2002 CHRYSLER CARAVAN oil pressure

LUBRICATION
DESCRIPTION
The lubrication system is a full-flow filtration,
pressure feed type. The oil pump is mounted in the
front engine cover and driven by the crankshaft.
OPERATION
Engine oil drawn up through the pickup tube and
is pressurized by the oil pump and routed through
the full-flow filter to the main oil gallery running the
length of the cylinder block. A diagonal hole in each
bulkhead feeds oil to each main bearing. Drilled pas-
sages within the crankshaft route oil from main bear-
ing journals to connecting rod journals. Balance shaft
lubrication is provided through an oil passage from
the number one main bearing cap through the bal-
ance shaft carrier support leg. This passage directly
supplies oil to the front bearings and internal
machined passages in the shafts that routes oil from
front to the rear shaft bearing journals. A vertical
hole at the number five bulkhead routes pressurized
oil through a restrictor (integral to the cylinder head
gasket) up past a cylinder head bolt to an oil galleryrunning the length of the cylinder head. The cam-
shaft journals are partially slotted to allow a prede-
termined amount of pressurized oil to pass into the
bearing cap cavities. Lubrication of the camshaft
lobes are provided by small holes in the camshaft
bearing caps that are directed towards each lobe. Oil
returning to the pan from pressurized components
supplies lubrication to the valve stems. Cylinder
bores and wrist pins are splash lubricated from
directed slots on the connecting rod thrust collars.
DIAGNOSIS AND TESTING - CHECKING
ENGINE OIL PRESSURE
(1) Disconnect and remove oil pressure switch.
(Refer to 9 - ENGINE/LUBRICATION/OIL PRES-
SURE SENSOR/SWITCH - REMOVAL)
(2) Install Special Tools C-3292 Gauge with 8406
Adaptor fitting.
(3) Start engine and record oil pressure. Refer to
Specifications for correct oil pressure requirements.
(Refer to 9 - ENGINE - SPECIFICATIONS)
CAUTION: If oil pressure is 0 at idle, do not perform
the 3000 RPM test
(4) If oil pressure is 0 at idle. Shut off engine,
check for pressure relief valve stuck open, a clogged
oil pick-up screen or a damaged oil pick-up tube
O-ring.
(5) After test is complete, remove test gauge and
fitting.
(6) Install oil pressure switch and connector. (Refer
to 9 - ENGINE/LUBRICATION/OIL PRESSURE
SENSOR/SWITCH - INSTALLATION)
OIL
STANDARD PROCEDURE
ENGINE OIL LEVEL CHECK
The best time to check engine oil level is after it
has sat overnight, or if the engine has been running,
allow the engine to be shut off for at least 5 minutes
before checking oil level.
Checking the oil while the vehicle is on level
ground will improve the accuracy of the oil level
reading. Remove dipstick and observe oil level. Add
oil only when the level is at or below the ADD mark
(Fig. 87).
Fig. 86 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
RSENGINE 2.4L9-53
RIGHT MOUNT (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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DISASSEMBLY
(1) To remove the relief valve, proceed as follows:
(a) Remove the threaded plug and gasket from
the oil pump (Fig. 94) .
(b) Remove spring and relief valve (Fig. 94) .
(2) Remove oil pump cover fasteners, and lift off
cover (Fig. 95) .
(3) Remove pump rotors (Fig. 95) .
(4) Wash all parts in a suitable solvent and
inspect carefully for damage or wear.
Fig. 91 Crankshaft Sprocket - Removal
1 - SPECIAL TOOL 6793
2 - SPECIAL TOOL C-4685±C2
3 - CRANKSHAFT SPROCKET
Fig. 92 Crankshaft Key
1 - CRANKSHAFT KEY
Fig. 93 Oil Pump
1 - BOLTS
2 - BOLTS
3 - OIL PUMP
Fig. 94 Oil Pressure Relief Valve
1 - PLUG
2 - OIL PUMP BODY
3 - RELIEF VALVE
4 - SPRING
5 - SEAL
9 - 56 ENGINE 2.4LRS
OIL PUMP (Continued)
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ASSEMBLY
(1) Assemble pump, using new parts as required.
Install the inner rotor with chamfer facing the
cast iron oil pump cover.
(2) Prime oil pump before installation by filling
rotor cavity with engine oil.
(3) Install cover and tighten fasteners to 12 N´m
(105 in. lbs.) (Fig. 95).
CAUTION: Oil pump pressure relief valve must be
installed as shown in (Fig. 94) or serious engine
damage may occur.
(4) Install relief valve, spring, gasket and cap as
shown in (Fig. 94). Tighten cap to 41 N´m (30 ft.
lbs.).
INSTALLATION
(1) Make sure all surfaces are clean and free of oil
and dirt.(2) Apply MopartGasket Maker to oil pump as
shown in (Fig. 100). Install O-ring into oil pump body
discharge passage.
(3) Prime oil pump with engine oil before installa-
tion.
(4) Align oil pump rotor flats with flats on crank-
shaft. Install the oil pump to the block (Fig. 93).
CAUTION: To align, the front crankshaft seal MUST
be out of pump, or damage may result.
(5) Install new front crankshaft seal using Special
Tool 6780 (Fig. 101).
(6) Install crankshaft key (Fig. 92).
CAUTION: The crankshaft sprocket is set to a pre-
determined depth from the factory for correct tim-
ing belt tracking. If removed, use of Special Tool
6792 is required to set the sprocket to original
installation depth. An incorrectly installed sprocket
will result in timing belt and engine damage.
(7) Install crankshaft sprocket using Special Tool
6792 (Fig. 102).
(8) Install oil pump pick-up tube.
(9) Install oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION).
(10) Install timing belt rear cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT COVER(S)
- INSTALLATION).
(11) Install timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
INSTALLATION).
Fig. 98 Measuring Outer Rotor Thickness
Fig. 99 Measuring Inner Rotor Thickness
Fig. 100 Oil Pump Sealing
1 - O-RING
2 - SEALER LOCATION
9 - 58 ENGINE 2.4LRS
OIL PUMP (Continued)
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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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(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
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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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