2002 CHRYSLER CARAVAN engine

(5) Remove the pull pin or Allen wrench from the
belt tensioner.
(6) Once the timing belt has been installed and
tensioner released, rotate the crankshaft two (2) com-
plete revolutions. Verify that the TDC marks on
crankshaft and timing marks on the camshafts are
aligned as shown in (Fig. 123).
(7) Install engine mount bracket to engine (Fig.
116).
(8) Install timing belt front covers and bolts.
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT / CHAIN COVER(S) - INSTALLATION)
(9) Install air conditioning/generator belt tensioner
and pulley. (Refer to 7 - COOLING/ACCESSORY
DRIVE/BELT TENSIONERS - INSTALLATION)
(10) Install right engine mount. (Refer to 9 -
ENGINE/ENGINE MOUNTING/RIGHT MOUNT -
INSTALLATION)(11) Install crankshaft vibration damper. (Refer to
9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - INSTALLATION)
(12) Install accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION)
(13) Install drive belt splash shield.
(14) Install right front wheel.
(15) Connect make-up air hose to cylinder head
cover.
(16) Install air cleaner housing, upper cover, and
clean air tube.
TIMING BELT TENSIONER &
PULLEY
REMOVAL
(1) Remove the timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
REMOVAL).
(2) Remove timing belt idler pulley.
(3) Hold camshaft sprocket with Special Tool 6847
while removing bolt (Fig. 124). Remove both cam
sprockets.
Fig. 123 Crankshaft and Camshaft Timing
1 - CAMSHAFT TIMING MARKS
2 - CRANKSHAFT TDC MARKS
3 - TRAILING EDGE OF SPROCKET TOOTH
Fig. 124 Camshaft Sprocket - Removal/Installation
1 - SPECIAL TOOL 6847
9 - 68 ENGINE 2.4LRS
TIMING BELT AND SPROCKET(S) (Continued)
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(4) Remove rear timing belt cover fasteners and
remove cover from engine (Fig. 125).
(5) Remove lower bolt attaching timing belt ten-
sioner assembly to engine and remove tensioneras
an assembly(Fig. 126).
INSTALLATION
(1) Align timing belt tensioner assembly to engine
and install lower mounting boltbut do not tighten
(Fig. 126). To properly align tensioner assemblyÐin-
stall one of the engine bracket mounting bolts (M10)
5 to 7 turns into the tensioner's upper mounting loca-
tion (Fig. 126).
(2) Torque the tensioner's lower mounting bolt to
61 N´m (45 ft. lbs.). Remove the upper bolt used for
tensioner alignment.(3) Install rear timing belt cover and fasteners
(Fig. 125).
(4) Install timing belt idler pulley and torque
mounting bolt to 61 N´m (45 ft. lbs.).
(5) Install camshaft sprockets. Use Special Tool
6847 to hold sprockets (Fig. 124), torque bolts to 101
N´m (75 ft. lbs.).
(6) Install the timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
INSTALLATION).BALANCE SHAFTS AND
CARRIER ASSEMBLY
DESCRIPTION
The 2.4L engine is equipped with two nodular cast
iron balance shafts installed in a cast aluminum car-
rier attached to the lower cylinder block (Fig. 127).
Fig. 125 Rear Timing Belt Cover Fasteners
1 - BOLTS - REAR COVER 12 N´m (105 in. lbs.)
2 - BOLTS - REAR COVER 28 N´m (250 in. lbs.)
3 - TIMING BELT TENSIONER
Fig. 126 Timing Belt Tensioner AssemblyÐRemoval/
Installation
1 - TIMING BELT TENSIONER ASSEMBLY
2 - TENSIONER ASSEMBLY UPPER BOLT
3 - TENSIONER ASSEMBLY LOWER BOLT
RSENGINE 2.4L9-69
TIMING BELT TENSIONER & PULLEY (Continued)
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OPERATION
The balance shafts are driven by the crankshaft
via a roller chain and sprockets. The balance shafts
are connected by helical gears. The dual counter
rotating shafts decrease second order vertical shak-
ing forces caused by component movement.
