2002 CHRYSLER CARAVAN timing belt

INTERNAL VACUUM PUMP
DESCRIPTION
The diesel engine uses a internal vacuum pump.
This vacuum pump is mounted in the front of the
engine block under the engine front cover (Fig. 45).
The vacuum pump is driven by a sprocket on the
crankshaft.
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove air cleaner housing.
(3) Remove power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(4) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(5) Support engine and remove right engine mount
(Refer to 9 - ENGINE/ENGINE MOUNTING/RIGHT
MOUNT - REMOVAL).
(6) Remove vibration damper/crankshaft pulley
(Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL).
(7) Remove outer timing belt cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(8) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL).
(9) Remove timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
NOTE: Crankshaft hub has LHD thread.
(10) Remove crankshaft hub.
(11) Remove front engine cover (Refer to 9 -
ENGINE/ENGINE BLOCK/ENGINE COVER -
REMOVAL).
(12) Remove crankshaft sprocket (Fig. 46).
(13) Remove vacuum pump (Fig. 46).
INSTALLATION
(1) Lubricate vacuum pump blades and install in
vacuum pump body as shown (Fig. 47).
(2) Install vacuum pump in engine block (Fig. 46).
Torque bolts to 10.8N´m.
(3) Install crankshaft sprocket (Fig. 46). Torque
bolts to 10.8N´m.
(4) Install front engine cover (Refer to 9 -
ENGINE/ENGINE BLOCK/ENGINE COVER -
INSTALLATION).
(5) Install front crankshaft hub. Torque bolt to
304N´m.
(6) Install timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(7) Install timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION) .
(8) Install timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(9) Install vibration damper/crankshaft pulley.
Fig. 45 VACUUM PUMP
Fig. 46 OIL PUMP AND VACUUM PUMP
1 - VACUUM PUMP
2 - CRANKSHAFT SPROCKET
3 - OIL PUMP
4 - ENGINE BLOCK
5 - CRANKSHAFT
RGENGINE9a-35
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CRANKSHAFT OIL SEAL -
FRONT
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove air cleaner housing.
(3) Support engine and remove right engine mount
(Refer to 9 - ENGINE/ENGINE MOUNTING/RIGHT
MOUNT - REMOVAL).
(4) Remove power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(5) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(6) Remove vibration damper/crankshaft pulley
(Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL).
(7) Remove outer timing belt cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(8) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL).
(9) Remove timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
NOTE: Crankshaft hub retaining bolt has LHD
thread.
(10) Remove crankshaft hub.
(11) Remove front engine cover (Fig. 59) (Refer to
9 - ENGINE/ENGINE BLOCK/ENGINE COVER -
REMOVAL).
(12) With cover on work bench, pry out old seal.
INSTALLATION
(1) Clean engine block and front engine cover seal-
ing surfaces.
(2) Install crankshaft oil seal on VM.1061 (Fig.
60).
(3) Place sleeve for VM.1061 on workbench as
shown (Fig. 60).
Fig. 59 ENGINE COVER - FRONT
1 - CRANKSHAFT HUB RETAINING BOLT
2 - FRONT ENGINE COVER RETAINING BOLTS
3 - ENGINE BLOCK
4 - FRONT ENGINE COVER ALIGNMENT DOWELS
5 - FRONT ENGINE COVER
6 - CRANKSHAFT HUB
Fig. 60 VM.1061 PLACEMENT
1 - VM.1061
2 - FRONT ENGINE COVER
3 - WORK BENCH
4 - SLEEVE FROM VM.1061
RGENGINE9a-41
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(4) Using hammer, install new seal into front
engine cover (Fig. 61).
(5) Install front engine cover (Refer to 9 -
ENGINE/ENGINE BLOCK/ENGINE COVER -
INSTALLATION).
(6) Install crankshaft hub and retaining bolt.
Torque bolt to 304N´m.
(7) Install timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(8) Install timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION) .
(9) Install timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(10) Install vibration damper/crankshaft pulley
(Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - INSTALLATION).
(11) Install accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(12) Install power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(13) Install right engine mount (Refer to 9 -
ENGINE/ENGINE MOUNTING/RIGHT MOUNT -
INSTALLATION).
(14) Install air cleaner housing.
(15) Connect negative battery cable.VIBRATION DAMPER
REMOVAL
(1) Remove power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(2) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(3) Remove vibration damper retaining bolts and
damper (Fig. 62).
INSTALLATION
(1) Install vibration damper and retaining bolts
(Fig. 62). Torque bolts to 27.5N´m.
