2002 CHRYSLER CARAVAN battery

NOTE: Multi-Layer Steel (MLS) head gaskets require
a scratch free sealing surface.
Only use the following for cleaning gasket surfaces:
²Solvent or a commercially available gasket
remover
²Plastic or wood scraper (Fig. 3)
²Drill motor with 3M RolocŸ Bristle Disc (white
or yellow) (Fig. 3)
CAUTION: Excessive pressure or high RPM (beyond
the recommended speed), can damage the sealing
surfaces. The mild (white, 120 grit) bristle disc is
recommended. If necessary, the medium (yellow, 80
grit) bristle disc may be used on cast iron surfaces
with care.
STANDARD PROCEDURE - MEASURING
BEARING CLEARANCE USING PLASTIGAGE
Engine crankshaft bearing clearances can be deter-
mined by use of Plastigage or equivalent. The follow-
ing is the recommended procedure for the use of
Plastigage:
(1) Remove oil film from surface to be checked.
Plastigage is soluble in oil.
(2) Place a piece of Plastigage across the entire
width of the bearing shell in the cap approximately
6.35 mm (1/4 in.) off center and away from the oil
holes (Fig. 4). (In addition, suspected areas can be
checked by placing the Plastigage in the suspected
area). Torque the bearing cap bolts of the bearing
being checked to the proper specifications.(3) Remove the bearing cap and compare the
width of the flattened Plastigage with the metric
scale provided on the package. Locate the band clos-
est to the same width. This band shows the amount
of clearance in thousandths of a millimeter. Differ-
ences in readings between the ends indicate the
amount of taper present. Record all readings taken.
Compare clearance measurements to specs found in
engine specifications (Refer to 9 - ENGINE - SPECI-
FICATIONS).Plastigage generally is accompa-
nied by two scales. One scale is in inches, the
other is a metric scale.
NOTE: Plastigage is available in a variety of clear-
ance ranges. Use the most appropriate range for
the specifications you are checking.
(4) Install the proper crankshaft bearings to
achieve the specified bearing clearances.
REMOVAL - ENGINE ASSEMBLY
(1) Perform fuel pressure release procedure (Refer
to 14 - FUEL SYSTEM/FUEL DELIVERY - STAN-
DARD PROCEDURE)
(2) Disconnect battery negative cable.
(3) Remove air cleaner housing and inlet tube.
(4) Disconnect the fuel line from fuel rail. (Refer to
14 - FUEL SYSTEM/FUEL DELIVERY/FUEL LINES
- STANDARD PROCEDURE)
(5) Disconnect all vacuum hoses.
(6) Drain cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(7) Remove radiator fans. (Refer to 7 - COOLING/
ENGINE/RADIATOR FAN - REMOVAL)
(8) Remove radiator upper and lower hoses.
Fig. 3 Proper Tool Usage For Surface Preparation
1 - ABRASIVE PAD
2 - 3M ROLOCŸ BRISTLE DISC
3 - PLASTIC/WOOD SCRAPER
Fig. 4 Plastigage Placed in Lower ShellÐTypical
1 - PLASTIGAGE
9 - 12 ENGINE 2.4LRS
ENGINE 2.4L (Continued)
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INSTALLATION - ENGINE ASSEMBLY
(1) Position engine and transmission assembly
under vehicle and slowly lower the vehicle over the
engine and transmission.
(2) Align engine and transmission mounts to
attaching points. Install mounting bolts at the right
(Fig. 9) and left mounts (Fig. 10).
(3) Remove safety straps.
(4) Slowly raise vehicle enough to remove the
engine dolly and cradle Special Tools 6135 and 6710.
(5) Install rear mount bracket and rear mount
through bolt. (Refer to 9 - ENGINE/ENGINE
MOUNTING/REAR MOUNT - INSTALLATION)
(6) Install the flex plate to torque converter bolts.
(7) Install structural collar. (Refer to 9 - ENGINE/
ENGINE BLOCK/STRUCTURAL COVER - INSTAL-
LATION)
(8) Install front mount bracket and front mount
through bolt. (Refer to 9 - ENGINE/ENGINE
MOUNTING/FRONT MOUNT - INSTALLATION)
(9) Connect exhaust system to manifold (Fig. 7).
(10) Install crossmember cradle plate (Fig. 6).
(11) Install new oil filter.
(12) Install power steering pump and bracket.(13) Connect power steering supply line to pump
and remove pinch-off pliers.
(14) Connect A/C compressor hoses to compressor.
(15) Install accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION)
(16) Install axle shafts. (Refer to 3 - DIFFEREN-
TIAL & DRIVELINE/HALF SHAFT - INSTALLA-
TION)
(17) Install accessory drive belt splash shield.
