2002 CHRYSLER CARAVAN lock

REMOVAL
REMOVAL - CYLINDER HEAD OFF
(1) With the cylinder head on a bench, position
Special Tool C-3422-D with 8464 Adapter on the
valve and spring retainer (Fig. 37).
(2) Compress the spring only enough to remove the
valve retainer locks.
(3) Slowly release the spring tension and remove
the valve spring and retainer.
(4) For removal of the valve stem seal (Refer to 9 -
ENGINE/CYLINDER HEAD/VALVE STEM SEALS -
REMOVAL).
REMOVAL - CYLINDER HEAD ON
(1) Disconnect negative cable from battery.
(2) Remove spark plug wires and all spark plugs.
(3) Remove cylinder head cover(s). (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL)(4) Remove rocker arms and shaft. (Refer to 9 -
ENGINE/CYLINDER HEAD/ROCKER ARMS -
REMOVAL)
(5) Rotate engine until the piston in the cylinder
bore requiring spring removal is at TDC.
(6) Install Special Tool 8453 to the cylinder head
(Fig. 38). Tighten the attaching bolts to 23 N´m (200
in. lbs.).
(7) Install a spark plug adapter in the spark plug
hole. Connect air hose that can supply 620.5±689 kPa
(90±100 psi) of air pressure to adapter. This is to
hold valves in place while servicing components.
(8) Locate the forcing screw and spring retainer
adapter assembly over the spring requiring removal
(Fig. 38).
(9) Slowly turn the forcing screw clockwise (com-
pressing the valve spring) until the valve keepers can
be removed.
(10) Turn forcing screw counterclockwise to relieve
spring tension. Remove retainer and valve spring.
Fig. 36 VALVE COMPONENTS
1 - VALVE LOCKS 5 - SPRING SEATS
2 - RETAINERS 6 - CYLINDER HEAD
3 - VALVE SPRINGS 7 - VALVE - EXHAUST
4 - VALVE STEM SEALS 8 - VALVE - INTAKE
9 - 108 ENGINE 3.3/3.8LRS
VALVE SPRINGS (Continued)
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(11) Repeat procedure for each cylinder requiring
valve spring removal.
INSPECTION
Whenever valves have been removed for inspection,
reconditioning or replacement, valve springs should
be tested (Fig. 39).As an example;the compression
length of a spring to be tested is 38.00 mm (1.496
in.). Turn the table of Tool C-647 until surface is in
line with the 38.00 mm (1.496 in.) mark on the
threaded stud and the zero mark on the front. Placespring over stud on the table and lift compressing
lever to set tone device. Pull on torque wrench until
ping is heard. Take reading on torque wrench at this
instant. Multiply this reading by two. This will give
the spring load at test length. Fractional measure-
ments are indicated on the table for finer adjust-
ments. Refer to Engine Specifications to obtain
specified height and allowable tensions (Refer to 9 -
ENGINE - SPECIFICATIONS). Replace any springs
that do not meet specifications.
INSTALLATION
INSTALLATION - CYLINDER HEAD OFF
(1) If removed, install a new valve stem seal (Refer
to 9 - ENGINE/CYLINDER HEAD/VALVE STEM
SEALS - INSTALLATION).
(2) Position valve spring and retainer on spring
seat.
(3) Using Special Tool C-3422-D with 8464 Adapter
(Fig. 37), compress the spring only enough to install
the valve retainer locks. Install valve retainer locks.
(4) Slowly release the spring tension. Ensure the
retainer locks are seated properly.
INSTALLATION - CYLINDER HEAD ON
(1) The intake valve stem seals should be pushed
firmly and squarely over the valve guide using the
valve stem as guide.Do Not Forceseal against top
of guide. When installing the valve retainer locks,
compress the springonly enoughto install the
locks.
CAUTION: Do not pinch seal between retainer and
top of valve guide.
Fig. 37 VALVE SPRING - REMOVE/INSTALL
1 - SPECIAL TOOL C-3422-D SPRING COMPRESSOR
2 - SPECIAL TOOL 8464 ADAPTER
Fig. 38 VALVE SPRING - REMOVE/INSTALL (HEAD
ON)
1 - SPECIAL TOOL 8453
2 - BOLTS - SPECIAL TOOL ATTACHING
3 - AIR SUPPLY HOSE ADAPTER
Fig. 39 TESTING VALVE SPRING
1 - SPECIAL TOOL C-647
RSENGINE 3.3/3.8L9 - 109
VALVE SPRINGS (Continued)
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REMOVAL
(1) Remove the valve springs. (Refer to 9 -
ENGINE/CYLINDER HEAD/VALVE SPRINGS -
REMOVAL)
(2) Remove the valve stem seal (Fig. 44).
