balance shaft assembly on work bench.
Insert special tool VM.1056 into balance shaft assem-bly (Fig. 91). This will ensure proper balance shaft
and crankshaft timing after assembly.
Fig. 89 BALANCE SHAFT ASSEMBLY
1 - BALANCE SHAFT
2 - OIL JET RETAINING BOLT
3 - OIL JET
4 - ENGINE BLOCK
5 - CRANKSHAFT
6 - BALANCE SHAFT RETAINING BOLTS
7 - OIL DIPSTICK TUBE RETAINER
8 - RUBBER BUSHING
9 - RETAINING BOLT
Fig. 90 TDC AND 90 DEGREES AFTER TDC
ALIGNMENT PIN LOCATION
1 - ENGINE BLOCK
2 - VM.1051 TDC PIN OR VM.1068 90 DEGREES ATDC PIN
3 - FLYWHEEL
Fig. 91 BALANCE SHAFT ALIGNMENT PIN VM.1056
1 - VM.1056
2 - BALANCE SHAFT ASSEMBLY
RGENGINE9a-55
BALANCE SHAFT (Continued)
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REMOVAL
The front cradle crossmember must be installed in
the design location to achieve proper front end sus-
pension alignment. If the cradle crossmember is
removed without applying reference marks on the
frame rails, align the cradle crossmember according
to the dimensions provided in this group.
NOTE: If the caged nuts in the frame rails become
damaged and cannot be reused, a replacement nut
can be obtained through MoparT.
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove steering column lower cover from
instrument panel (Refer to 23 - BODY/INSTRU-
MENT PANEL/STEERING COLUMN OPENING
COVER - REMOVAL).
(3) Remove steering column cover backing plate
(Refer to 23 - BODY/INSTRUMENT PANEL/STEER-
ING COLUMN COVER BACKING PLATE - REMOV-
AL).
(4) Position steering so front wheels are straight
ahead.
CAUTION: Do not rotate steering wheel after disen-
gaging lower coupling from steering gear, damage
to air bag clock spring can result.
(5) Remove clinch bolt attaching steering column
coupling to steering gear shaft (Fig. 10).(6) Remove steering column coupling from tele-
scoping steering gear shaft.
(7) Hoist vehicle and support on safety stands.
(8) Position a drain pan under power steering
pump and oil return hose coupling.
(9) Using a hose pinch-off pliers (C-4390), pinch
power steering oil return hose off between the cross-
member coupling and the pump.
(10) Loosen hose clamp at the cradle crossmember
coupling.
(11) Disconnect return hose from metal tube.
(12) While holding pressure relief valve nut on
back of power steering pump, Remove flare nut
attaching high pressure hose to back of pump.
(13) Remove high pressure hose from pump.
(14) Allow power steering fluid to drain into pan.
(15) Remove bolts attaching anti-lock brake sensor
leads to cradle crossmember.
(16) Position anti-lock brake leads out of the way.
(17) Disconnect stabilizer bar links from ends of
stabilizer bar.
(18) Disconnect lower ball joints from lower steer-
ing knuckles (Refer to 2 - SUSPENSION/FRONT/
LOWER BALL JOINT - REMOVAL).
(19) Remove the rear engine mount heat shield
(Fig. 11).
(20) Remove through bolt attaching rear engine
mount to cradle crossmember (Fig. 12).
(21) Using paint or grease pencil, mark outline of
cradle crossmember on frame rails to aid installation.
(22) Support cradle crossmember on suitable lift-
ing device (Fig. 14).
(23) Remove bolts attaching crossmember to front
frame rails (Fig. 13).
Fig. 10 STEERING COUPLING
1 - STEERING SHAFT BOOT
2 - STEERING SHAFT
3 - CROSSMEMBER
4 - STEERING GEAR
5 - MOUNT
6 - TRANSAXLE
Fig. 11 REAR MOUNT HEAT SHIELD
1 - BOLT
2 - HEAT SHIELD
3 - CLIP
4 - REAR ENGINE MOUNT
13 - 10 FRAME & BUMPERSRS
FRONT CRADLE CROSSMEMBER (Continued)
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CONDITION POSSIBLE CAUSES CORRECTION
11. Worn or binding seat and bearing
in front strut assembly.11. Replace seat and bearing in front strut
assembly.
STEERING WHEEL DOES
NOT RETURN TO
CENTER POSITION.1. Tires not inflated properly. 1. Inflate tires to specified pressure.
2. Improper front wheel alignment. 2. Check and adjust wheel alignment as
necessary.
3. Lack of lubrication causing binding
in front lower control arm ball joints.3. Lubricate ball joints if ball joints are not a
lubricated for life type of ball joint, then
inspect ball joint for wear, replace lower
control arm as necessary. If ball joint is a
lubricated for life ball joint, replace lower
control arm ball joint.
4. Steering column coupling joints
misaligned.4. Realign steering column coupling joints.
5. Steering wheel rubbing.** 5. Adjust steering column shrouds to
eliminate rubbing condition.
6. Damaged, mispositioned or
unlubricated steering column coupler
to dash seal.**6. Replace, reposition, or lubricate dash
seal.
7. Binding mount bearing in front
strut assembly.7. Replace mount bearing in front strut
assembly.
8. Binding shaft bearing in steering
column.8. Replace the steering column.
9. Excessive friction in steering
column coupling.9. Replace steering column coupling.
10. Excessive friction in power
steering gear.10. Replace power steering gear.
EXCESSIVE STEERING
WHEEL KICKBACK OR
TOO MUCH STEERING
WHEEL FREE PLAY.1. Air in the fluid of the power
steering system.1. Bleed air from system following the the
power steering pump initial operation
service procedure.*
2. Power steering gear loose on
cradle/crossmember.2. Inspect power steering gear mounting
bolts. Replace as necessary. Tighten to the
specified torque.
3. Steering column coupling or
intermediate shaft worn, broken or
loose.3. Replace steering column coupling or
intermediate shaft.
4. Free play in steering column. 4. Check all components of the steering
column and repair or replace as required.
5. Worn lower control arm ball joints. 5. Replace lower control arm ball joints as
required.
6. Loose steering knuckle-to-ball joint
stud pinch bolt.6. Inspect pinch bolt, replace as necessary,
and tighten to specified torque.
7. Front wheel bearing loose or
worn.7. Replace hub and bearing as necessary.
8. Loose outer tie rod end. 8. Replace outer tie rod end that has
excessive free play.
RSSTEERING19-7
STEERING (Continued)
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