REMOVAL
BALANCE SHAFTS/CHAIN/SPROCKETS
NOTE: For service procedures requiring only tem-
porary relocation of carrier assembly refer to BAL-
ANCE SHAFT CARRIER procedure below.
(1) Drain engine oil.
(2) Remove the oil pan and pick-up tube (Refer to
9 - ENGINE/LUBRICATION/OIL PAN - REMOVAL).
(3) If replacing crankshaft sprocket, remove oil
pump (Refer to 9 - ENGINE/LUBRICATION/OIL
PUMP - REMOVAL).
(4) Remove chain cover, guide and tensioner (Fig.
128).(5) Remove screw retaining balance shaft drive
sprocket (Fig. 129). Remove chain and sprocket.
(6) Using two wide pry bars, work the crankshaft
sprocket back and forth until it is off the crankshaft-
shaft.
(7) Remove gear cover retaining stud (double
ended to also retain chain guide). Remove cover and
balance shaft gears (Fig. 130).
(8) Remove rear cover and balance shafts (Fig.
131).
(9) Remove four carrier to crankcase attaching
bolts to separate carrier from engine bedplate.
BALANCE SHAFT CARRIER
The following components will remain intact dur-
ing carrier removal: Gear cover, gears, balance shafts
and the rear cover (Fig. 127).
(1) Drain engine oil.
(2) Remove the oil pan and pick-up tube (Refer to
9 - ENGINE/LUBRICATION/OIL PAN - REMOVAL).
(3) Remove chain cover, guide and tensioner (Fig.
128).
Fig. 127 Balance Shafts and Carrier Assembly
1 - SPROCKET 7 - GEARS
2 - TENSIONER 8 - GEAR COVER
3 - PLUG 9 - CHAIN COVER
4 - CARRIER 10 - SPROCKET
5 - REAR COVER 11 - GUIDE
6 - BALANCE SHAFTS 12 - CHAIN
9 - 70 ENGINE 2.4LRS
BALANCE SHAFTS AND CARRIER ASSEMBLY (Continued)
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(4) Remove screw retaining balance shaft drive
sprocket (Fig. 129).
(5) Move balance shaft inboard through drive
chain sprocket. Sprocket will hang in lower chain
loop.
(6) Remove carrier to crankcase attaching bolts to
remove carrier.
INSTALLATION
BALANCE SHAFT INSTALLATION/TIMING
Balance shaft and carrier assembly installation is
the reverse of the removal procedure.During instal-
lation crankshaft-to-balance shaft timing must
be established. Refer to Timing procedure in
this section.
(1) With balance shafts installed in carrier (Fig.
127) position carrier on crankcase and install four
attaching bolts and tighten to 54 N´m (40 ft. lbs.).
(2) Turn balance shafts until both shaft key ways
are up, parallel to vertical centerline of engine.
Install short hub drive gear on sprocket driven shaft
and long hub gear on gear driven shaft. After instal-
lation gear and balance shaft keyways must be upwith gear timing marks meshed as shown in (Fig.
132).
(3) Install gear cover and tighten double ended
stud/washer fastener to 12 N´m (105 in. lbs.).
Fig. 128 Chain Cover, Guide and Tensioner
1 - STUD
2 - TENSIONER (ADJUSTER)
3 - GEAR COVER
4 - ADJUST SCREW
5 - PIVOT SCREW
6 - CHAIN COVER (CUTAWAY)
7 - GUIDE
Fig. 129 Drive Chain and Sprockets
1 - NICKEL PLATED LINK AND MARK
2 - GEAR/SPROCKET SCREWS
3 - NICKEL PLATED LINK AND DOT
Fig. 130 Gear Cover and Gears
1 - STUD (DOUBLE ENDED)
2 - DRIVE GEAR
3 - DRIVEN GEAR
4 - CARRIER DOWEL
5 - GEAR(S)
6 - GEAR COVER
RSENGINE 2.4L9-71
BALANCE SHAFTS AND CARRIER ASSEMBLY (Continued)
ProCarManuals.com

(4) Align flat on balance shaft drive sprocket to the
flat on crankshaft (Fig. 133).