INSTALLATION
(1) Install the valve stem seal squarely over the
valve guide, using the valve stem as a guide (Fig.
44). Do not force the seal against top of the valve
guide.
(2) Install the valve spring. (Refer to 9 - ENGINE/
CYLINDER HEAD/VALVE SPRINGS - INSTALLA-
TION)
ENGINE BLOCK
DESCRIPTION
The cylinder block is made of cast iron and is a
deep skirt design.
STANDARD PROCEDURE - CYLINDER BORE
HONING
(1) Used carefully, the cylinder bore resizing hone,
recommended tool C-823 or equivalent, equipped
with 220 grit stones, is the best tool for this honing
procedure. In addition to deglazing, it will reduce
taper and out-of-round as well as removing light
scuffing, scoring or scratches. Usually a few strokes
will clean up a bore and maintain the required lim-
its.
(2) Deglazing of the cylinder walls may be done
using a cylinder surfacing hone, recommended tool
C-3501 or equivalent, equipped with 280 grit stones,
if the cylinder bore is straight and round. 20±60
strokes depending on the bore condition, will be suf-
ficient to provide a satisfactory surface. Use a light
honing oil.Do not use engine or transmission oil,
mineral spirits or kerosene.Inspect cylinder walls
after each 20 strokes.
(3) Honing should be done by moving the hone up
and down fast enough to get a cross-hatch pattern.
When hone marksintersectat 40-60 degrees, the
cross hatch angle is most satisfactory for proper seat-
ing of rings (Fig. 45).
(4) A controlled hone motor speed between
200±300 RPM is necessary to obtain the proper cross-
hatch angle. The number of up and down strokes per
minute can be regulated to get the desired 40±60
degree angle. Faster up and down strokes increase
the cross-hatch angle.
(5) After honing, it is necessary that the block be
cleaned again to remove all traces of abrasive.CAUTION: Ensure all abrasives are removed from
engine parts after honing. It is recommended that a
solution of soap and hot water be used with a
brush and the parts then thoroughly dried. The bore
can be considered clean when it can be wiped
clean with a white cloth and cloth remains clean.
Oil the bores after cleaning to prevent rusting.
CLEANING
Clean cylinder block thoroughly using a suitable
cleaning solvent.
INSPECTION
ENGINE BLOCK
(1) Clean cylinder block thoroughly and check all
core hole plugs for evidence of leaking.
(2) If new core plugs are to be installed, (Refer to 9
- ENGINE - STANDARD PROCEDURE - ENGINE
CORE AND OIL GALLERY PLUGS).
(3) Examine block and cylinder bores for cracks or
fractures.
(4) Check block deck surfaces for flatness. Deck
surface must be within service limit of 0.1 mm (0.004
in.).
CYLINDER BORE
NOTE: The cylinder bores should be measured at
normal room temperature, 21ÉC (70ÉF).
Fig. 45 Cylinder Bore Cross-Hatch Pattern
1 - CROSS-HATCH PATTERN
2 - 40ɱ60É
RSENGINE 3.3/3.8L9 - 113
VALVE STEM SEALS (Continued)
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The cylinder walls should be checked for out-of-
round and taper with Tool C119 or equivalent (Fig.
46) (Refer to 9 - ENGINE - SPECIFICATIONS). If
the cylinder walls are badly scuffed or scored, the
cylinder block should be replaced, and new pistons
and rings fitted.
Measure the cylinder bore at three levels in direc-
tions A and B (Fig. 46). Top measurement should be
10 mm (3/8 in.) down and bottom measurement
should be 10 mm (3/8 in.) up from bottom of bore.
(Refer to 9 - ENGINE - SPECIFICATIONS).
CAMSHAFT & BEARINGS (IN
BLOCK)
DESCRIPTION
The nodular iron camshaft is mounted in the
engine block and supported with four steel backed
aluminum bearings (Fig. 47). A thrust plate, located
in front of the first bearing, is bolted to the block and
controls the camshaft end play (Fig. 47). To distin-
guish camshafts between the 3.3L and 3.8L engines,
a cast-in ring is located between the rear bearing
journal and rear lobe (Fig. 48). The 3.3L engine
application is as-cast only. The 3.8L engine applica-
tion the cast ring is machined off.
