2003 CHRYSLER CARAVAN maintenance

TIMING BELT AND SPROCKET(S)
REMOVAL
REMOVAL - TIMING BELT...............63
REMOVAL - CAMSHAFT SPROCKETS.....64
REMOVAL - CRANKSHAFT SPROCKET....64
CLEANING............................64
INSTALLATION
INSTALLATION - CRANKSHAFT SPROCKET . 65
INSTALLATION - CAMSHAFT SPROCKETS . . 65INSTALLATION - TIMING BELT...........65
TIMING BELT TENSIONER & PULLEY
REMOVAL.............................68
INSTALLATION.........................69
BALANCE SHAFTS AND CARRIER ASSEMBLY
DESCRIPTION.........................69
OPERATION...........................69
REMOVAL.............................69
INSTALLATION.........................72
ENGINE 2.4L
DESCRIPTION
The 2.4 Liter (148 cu. in.) in-line four cylinder
engine is a double over head camshaft with hydraulic
lash adjusters and four valve per cylinder design.
The engine is free-wheeling; meaning it has provi-
sions for piston-to-valve clearance. However valve-to-
valve interference can occur, if camshafts are rotated
independently.
The cylinders are numbered from front of the
engine to the rear. The firing order is 1±3±4±2.
The engine identification number is located on the
rear of the cylinder block (Fig. 1).
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION
Engine diagnosis is helpful in determining the
causes of malfunctions not detected and remedied by
routine maintenance.
These malfunctions may be classified as either
mechanical (e.g., a strange noise), or performance
(e.g., engine idles rough and stalls).
Refer to the Engine Mechanical and the Engine
Performance diagnostic charts, for possible causes
and corrections of malfunctions (Refer to 9 - ENGINE
- DIAGNOSIS AND TESTING - MECHANICAL)
(Refer to 9 - ENGINE - DIAGNOSIS AND TESTING
- PERFORMANCE).
For fuel system diagnosis, (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY - DIAGNOSIS AND
TESTING).
Additional tests and diagnostic procedures may be
necessary for specific engine malfunctions that can-
not be isolated with the Service Diagnosis charts.
Information concerning additional tests and diagno-
sis is provided within the following:
²Cylinder Compression Pressure Test
²Cylinder Combustion Pressure Leakage Test
²Engine Cylinder Head Gasket Failure Diagnosis
²Intake Manifold Leakage Diagnosis
²Hydraulic Lash Adjuster Noise Diagnosis
²Engine Oil Leak Inspection
Fig. 1 Engine Identification
1 - ENGINE IDENTIFICATION LOCATION
RSENGINE 2.4L9-3
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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. 86).
STANDARD PROCEDURE - ENGINE OIL AND
FILTER CHANGE
Change engine oil at mileage and time intervals
described in the Maintenance Schedule. (Refer to
LUBRICATION & MAINTENANCE/MAINTE-
NANCE SCHEDULES - DESCRIPTION)
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY. CONTACT YOUR DEALER OR GOVERN-
MENT AGENCY FOR LOCATION OF COLLECTION
CENTER IN YOUR AREA.
Run engine until achieving normal operating tem-
perature.
(1) Position the vehicle on a level surface and turn
engine off.
(2) Remove oil fill cap.
(3) Hoist and support vehicle on safety stands.
Refer to Hoisting and Jacking Recommendations.
(Refer to LUBRICATION & MAINTENANCE/HOIST-
ING - STANDARD PROCEDURE)(4) Place a suitable drain pan under crankcase
drain.
(5) Remove drain plug from crankcase and allow
oil to drain into pan. Inspect drain plug threads for
stretching or other damage. Replace drain plug and
gasket if damaged.
(6) Remove oil filter. (Refer to 9 - ENGINE/LUBRI-
CATION/OIL FILTER - REMOVAL)
(7) Install and tighten drain plug in crankcase.
(8) Install new oil filter. (Refer to 9 - ENGINE/LU-
BRICATION/OIL FILTER - INSTALLATION)
(9) Lower vehicle and fill crankcase with specified
type and amount of engine oil. (Refer to LUBRICA-
TION & MAINTENANCE/FLUID TYPES -
DESCRIPTION)
(10) Install oil fill cap.
(11) Start engine and inspect for leaks.
(12) Stop engine and inspect oil level.
NOTE: Care should be exercised when disposing
used engine oil after it has been drained from a
vehicle engine. Refer to the WARNING listed above.
OIL FILTER
DESCRIPTION
The engine oil filter (Fig. 87) is a high quality full-
flow, disposable type. Replace the oil filter with a
Mopartor the equivalent.
REMOVAL
(1) Raise vehicle on hoist.
(2) Position an oil collecting container under oil fil-
ter location.
CAUTION: When servicing the oil filter avoid
deforming the filter can by installing the remove/in-
stall tool band strap against the can to base lock
seam. The lock seam joining the can to the base is
reinforced by the base plate.
(3) Using a suitable filter wrench, turn oil filter
(Fig. 87) counterclockwise to remove.