(5) Install balance shaft drive sprocket on crank-
shaft using Special Tool 6052 (Fig. 134).
(6) Turn crankshaft until number 1 cylinder is at
top dead center (TDC). The timing marks on the
chain sprocket should line up with the parting line
on the left side of number one main bearing cap.
(Fig. 135).
(7) Place chain over crankshaft sprocket so that
the plated link of the chain is over the number 1 cyl-inder timing mark on the balance shaft crankshaft
sprocket (Fig. 135).
(8) Place balance shaft sprocket into the timing
chain (Fig. 135) and align the timing mark on the
sprocket (dot) with the (lower) plated link on the
chain.
NOTE: The lower plated link is 8 links from the
upper link.
Fig. 131 Balance Shaft - Removal/Installation
1 - REAR COVER
2 - CARRIER
3 - BALANCE SHAFT
Fig. 132 Gear Timing
1 - KEY WAYS UP
2 - GEAR ALIGNMENT DOTS
Fig. 133 Balance Shaft Sprocket Alignment to
Crankshaft
1 - ALIGN FLATS
Fig. 134 Balance Shaft Drive
1 - SPROCKET
2 - SPECIAL TOOL 6052
9 - 72 ENGINE 2.4LRS
BALANCE SHAFTS AND CARRIER ASSEMBLY (Continued)
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(9) With balance shaft keyways pointing up (12
o'clock) slide the balance shaft sprocket onto the nose
of the balance shaft. The balance shaft may have to
be pushed in slightly to allow for clearance.
NOTE: THE TIMING MARK ON THE SPROCKET, THE
(LOWER) NICKEL PLATED LINK, AND THE ARROW
ON THE SIDE OF THE GEAR COVER SHOULD LINE
UP WHEN THE BALANCE SHAFTS ARE TIMED
CORRECTLY.
(10) If the sprockets are timed correctly, install the
balance shaft bolts and tighten to 28 N´m (250 in.
lbs.). A wood block placed between crankcase and
crankshaft counterbalance will prevent crankshaft
and gear rotation.(11)CHAIN TENSIONING:
(a) Install chain tensioner loosely assembled.
(b) Position guide on double ended stud making
sure tab on the guide fits into slot on the gear
cover. Install and tighten nut/washer assembly to
12 N´m (105 in. lbs.).
(c) Place a shim 1 mm (0.039 in.) thick x 70 mm
(2.75 in.) long or between tensioner and chain.
Push tensioner and shim up against the chain.
Apply firm pressure 2.5±3 Kg (5.5±6.6 lbs.)
directly behind the adjustment slot to take up
all slack.Chain must have shoe radius contact as
shown in (Fig. 136).
(d) With the load applied, tighten top tensioner
bolt first, then bottom pivot bolt. Tighten bolts to
12 N´m (105 in. lbs.). Remove shim.
(e) Install carrier covers and tighten screws to
12 N´m (105 in. lbs.).
(12) If removed, install oil pump (Refer to 9 -
ENGINE/LUBRICATION/OIL PUMP - INSTALLA-
TION).
(13) Install pick-up tube and oil pan (Refer to 9 -
ENGINE/LUBRICATION/OIL PAN - INSTALLA-
TION).
(14) Fill engine crankcase with proper oil to cor-
rect level.