OPERATION
The camshaft is driven by the crankshaft through
a timing chain and sprockets. The camshaft has pre-cisely machined (egg-shaped) lobes to provide accu-
rate valve timing and duration.
REMOVAL
(1) Remove the engine assembly from vehicle.
(Refer to 9 - ENGINE - REMOVAL)
Remove the cylinder heads. (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL)
(2) Remove the timing chain and camshaft
sprocket. (Refer to 9 - ENGINE/VALVE TIMING/
TIMING BELT/CHAIN AND SPROCKETS -
REMOVAL)
(3) Remove the hydraulic lifters. (Refer to 9 -
ENGINE/ENGINE BLOCK/HYDRAULIC LIFTERS
(CAM IN BLOCK) - REMOVAL). Identify each tappet
for reinstallation in original location.
Fig. 46 Checking Cylinder Bore Size
Fig. 47 CAMSHAFT AND BEARINGS
1 - CAMSHAFT
2 - THRUST PLATE
3 - BOLT
4 - CAMSHAFT BEARINGS (SERVICED WITH BLOCK)
Fig. 48 CAMSHAFT IDENTIFICATION
1 - CAMSHAFT - 3.3L ENGINE
2 - CAST-IN RING
3 - CAMSHAFT - 3.8L ENGINE
4 - MACHINED CAST-IN RING
9 - 114 ENGINE 3.3/3.8LRS
ENGINE BLOCK (Continued)
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(4) Remove camshaft thrust plate (Fig. 47).
(5) Install a long bolt into front of camshaft to
facilitate removal of the camshaft.
(6) Remove the camshaft (Fig. 47), being careful
not to damage cam bearings with the cam lobes.
NOTE: The camshaft bearings are serviced with the
engine block.
INSPECTION
(1) Check the cam lobes and bearing surfaces for
abnormal wear and damage (Fig. 49). Replace cam-
shaft as required.
NOTE: If camshaft is replaced due to lobe wear or
damage, always replace the lifters.
(2) Measure the lobe actual wear (unworn area -
wear zone = actual wear) (Fig. 49) and replace cam-
shaft if out of limit. Standard value is 0.0254 mm
(0.001 in.), wearlimitis 0.254 mm (0.010 in.).
INSTALLATION
(1) Lubricate camshaft lobes and camshaft bearing
journals with engine oil.
(2) Install a long bolt into the camshaft to assist in
the installation of the camshaft.
(3) Carefully install the camshaft in engine block.
(4) Install camshaft thrust plate and bolts (Fig.
47). Tighten to 12 N´m (105 in. lbs.) torque.
(5) Measure camshaft end play. (Refer to 9 -
ENGINE - SPECIFICATIONS) If not within specifi-
cations, replace thrust plate.(6) Install the timing chain and sprockets. (Refer
to 9 - ENGINE/VALVE TIMING/TIMING BELT/
CHAIN AND SPROCKETS - INSTALLATION)
NOTE: When camshaft is replaced, all of the
hydraulic lifters must be replaced also.
(7) Install the hydraulic lifters (Refer to 9 -
ENGINE/ENGINE BLOCK/HYDRAULIC LIFTERS
(CAM IN BLOCK) - INSTALLATION). Each lifter
reused must be installed in the same position from
which it was removed.
(8) Install the timing chain cover. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION)
(9) Install the cylinder heads. (Refer to 9 -
ENGINE/CYLINDER HEAD - INSTALLATION)
(10) Install the cylinder head covers. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION)
(11) Install the lower and upper intake manifolds.
(Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANI-
FOLD - INSTALLATION)
(12) Install the engine assembly. (Refer to 9 -
ENGINE - INSTALLATION)
CONNECTING ROD BEARINGS
STANDARD PROCEDURE - MEASURING
CONNECTING ROD BEARING CLEARANCE
The bearing caps are not interchangeable and
should be marked at removal to ensure correct
assembly. The bearing shells must be installed with
the tangs inserted into the machined grooves in the
rods and caps. Install cap with the tangs on the same
side as the rod. Fit all rods on one bank until com-
plete. Connecting rod bearings are available in the
standard size and the following undersizes: 0.025
mm (0.001 in.) and 0.250 mm (0.010 in.).