(18) Install front wheels and tires.
(19) Remove plugs from transmission cooler hoses
and install transaxle oil cooler line service splice kit.
Refer to instructions included with kit.
(20) Connect the transaxle shift linkage and elec-
trical connectors.
(21) Connect heater hoses (Fig. 5).
(22) Install ground straps.
(23) Connect all engine and throttle body electrical
connections.
(24) Connect all vacuum lines.
(25) Connect the throttle cables.
(26) Connect the fuel line. (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY/QUICK CONNECT FIT-
TING - STANDARD PROCEDURE)
(27) Connect radiator lower and upper hoses.
(28) Install radiator fans. (Refer to 7 - COOLING/
ENGINE/RADIATOR FAN - INSTALLATION)
(29) Fill cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(30) Connect battery cables.
(31) Install air cleaner and inlet hose.
Fig. 9 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
Fig. 10 LEFT MOUNT TO FRAME BRACKET
1 - FRAME BRACKET
2 - FRAME RAIL - LEFT
3 - BOLT
4 - TRANSAXLE MOUNT
9 - 16 ENGINE 2.4LRS
ENGINE 2.4L (Continued)
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AIR CLEANER ELEMENT
REMOVAL
(1) Unsnap 2 clips.
(2) Lift cover and pull toward the engine and
remove cover tabs from air box.
(3) Lift cover and remove the element (Fig. 11).
INSTALLATION
(1) Install the air filter element into air box (Fig.
11).
(2) Move cover so that the tabs insert into the air
box.
(3) Push cover down and snap the 2 clips.
AIR CLEANER HOUSING
REMOVAL
(1) Disconnect the negative battery cable.
(2) Disconnect the inlet air temperature sensor
(Fig. 12).
(3) Remove the inlet hose to throttle body (Fig. 11).
(4) Remove the bolt for air box at upper radiator
cross member.
(5) Pull air box up and off over the single locating
pin.
(6) Remove air box from vehicle
INSTALLATION
(1) Install air box into vehicle and onto the locat-
ing pin.(2) Install bolt to hold air box to the upper radia-
tor cross member.
(3) Install the inlet hose to the throttle body.
(4) Connect the inlet air temperature sensor (Fig.
12).
(5) Connect the negative battery cable.
CYLINDER HEAD
DESCRIPTION
The cross flow designed, aluminum cylinder head
contains dual over-head camshafts with four valves
per cylinder (Fig. 13). The valves are arranged in two
in-line banks. The intake valves face toward the
front of the vehicle. The exhaust valves face the dash
panel. The cylinder head incorporates powdered
metal valve guides and seats. The cylinder head is
sealed to the block using a multi-layer steel head
gasket and retaining bolts.
Integral oil galleries provide lubrication passages
to the hydraulic lash adjusters, camshafts, and valve
mechanisms.
OPERATION
The cylinder head closes the combustion chamber,
allowing the pistons to compress the fuel/air mixture
for ignition. The valves are actuated by the lobe pro-
files on the camshaft to open and close at specified
duration to either allow clean air in the combustion
chamber or the exhaust gases out; depending on the
stroke of the engine.
DIAGNOSIS AND TESTINGÐCYLINDER HEAD
GASKET
A cylinder head gasket leak can be located between
adjacent cylinders or between a cylinder and the
adjacent water jacket.
Fig. 11 AIR BOX COVER
Fig. 12 IAT SENSOR 2.4L
9 - 24 ENGINE 2.4LRS
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Possible indications of the cylinder head gasket
leaking between adjacent cylinders are:
²Loss of engine power
²Engine misfiring
²Poor fuel economy
Possible indications of the cylinder head gasket
leaking between a cylinder and an adjacent water
jacket are:
²Engine overheating
²Loss of coolant
²Excessive steam (white smoke) emitting from
exhaust
²Coolant foaming
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determine if an engine cylinder head gasket is
leaking between adjacent cylinders, follow the proce-
dures in Cylinder Compression Pressure Test (Refer
to 9 - ENGINE - DIAGNOSIS AND TESTING). An
engine cylinder head gasket leaking between adja-
cent cylinders will result in approximately a 50±70%
reduction in compression pressure.
CYLINDER-TO-WATER JACKET LEAKAGE TEST
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING WITH COOLANT PRES-
SURE CAP REMOVED.VISUAL TEST METHOD
With the engine cool, remove the coolant pressure
cap. Start the engine and allow it to warm up until
thermostat opens.
If a large combustion/compression pressure leak
exists, bubbles will be visible in the coolant.