Fig. 135 Balance Shaft Timing
1 - MARK ON SPROCKET
2 - KEYWAYS UP
3 - ALIGN MARKS
4 - PLATED LINK
5 - PARTING LINE (BEDPLATE TO BLOCK)
6 - PLATED LINK
Fig. 136 Chain Tension Adjustment
1 - 1MM (0.039 IN.) SHIM
2 - TENSIONER (ADJUSTER) BOLT
3 - PIVOT BOLT
RSENGINE 2.4L9-73
BALANCE SHAFTS AND CARRIER ASSEMBLY (Continued)
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ENGINE 3.3/3.8L
TABLE OF CONTENTS
page page
ENGINE 3.3/3.8L
DESCRIPTION.........................76
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION...........77
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - PERFORMANCE...........78
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - MECHANICAL.............80
DIAGNOSIS AND TESTING - ENGINE OIL
LEAK INSPECTION....................82
DIAGNOSIS AND TESTING - CYLINDER
COMPRESSION PRESSURE TEST........83
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE
TEST...............................83
STANDARD PROCEDURE
STANDARD PROCEDURE - MEASURING
BEARING CLEARANCE USING
PLASTIGAGE........................84
STANDARD PROCEDURE - FORM-IN-
PLACE GASKETS AND SEALERS.........84
STANDARD PROCEDURE - ENGINE
GASKET SURFACE PREPARATION........85
STANDARD PROCEDURE - HYDROSTATIC
LOCKED ENGINE.....................86
STANDARD PROCEDURE - REPAIR OF
DAMAGED OR WORN THREADS.........86
STANDARD PROCEDURE - ENGINE CORE
AND OIL GALLERY PLUGS..............86
REMOVAL - ENGINE ASSEMBLY...........87
INSTALLATION - ENGINE ASSEMBLY........90
SPECIFICATIONS
3.3/3.8L ENGINE......................92
SPECIFICATIONS - TORQUE............95
SPECIAL TOOLS
3.3/3.8L ENGINE......................96
AIR CLEANER ELEMENT
REMOVAL.............................99
INSTALLATION.........................99
AIR CLEANER HOUSING
REMOVAL.............................99
INSTALLATION........................100
CYLINDER HEAD
DESCRIPTION........................100
OPERATION..........................100
DIAGNOSIS AND TESTINGÐCYLINDER HEAD
GASKET...........................100
REMOVAL - CYLINDER HEAD............100
CLEANING...........................101INSPECTION.........................101
INSTALLATION - CYLINDER HEAD.........102
CYLINDER HEAD COVER(S)
DESCRIPTION........................103
CYLINDER HEAD COVER - RIGHT
REMOVAL............................103
INSTALLATION........................103
CYLINDER HEAD COVER - LEFT
REMOVAL............................105
INSTALLATION........................105
INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION........................105
OPERATION..........................105
STANDARD PROCEDURE - REFACING
VALVESANDVALVESEATS ............105
REMOVAL............................106
CLEANING...........................106
INSPECTION.........................106
INSTALLATION........................107
VALVE SPRINGS
DESCRIPTION........................107
OPERATION..........................107
REMOVAL
REMOVAL - CYLINDER HEAD OFF.......108
REMOVAL - CYLINDER HEAD ON........108
INSPECTION.........................109
INSTALLATION
INSTALLATION - CYLINDER HEAD OFF . . . 109
INSTALLATION - CYLINDER HEAD ON....109
ROCKER ARMS
DESCRIPTION
DESCRIPTION - ROCKER ARMS.........110
DESCRIPTION - PUSHRODS............110
OPERATION
OPERATION - ROCKER ARMS..........110
OPERATION - PUSHRODS.............110
REMOVAL - ROCKER ARMS AND SHAFT....110
DISASSEMBLY - ROCKER ARMS AND
SHAFT.............................110
ASSEMBLY - ROCKER ARMS AND SHAFT . . . 111
INSTALLATION - ROCKER ARMS AND
SHAFT.............................111
VALVE STEM SEALS
DESCRIPTION........................112
REMOVAL............................113
INSTALLATION........................113
ENGINE BLOCK
DESCRIPTION........................113
STANDARD PROCEDURE - CYLINDER BORE
HONING............................113
9 - 74 ENGINE 3.3/3.8LRS
ProCarManuals.com

CLEANING...........................113