CAUTION: Install the bearings in pairs. Do not use a
new bearing half with an old bearing half. Do not
file the rods or bearing caps.
Measure connecting rod journal for taper and out-
of-round. (Refer to 9 - ENGINE/ENGINE BLOCK/
CRANKSHAFT - INSPECTION)
The connecting rod bearing clearances can be
determined by use of Plastigage or the equivalent.
The following is the recommended procedure for the
use of Plastigage:
(1) Rotate the crankshaft until the connecting rod
to be checked is at the bottom of its stroke.
(2) Remove oil film from surface to be checked.
Plastigage is soluble in oil.
Fig. 49 Checking Camshaft for Wear (Typical)
1 - UNWORN AREA
2 - ACTUAL WEAR
3 - BEARING JOURNAL
4 - LOBE
5 - WEAR ZONE
RSENGINE 3.3/3.8L9 - 115
CAMSHAFT & BEARINGS (IN BLOCK) (Continued)
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(3) Place a piece of Plastigage across the entire
width of the bearing shell in the bearing cap approx-
imately 6.35 mm (1/4 in.) off center and away from
the oil hole. In addition, suspect areas can be
checked by placing Plastigage in that area.
(4) Assemble the rod cap with Plastigage in place.
Tighten the rod cap to the specified torque.Do not
rotate the crankshaft while assembling the cap
or the Plastigage may be smeared, giving inac-
curate results.
(5) Remove the bearing cap and compare the
width of the flattened Plastigage with the scale pro-
vided on the package (Fig. 50). Locate the band clos-
est to the same width. This band indicates the
amount of oil clearance. Differences in readings
between the ends indicate the amount of taper
present. Record all readings taken. Refer to Engine
Specifications (Refer to 9 - ENGINE - SPECIFICA-
TIONS).Plastigage generally is accompanied by
two scales. One scale is in inches, the other is a
metric scale. If the bearing clearance exceeds
wear limit specification, replace the bearing.CRANKSHAFT
DESCRIPTION
DESCRIPTION - 3.3L
The nodular iron crankshaft is supported by four
main bearings, with number two position the thrust
bearing (Fig. 51). Crankshaft end sealing is provided
by front and rear rubber seals.
Fig. 50 Measuring Connecting Rod Bearing
Clearance
Fig. 51 CRANKSHAFT AND ENGINE BLOCK - 3.3L
1 - MAIN BEARING CAP No. 4
2 - MAIN BEARING CAP No. 3
3 - MAIN BEARING CAP No. 2
4 - MAIN BEARING CAP BOLT (QTY. 2 PER CAP)
5 - MAIN BEARING CAP No. 1
6 - LOWER MAIN BEARING - THRUST
7 - UPPER MAIN BEARING - THRUST
8 - ENGINE BLOCK
9 - UPPER MAIN BEARINGS
10 - CRANKSHAFT
11 - LOWER MAIN BEARINGS
9 - 116 ENGINE 3.3/3.8LRS
CONNECTING ROD BEARINGS (Continued)
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DESCRIPTION - 3.8L
The nodular iron crankshaft is supported by four
main bearings, with number two position providing
thrust bearing location (Fig. 52). Each main bearing
cap has two vertical retaining bolts. The two center
main caps have horizontal bolts to add increased
rigidity to the lower engine block (Fig. 52). Crank-
shaft end sealing is provided by front and rear rub-
ber seals.
OPERATION
The crankshaft transfers force generated by com-
bustion within the cylinder to the flywheel or flex-
plate.
STANDARD PROCEDURE - MEASURING
CRANKSHAFT END PLAY
(1) Mount a dial indicator to front of engine with
the locating probe on nose of crankshaft (Fig. 53).
(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 9 - ENGINE -
SPECIFICATIONS) for end play specification.
REMOVAL
(1) Remove the engine assembly. (Refer to 9 -
ENGINE - REMOVAL)
(2) Separate transaxle from engine.
(3) Mount engine on an engine stand.
(4) Remove the oil filter.
(5) Remove the oil pan and oil pick-up tube. (Refer
to 9 - ENGINE/LUBRICATION/OIL PAN -
REMOVAL)
(6) Remove the timing chain cover. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL)
(7) Remove timing chain and sprockets. (Refer to 9
- ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - REMOVAL)
(8) Remove crankshaft rear oil seal and retainer.