(2) Install accessory drive belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(3) Install power steering belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
Fig. 61 CRANKSHAFT OIL SEAL INSTALLATION
WITH VM.1061
1 - VM.1061
2 - FRONT ENGINE COVER
3 - WORK BENCH
Fig. 62 VIBRATION DAMPER
1 - BELT TENSIONER RETAINING BOLT
2 - BELT TENSIONER
3 - IDLER PULLEY
4 - VIBRATION DAMPER/CRANKSHAFT PULLEY
5 - VIBRATION DAMPER/CRANKSHAFT PULLEY RETAINING
BOLTS
9a - 42 ENGINERG
CRANKSHAFT OIL SEAL - FRONT (Continued)
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ENGINE COVER - FRONT
DESCRIPTION
The front engine cover on this engine is a stamped
steel cover which covers the oil pump and vacuum
pump.
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove air cleaner housing.
(3) Support engine and remove right engine mount
(Refer to 9 - ENGINE/ENGINE MOUNTING/RIGHT
MOUNT - REMOVAL).
(4) Remove power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(5) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(6) Remove vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(7) Remove timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
CAUTION: Before removing the cylinder head cover/
intake manifold or timing belt the engine must put
at 90É after TDC. Failure to do so could result in
valve and/or piston damage during reassembly.
(Refer to 9 - ENGINE/VALVE TIMING - STANDARD
PROCEDURE)
(8) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL).
(9) Remove timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
NOTE: Crankshaft hub has LHD thread.
(10) Remove crankshaft hub.
(11) Remove front engine cover (Fig. 63).
INSTALLATION
(1) Clean engine block and front engine cover seal-
ing surfaces.
(2) Apply a continous 3mm bead of Silicone Sealer
to cover, install within 10 minutes (Fig. 63). Torque
bolts to 11.8N´m.
(3) Install crankshaft hub (Fig. 63). Torque bolt to
304N´m.
(4) Install timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).(5) Install timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION) .
(6) Install timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(7) Install vibration damper (Refer to 9 - ENGINE/
ENGINE BLOCK/VIBRATION DAMPER - INSTAL-
LATION).
(8) Install right engine mount (Refer to 9 -
ENGINE/ENGINE MOUNTING/RIGHT MOUNT -
INSTALLATION).
(9) Install accessory drive belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(10) Install power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(11) Install air cleaner housing.
(12) Connect negative battery cable.
Fig. 63 ENGINE COVER - FRONT
1 - CRANKSHAFT HUB RETAINING BOLT
2 - FRONT ENGINE COVER RETAINING BOLTS
3 - ENGINE BLOCK
4 - FRONT ENGINE COVER ALIGNMENT DOWELS
5 - FRONT ENGINE COVER
6 - CRANKSHAFT HUB
RGENGINE9a-43
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OIL PUMP
REMOVAL
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(3) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(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 front engine cover (Refer to 9 -
ENGINE/ENGINE BLOCK/ENGINE COVER -
REMOVAL).
(8) Remove crankshaft sprocket (Fig. 71).
(9) Remove oil pump retaining bolts and remove
pump from engine block (Fig. 71).
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 oil pump pickup tube retaining bolt
and pull pickup tube from engine block (Fig. 72).
INSTALLATION
INSTALLATION
(1) Lubricate oil pump rotor with engine oil.
(2) Install oil pump in bore in engine block (Fig.
71).
Fig. 71 OIL PUMP AND VACUUM PUMP
1 - VACUUM PUMP
2 - CRANKSHAFT SPROCKET
3 - OIL PUMP
4 - ENGINE BLOCK
5 - CRANKSHAFT
Fig. 72 OIL PUMP PICKUP TUBE 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
RGENGINE9a-47
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(3) Install oil pump retaining bolts (Fig. 71).
Torque bolts to 10.8N´m.
(4) Install crankshaft sprocket (Fig. 71). Torque
bolts to 10.8N´m.
(5) Install front engine cover (Refer to 9 -
ENGINE/ENGINE BLOCK/ENGINE COVER -
INSTALLATION).
(6) Install timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(7) Install timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION) .
(8) Install timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(9) Install accessory drive belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(10) Install power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(11) Connect negative battery cable.
INSTALLATION
(1) Lubricate o-ring on oil pump pickup tube with
engine oil.
(2) Install pickup tube in engine block and install
retaining bolt (Fig. 72). Torque bolt to 32.4N´m.
(3) Install oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION).
(4) Refill engine oil to proper level.
(5) Connect negative battery cable.
OIL PRESSURE SENSOR/
SWITCH
DESCRIPTION
The oil pressure switch is located on the right side
of the engine block. The switch screws into the
engines main oil gallery (Fig. 73).
REMOVAL
(1) Disconnect negative battery cable.
(2) Raise vehicle on hoist.
(3) Disconnect oil pressure switch electrical con-
nector (Fig. 73).
(4) Remove oil pressure switch from engine block.
INSTALLATION
(1) Apply MopartThread Sealant to the switch
threads.