COOLING SYSTEM TESTER METHOD
WARNING: WITH COOLING SYSTEM TESTER IN
PLACE, PRESSURE WILL BUILD UP FAST. EXCES-
SIVE PRESSURE BUILT UP, BY CONTINUOUS
ENGINE OPERATION, MUST BE RELEASED TO A
SAFE PRESSURE POINT. NEVER PERMIT PRES-
SURE TO EXCEED 138 kPa (20 psi).
Install Cooling System Tester 7700 or equivalent to
pressure cap neck. Start the engine and observe the
tester's pressure gauge. If gauge pulsates with every
power stroke of a cylinder a combustion pressure
leak is evident.
CHEMICAL TEST METHOD
Combustion leaks into the cooling system can also
be checked by using Bloc-Chek Kit C-3685-A or
equivalent. Perform test following the procedures
supplied with the tool kit.
REMOVAL - CYLINDER HEAD
(1) Perform fuel system pressure release procedure
before attempting any repairs.(Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY - SPECIFICA-
TIONS)
(2) Disconnect battery negative cable.
(3) Drain cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(4) Remove air filter housing and inlet tube.
(5) Remove upper intake manifold. (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
REMOVAL)
(6) Remove heater tube support bracket from cyl-
inder head.
(7) Disconnect radiator upper and heater supply
hoses from intake manifold water outlet connections.
(8) Remove accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)
(9) Raise vehicle and remove exhaust pipe from
manifold.
(10) Remove power steering pump reservoir and
line support bracket from lower intake manifold and
set aside. Do not disconnect lines.
(11) Remove ignition coil and wires from engine.
(12) Disconnect cam sensor and fuel injector wir-
ing connectors.
Fig. 13 Cylinder Head and Camshafts
1 - CAMSHAFT BEARING CAPS
2 - PLUG
3 - CAMSHAFT
4 - CYLINDER HEAD
5 - CAMSHAFT OIL SEAL
RSENGINE 2.4L9-25
CYLINDER HEAD (Continued)
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(19) Install air inlet tube and housing.
(20) Connect all vacuum lines, electrical wiring,
ground straps and fuel line.
(21) Fill cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(22) Connect battery negative cable.
CAMSHAFT OIL SEAL(S)
REMOVAL
(1) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
REMOVAL).
(2) Hold each camshaft sprocket with Special Tool
6847 while removing center bolt (Fig. 20).
(3) Remove camshaft sprockets.
(4) Remove rear timing belt cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT COVER(S)
- REMOVAL).
(5) Remove camshaft seal using Special Tool
C-4679A (Fig. 21).
CAUTION: Do not nick shaft seal surface or seal
bore.
INSTALLATION
(1) Shaft seal surface must be free of varnish, dirt
or nicks. Polish with 400 grit paper if necessary.
(2) Install camshaft seals into cylinder head using
Special Tool MD-998306 until flush with head (Fig.
22).(3) Install timing belt rear cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT COVER(S)
- INSTALLATION).
(4) Install camshaft sprockets. Hold each sprocket
with Special Tool 6847 and tighten center bolt to 101
N´m (75 ft. lbs.) (Fig. 20).
(5) Install timing belt and front covers (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT AND
SPROCKETS - INSTALLATION) (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT COVER(S)
- INSTALLATION).
Fig. 20 Camshaft Sprocket - Removal/Installation
1 - SPECIAL TOOL 6847
Fig. 21 Camshaft Oil Seal - Removal With C-4679A
1 - SPECIAL TOOL C-4679
Fig. 22 Camshaft Seal - Installation
1 - SPECIAL TOOL MD-998306
9 - 28 ENGINE 2.4LRS
CYLINDER HEAD (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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INTAKE MANIFOLD - UPPER
REMOVAL
(1) Disconnect negative cable from battery.
(2) Disconnect connector from inlet air tempera-
ture sensor (Fig. 104).
(3) Disconnect air intake tube at throttle body and
remove upper air cleaner housing.
(4) Disconnect connector from throttle position
sensor (TPS) (Fig. 106).
(5) Disconnect connector from idle air control (IAC)
motor (Fig. 106).
(6) Disconnect connector from MAP sensor (Fig.
105).
(7) Remove vacuum lines for purge solenoid and
PCV valve at intake manifold.(8) Remove vacuum lines for power brake booster,
LDP, EGR transducer, and speed control vacuum res-
ervoir (if equipped) at upper intake manifold fittings.