(Refer to 9 - ENGINE/ENGINE BLOCK/CRANK-
SHAFT OIL SEAL - REAR - REMOVAL)
(9) Rotate the crankshaft until connecting rod cap
is accessible.
(10) Mark connecting rod cap position using a suit-
able marker/scribe tool.
(11) Remove connecting rod bearing cap. Use care
to prevent damage to the crankshaft bearing sur-
faces.
(12) Repeat removal procedure for each connecting
rod cap.
Fig. 52 CRANKSHAFT AND BLOCK - 3.8L
1 - MAIN BEARING CAP No. 4
2 - MAIN BEARING CAP No. 3
3 - MAIN BEARING CAP No. 2
4 - MAIN BEARING CAP BOLT
5 - MAIN BEARING CAP No. 1
6 - THRUST MAIN BEARING - LOWER
7 - THRUST MAIN BEARING - UPPER
8 - MAIN BEARING CAP CROSS BOLT
9 - ENGINE BLOCK
10 - MAIN BEARING - UPPER
11 - CRANKSHAFT
12 - MAIN BEARING - LOWER
Fig. 53 Checking Crankshaft End PlayÐTypical
RSENGINE 3.3/3.8L9 - 117
CRANKSHAFT (Continued)
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(13) Remove and discard the main bearing cross
bolts and washers (3.8L engine only).
NOTE: Install new cross bolt and washer assembly
(3.8L engine only) upon reassembly.
(14) Remove the main bearing cap bolts
(15) Remove the main bearing caps.
(16) Remove the crankshaft from engine block.
INSPECTION
The crankshaft journals should be checked for
excessive wear, taper and scoring (Fig. 54). Limits of
taper or out of round on any crankshaft journals
should within specitifications. (Refer to 9 - ENGINE -
SPECIFICATIONS) Journal grinding should not
exceed 0.305 mm (0.012 in.) under the standard jour-
nal diameter. DO NOT grind thrust faces of No. 3
main bearing. DO NOT nick crank pin or bearing fil-
lets. After grinding, remove rough edges from crank-
shaft oil holes and clean out all passages.
CAUTION: With the nodular cast iron crankshafts, it
is important that the final paper or cloth polish be
in the same direction as normal rotation in the
engine.
INSTALLATION
(1) Lubricate with engine oil and install the crank-
shaft main bearing halves in the engine block.
(2) Position the crankshaft in engine block (Fig.
56).
(3) Perform main bearing fitting procedure. (Refer
to 9 - ENGINE/ENGINE BLOCK/CRANKSHAFT
MAIN BEARINGS - STANDARD PROCEDURE)
(4) Inspect main cap bolts for stretching (Fig. 55).
Replace bolts that are stretched.
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. 55).
(5) Install the main bearing caps and bolts.
Tighten bolts to 41 N´m (30 ft. lbs.) plus
1¤4turn.
NOTE: Install new cross bolt and washer assembly
(3.8L engine only) upon reassembly.
(6) Install and tighten the NEW cross bolts and
washer assemblies (3.8L engine only) to 61 N´m (45
ft. lbs.) (Fig. 57).
(7) Position and install the connecting rod and
bearing caps on the crankshaft. (Refer to 9 -
ENGINE/ENGINE BLOCK/CONNECTING ROD
BEARINGS - STANDARD PROCEDURE)
(8) Install the crankshaft rear oil seal. (Refer to 9 -
ENGINE/ENGINE BLOCK/CRANKSHAFT OIL
SEAL - REAR - INSTALLATION)
(9) Install the crankshaft sprocket. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - INSTALLATION)
(10) Install the timing chain and camshaft
sprocket. (Refer to 9 - ENGINE/VALVE TIMING/
TIMING BELT/CHAIN AND SPROCKETS -
INSTALLATION)
Fig. 54 Crankshaft Journal Measurements
Fig. 55 Check for Stretched (Necked) Bolts
1 - STRETCHED BOLT
2 - THREADS ARE NOT STRAIGHT ON LINE
3 - THREADS ARE STRAIGHT ON LINE
4 - UNSTRETCHED BOLT
9 - 118 ENGINE 3.3/3.8LRS
CRANKSHAFT (Continued)
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