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. 87) on until the gasket
contacts base. Tighten to 12 N´m (105 in. lbs.).
Fig. 86 Oil Level
1 - ENGINE OIL LEVEL DIPSTICK
RSENGINE 2.4L9-53
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INSPECTION.........................142
ASSEMBLY...........................143
INSTALLATION........................144
INTAKE MANIFOLD
DESCRIPTION........................144
DIAGNOSIS AND TESTING - INTAKE
MANIFOLD LEAKS....................145
INTAKE MANIFOLD - UPPER
STANDARD PROCEDURE
STANDARD PROCEDURE - MANIFOLD
STRIPPED THREAD REPAIR............145
STANDARD PROCEDURE - INTAKE
MANIFOLD VACUUM PORT REPAIR......145
REMOVAL - UPPER INTAKE MANIFOLD.....145
CLEANING...........................146
INSPECTION.........................146
INSTALLATION - UPPER INTAKE MANIFOLD . 147
INTAKE MANIFOLD - LOWER
REMOVAL - LOWER INTAKE MANIFOLD....148
CLEANING...........................148
INSPECTION.........................148
INSTALLATION - LOWER INTAKE MANIFOLD . 149
EXHAUST MANIFOLD - RIGHT
REMOVAL............................150
CLEANING...........................151INSPECTION.........................151
INSTALLATION........................151
EXHAUST MANIFOLD - LEFT
REMOVAL............................152
CLEANING...........................152
INSPECTION.........................152
INSTALLATION........................152
VALVE TIMING
STANDARD PROCEDURE
STANDARD PROCEDURE - VALVE TIMING
VERIFICATION.......................153
STANDARD PROCEDURE - MEASURING
TIMING CHAIN WEAR.................153
TIMING CHAIN COVER
REMOVAL............................153
INSTALLATION........................155
TIMING CHAIN AND SPROCKETS
REMOVAL
REMOVAL - TIMING CHAIN AND
CAMSHAFT SPROCKET...............156
REMOVAL - CRANKSHAFT SPROCKET . . . 156
INSTALLATION
INSTALLATION - CRANKSHAFT SPROCKET. . 156
INSTALLATION - TIMING CHAIN AND
CAMSHAFT SPROCKET...............157
ENGINE 3.3/3.8L
DESCRIPTION
The 3.3 Liter (201 cu. in.) and 3.8 Liter (231 cu.
in.) engines are 60É V-6 engines with cast iron cylin-
der blocks and aluminum cylinder heads (Fig. 1). The
engine uses a single, block mounted camshaft with
pushrods to actuate the valves. These engines do not
have provisions for a free wheeling valve train.
The firing order is 1±2±3±4±5±6. The cylinders are
numbered from the front of the engine to the rear.
The front cylinder bank is numbered 2, 4, and 6. The
rear cylinder bank is numbered 1, 3, and 5.
The engine identification number is located on the
rear of the cylinder block just below the cylinder
head (Fig. 2).
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION
Engine diagnosis is helpful in determining the
causes of malfunctions not detected and remedied by
routine maintenance.These malfunctions may be classified as either
mechanical (e.g., a strange noise), or performance
(e.g., engine idles rough and stalls).
Refer to the Engine Mechanical and the Engine
Performance diagnostic charts, for possible causes
and corrections of malfunctions (Refer to 9 - ENGINE
- DIAGNOSIS AND TESTING - MECHANICAL)
(Refer to 9 - ENGINE - DIAGNOSIS AND TESTING
- PERFORMANCE).
For fuel system diagnosis, (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY - DIAGNOSIS AND
TESTING).
Additional tests and diagnostic procedures may be
necessary for specific engine malfunctions that can-
not be isolated with the Service Diagnosis charts.
Information concerning additional tests and diagno-
sis is provided within the following:
²Cylinder Compression Pressure Test
²Cylinder Combustion Pressure Leakage Test
²Engine Cylinder Head Gasket Failure Diagnosis
²Intake Manifold Leakage Diagnosis
²Hydraulic Lash Adjuster Noise Diagnosis
²Engine Oil Leak Inspection
9 - 76 ENGINE 3.3/3.8LRS
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OIL
STANDARD PROCEDURE
STANDARD PROCEDURE - ENGINE OIL AND
FILTER CHANGE
Change engine oil at mileage and time intervals
described in the Maintenance Schedule. (Refer to
LUBRICATION & MAINTENANCE/MAINTE-
NANCE SCHEDULES - DESCRIPTION)
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY. CONTACT YOUR DEALER OR GOVERN-
MENT AGENCY FOR LOCATION OF COLLECTION
CENTER IN YOUR AREA.
Run engine until achieving normal operating tem-
perature.
(1) Position the vehicle on a level surface and turn
engine off.
(2) Open hood, remove oil fill cap (Fig. 96).
(3) Hoist and support vehicle on safety stands.
Refer to Hoisting and Jacking Recommendations.