(9) Disconnect throttle, speed control (if equipped),
and transaxle control (31TH equipped only) cables
from throttle lever and bracket. (Refer to 14 - FUEL
SYSTEM/FUEL INJECTION/THROTTLE CONTROL
CABLE - REMOVAL)
(10) Remove the EGR tube. (Refer to 25 - EMIS-
SIONS CONTROL/EXHAUST GAS RECIRCULA-
TION/TUBE - REMOVAL)
(11) Remove the upper manifold support bracket
bolt to manifold (Fig. 107).
Fig. 104 INLET AIR TEMPERATURE SENSOR - 2.4L
Fig. 105 MAP SENSOR - 2.4L
Fig. 106 Throttle Body Electrical Connectors -
Typical
1 - IDLE AIR CONTROL MOTOR CONNECTOR
2 - TPS CONNECTOR
Fig. 107 Upper Intake Manifold Support Bracket
1 - NUT - BRACKET TO CYLINDER HEAD COVER
2 - BOLT - BRACKET TO UPPER INTAKE MANIFOLD
3 - UPPER INTAKE MANIFOLD SUPPORT BRACKET
9 - 60 ENGINE 2.4LRS
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(12) Remove engine oil dipstick from tube.
(13) Remove upper intake manifold bolts (Fig.
108). Remove upper intake manifold.
CAUTION: Cover intake manifold to prevent foreign
material from entering engine.
INSPECTION
(1) Check manifold surfaces for flatness with
straight edge. Surface must be flat within 0.15 mm
per 300 mm (0.006 in. per foot) of manifold length.
(2) Inspect manifold for cracks or distortion.
Replace manifold if necessary.
INSTALLATION
(1) Clean manifold sealing surfaces.
(2) Apply a 1.5 mm (0.060 in.) bead MopartGas-
ket Maker to the perimeter of the lower intake man-
ifold runner openings.
(3) Install upper intake manifold and tighten fas-
teners to 28 N´m (250 in. lbs.) in sequence shown in
(Fig. 108). Repeat this procedures until all fasteners
are at specified torque.
(4) Install engine oil dipstick.
(5) Install upper bolt in intake manifold to front
support bracket (Fig. 107). Torque to 28 N´m (250 in.
lbs.).
(6) Install EGR tube. (Refer to 25 - EMISSIONS
CONTROL/EXHAUST GAS RECIRCULATION/
TUBE - INSTALLATION)
(7) Install throttle cables in bracket.
(8) Connect throttle, speed control, (if equipped),
transaxle control (31TH equipped only) cables to
throttle lever.
(9) Connect vacuum lines for power brake booster,
LDP, EGR transducer, and speed control vacuum res-
ervoir (if equipped) at upper intake manifold fittings.
(10) Connect vacuum lines for purge solenoid and
PCV valve.(11) Connect electrical connectors for MAP sensor,
throttle position sensor (TPS), and idle air control
(IAC) motor.
(12) Install air cleaner upper housing and air
intake tube to throttle body.
(13) Connect inlet air temperature sensor connec-
tor (Fig. 104).
(14) Connect negative cable to battery.
INTAKE MANIFOLD - LOWER
REMOVAL
(1) Perform fuel system pressure release proce-
durebefore attempting any repairs.(Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY - STANDARD
PROCEDURE)
(2) Remove upper intake manifold. (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
REMOVAL)
CAUTION: Cover intake manifold openings to pre-
vent foreign material from entering engine.
(3) Disconnect fuel line. (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/QUICK CONNECT FIT-
TING - STANDARD PROCEDURE)
(4) Drain the cooling system. (Refer to 7 - COOL-
ING - STANDARD PROCEDURE)
(5) Remove heater supply and radiator upper
hoses at intake manifold.
(6) Disconnect coolant temperature sensor/fuel
injector wire harness connector.
(7) Remove lower intake manifold support bracket
upper bolts (Fig. 109).
(8) Loosen the lower intake manfold support
bracket lower bolt (Fig. 109).
(9) Disconnect fuel injector harness.
(10) Remove the bolts attaching the power steering
reservoir to manifold. Set reservoir aside.Do not
disconnect line from reservoir.
(11) Remove lower intake manifold fasteners (Fig.
110). Remove the manifold from engine.
(12) Inspect the manifold. (Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD - INSPECTION)
INSPECTION
(1) Check manifold surfaces for flatness with
straight edge. Surface must be flat within 0.15 mm
per 300 mm (0.006 in. per foot) of manifold length.
(2) Inspect manifold for cracks or distortion.
Replace manifold if necessary.
INSTALLATION
If the following items were removed, install and
torque to specifications:
²Fuel rail bolts - 22 N´m (200 in. lbs.)
Fig. 108 Upper Intake Manifold Tightening Sequence
- 2.4L
RSENGINE 2.4L9-61
INTAKE MANIFOLD - UPPER (Continued)
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