(2) Install oil pressure switch in engine block.
(3) Connect oil pressure switch electrical connector
(Fig. 73).(4) Lower vehicle.
(5) Start engine and check for leaks.
(6) Check and adjust oil level as necessary.
OIL TEMPERATURE SENSOR
DESCRIPTION
The oil temperature sensor is located on the right
side of the engine block. The sensor screws into the
engines main oil gallery (Fig. 74).
REMOVAL
(1) Disconnect negative battery cable.
(2) Raise vehicle on hoist.
(3) Disconnect oil temperature sensor electrical
connector (Fig. 74).
(4) Remove oil temperature sensor from engine
block.
INSTALLATION
(1) Apply MopartThread Sealant to the sensor
threads.
(2) Install oil temperature sensor in engine block.
(3) Connect oil temperature sensor electrical con-
nector (Fig. 74)
Fig. 73 REAR ENGINE VIEW
1 - SUSPENSION CRADLE
2 - ENGINE BLOCK
3 - OIL PRESSURE SWITCH
4 - OIL TEMPERATURE SENSOR
5 - VEHICLE SPEED SENSOR
6 - TRANSMISSION
9a - 48 ENGINERG
OIL PUMP (Continued)
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(9) Remove plug in cylinder head cover/intake
manifold and insert VM.1052 to lock intake camshaft
in position (Fig. 87).
(10) At this point the timing belt can be removed
for service.
(11) After engine service is completed and timing
belt reinstalled, remove both camshaft locking pins
from cylinder head cover/intake manifold.
(12) Install both camshaft access plugs.
(13) Remove 90É after TDC engine locking pin.
(14) Install starter motor (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - INSTALLA-
TION).
(15) Install generator (Refer to 8 - ELECTRICAL/
CHARGING/GENERATOR - INSTALLATION).
(16) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
(17) Install front wiper unit (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
INSTALLATION).
(18) Connect negative battery cable.BALANCE SHAFT
DESCRIPTION
The 2.5L Common Rail Diesel engine is equipped
with two nodular cast iron balance shafts in a cast
aluminum carrier. The balance shaft assembly is
mounted to the engine block (Fig. 88).
OPERATION
The balance shaft is driven by the crankshaft. The
balance shafts are connected by heelical gears. The
dual-counter rotating shafts decrease second order
vertical shaking forces caused by component move-
ment.
Fig. 87 INTAKE CAMSHAFT LOCKING PIN VM.1052
1 - TIMING BELT INNER COVER
2 - GLOW PLUG ELECTRICAL CONNECTOR
3 - CYLINDER HEAD COVER/INTAKE MANIFOLD
4 - FUEL RAIL
5 - INTAKE CAMSHAFT LOCKING PIN VM.1052
Fig. 88 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
9a - 54 ENGINERG
VALVE TIMING (Continued)
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(3) Install balance shaft assembly and retaining
bolts (Fig. 89). Torque bolts to 32.4N´m.
(4) Install oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION).
(5) Refill engine oil to proper level.
(6) Connect negative battery cable.
TIMING BELT / CHAIN
COVER(S)
REMOVAL
REMOVAL - TIMING BELT OUTER COVER
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(3) Remove air cleaner housing.
(4) Support engine and remove right engine mount
and bracket.
(5) Remove power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(6) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(7) Remove vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(8) Remove timing belt outer cover retaining bolts
and remove cover (Fig. 92).
REMOVAL - TIMING BELT INNER COVER
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(3) Remove air cleaner housing.
(4) Support engine and remove right engine mount
and bracket.
(5) Remove power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(6) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(7) Remove vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(8) Remove timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(9) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL).(10) Remove timing belt idler pulleys (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT IDLER
PULLEY - REMOVAL).
(11) Using special tool VM.1055, remove camshaft
sprockets (Fig. 93).
(12) Remove timing belt tensioner (Refer to 9 -
ENGINE/VALVE TIMING/TMNG BELT/CHAIN
TENSIONER&PULLEY - REMOVAL) .
(13) Remove injection pump sprocket (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL INJEC-
TION PUMP - REMOVAL).
(14) Remove timing belt inner cover retaining bolts
and remove cover (Fig. 94).
INSTALLATION
INSTALLATION - TIMING BELT OUTER COVER
(1) Install timing belt outer cover seal and cover
(Fig. 92). Torque 3mm bolts to 10.8N´m and 8mm
bolts to 10.8N´m.
(2) Install vibration damper (Refer to 9 - ENGINE/
ENGINE BLOCK/VIBRATION DAMPER - INSTAL-
LATION).
Fig. 92 TIMING BELT COVER (OUTER)
1 - SEAL
2 - TIMING BELT OUTER COVER
3 - RETAINING BOLTS
9a - 56 ENGINERG
BALANCE SHAFT (Continued)
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