INSPECTION..........................113
CAMSHAFT & BEARINGS (IN BLOCK)
DESCRIPTION........................114
OPERATION..........................114
REMOVAL............................114
INSPECTION..........................115
INSTALLATION........................115
CONNECTING ROD BEARINGS
STANDARD PROCEDURE - MEASURING
CONNECTING ROD BEARING
CLEARANCE........................115
CRANKSHAFT
DESCRIPTION
DESCRIPTION - 3.3L..................116
DESCRIPTION - 3.8L..................117
OPERATION..........................117
STANDARD PROCEDURE - MEASURING
CRANKSHAFT END PLAY..............117
REMOVAL............................117
INSPECTION..........................118
INSTALLATION........................118
CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDURE - MAIN BEARING
FITTING............................119
REMOVAL - CRANKSHAFT MAIN
BEARINGS..........................121
INSTALLATION - CRANKSHAFT MAIN
BEARINGS..........................121
CRANKSHAFT OIL SEAL - FRONT
REMOVAL............................122
INSTALLATION........................123
CRANKSHAFT OIL SEAL - REAR
REMOVAL............................123
INSTALLATION........................123
CRANKSHAFT REAR OIL SEAL RETAINER
REMOVAL............................124
INSTALLATION........................124
FLEX PLATE
REMOVAL............................124
INSTALLATION........................124
HYDRAULIC LIFTERS (CAM IN BLOCK)
DESCRIPTION........................125
DIAGNOSIS AND TESTING - HYDRAULIC
LIFTERS...........................125
REMOVAL............................126
INSTALLATION........................126
PISTON & CONNECTING ROD
DESCRIPTION........................126
OPERATION..........................126
STANDARD PROCEDURE
STANDARD PROCEDURE - FITTING
CONNECTING RODS..................127
STANDARD PROCEDURE - FITTING
PISTONS...........................127
REMOVAL............................127
INSTALLATION........................128PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING............................130
REMOVAL............................131
INSTALLATION........................131
VIBRATION DAMPER
REMOVAL............................132
INSTALLATION........................132
ENGINE MOUNTING
DESCRIPTION........................133
FRONT MOUNT
REMOVAL............................133
INSTALLATION........................133
LEFT MOUNT
REMOVAL............................134
INSTALLATION........................134
REAR MOUNT
REMOVAL............................135
INSTALLATION........................136
RIGHT MOUNT
REMOVAL............................137
INSTALLATION........................137
LUBRICATION
DESCRIPTION........................137
OPERATION..........................137
DIAGNOSIS AND TESTING - ENGINE OIL
PRESSURE.........................137
OIL
STANDARD PROCEDURE
STANDARD PROCEDURE - ENGINE OIL
AND FILTER CHANGE.................138
STANDARD PROCEDURE - ENGINE OIL
LEVEL CHECK.......................139
OIL COOLER & LINES
DESCRIPTION........................140
OPERATION..........................140
REMOVAL............................140
INSTALLATION........................140
OIL FILTER
REMOVAL............................140
INSTALLATION........................140
OIL FILTER ADAPTER
REMOVAL............................141
INSTALLATION........................141
OIL PAN
REMOVAL............................141
CLEANING...........................141
INSPECTION.........................142
INSTALLATION........................142
OIL PRESSURE RELIEF VALVE
REMOVAL............................142
INSTALLATION........................143
OIL PRESSURE SWITCH
DESCRIPTION........................143
OPERATION..........................143
REMOVAL............................143
INSTALLATION........................143
RSENGINE 3.3/3.8L9-75
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