(Refer to LUBRICATION & MAINTENANCE/HOIST-
ING - STANDARD PROCEDURE)
(4) Place a suitable drain pan under crankcase
drain (Fig. 95).
(5) Remove drain plug from crankcase (Fig. 95)
and allow oil to drain into pan. Inspect drain plug
threads for stretching or other damage. Replace
drain plug and gasket if damaged.
(6) Remove oil filter. (Refer to 9 - ENGINE/LUBRI-
CATION/OIL FILTER - REMOVAL)
(7) Install and tighten drain plug in crankcase.(8) Install new oil filter. (Refer to 9 - ENGINE/LU-
BRICATION/OIL FILTER - INSTALLATION)
(9) Lower vehicle and fill crankcase with specified
type and amount of engine oil. (Refer to LUBRICA-
TION & MAINTENANCE/FLUID TYPES -
DESCRIPTION)
(10) Install oil fill cap.
(11) Start engine and inspect for leaks.
(12) Stop engine and inspect oil level.
NOTE: Care should be exercised when disposing
used engine oil after it has been drained from a
vehicle engine. Refer to the WARNING listed above.
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 (Fig. 96). Add only when the level is at or
below the ADD mark.
Fig. 95 Engine Oil Drain Plug and Oil Filter
1 - DRAIN PLUG
2 - OIL FILTER
RSENGINE 3.3/3.8L9 - 137
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(5) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(6) Remove front wheel and tire assemblies.
(7) Remove front emissions vapor canister. (Refer
to 25 - EMISSIONS CONTROL/EVAPORATIVE
EMISSIONS/VAPOR CANISTER - REMOVAL)
(8) Remove a single hose at power steering cooler
and allow fluid to drain.
(9) Remove 2 bolts attaching power steering cooler
to cradle crossmember reinforcement (Fig. 3).
(10) On both sides of vehicle, remove nut attaching
outer tie rod end to steering knuckle (Fig. 4).
Remove nut by holding tie rod end stud with a
socket while loosening and removing nut with
wrench.
(11) Remove bolts fastening leak detection pump to
cradle crossmember reinforcement. (Refer to 25 -
EMISSIONS CONTROL/EVAPORATIVE EMIS-
SIONS/LEAK DETECTION PUMP - REMOVAL)
(12) Remove both outer tie rods from steering
knuckles, using Puller, Special Tool C-3894±A (Fig.
5).
(13) Remove the lower control arm rear bushing
retainer bolts located on each side of each lower con-
trol arm rear bushing.
NOTE: The bolts fastening the cradle crossmember
reinforcement are of two different thread sizes. Note
the location of the various sizes.
Fig. 3 Power Steering Cooler
1 - CRADLE CROSSMEMBER REINFORCEMENT
2 - POWER STEERING COOLER
Fig. 4 Removing/Installing Tie Rod End Attaching
Nut
1 - TIE ROD END
2 - STEERING KNUCKLE
3 - WRENCH
4 - SOCKET
5 - TIE ROD END STUD
Fig. 5 Tie Rod Removal With Tool C-3894-A
1 - OUTER TIE ROD
2 - SPECIAL TOOL C-3894-A
3 - STEERING KNUCKLE
19 - 28 GEARRS
GEAR (Continued)
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REMOVAL - RHD GEAR
(1) Remove cap from power steering fluid reser-
voir.
(2) Using a siphon pump, remove as much fluid as
possible from the power steering fluid reservoir.
CAUTION: Locking the steering column in the
straight-ahead position will prevent the clockspring
from being accidentally over-extended when the
steering column is disconnected from the interme-
diate steering coupler.
(3) Position the steering wheel in the STRAIGHT-
AHEAD position. Lock the steering wheel in place
using a steering wheel holding tool.
(4) With the ignition key in the locked position
turn the steering wheel to the left until the steering
wheel is in the locked position.
(5) With the vehicle on the ground, disconnect the
steering column shaft coupler from the steering gear
intermediate coupler (Fig. 2).
(6) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(7) Remove front wheel and tire assemblies.
(8) If power steering cooler equipped, remove a
hose at power steering cooler and allow fluid to
drain.
(9) Remove 2 bolts attaching power steering cooler
to cradle crossmember reinforcement (Fig. 3).
(10) On both sides of vehicle, remove nut attaching
outer tie rod end to steering knuckle (Fig. 4).Remove nut by holding tie rod end stud with a
socket while loosening and removing nut with
wrench.
(11) Remove both tie rod ends from steering
knuckles using Puller, Special Tool C-3894±A (Fig. 5).
(12) Remove the lower control arm rear bushing
retainer bolts located on each side of each lower con-
trol arm rear bushing.
NOTE: The bolts fastening the cradle crossmember
reinforcement are of two different thread sizes. Note
the location of the various sizes.
(13) Remove the bolts attaching the cradle cross-
member reinforcement to the front suspension cradle
crossmember (Fig. 6). Remove the 2 bolts fastening
the reinforcement and rear of cradle crossmember to
the body of the vehicle. Remove the reinforcement.
(14) If the vehicle is equipped with All-Wheel-
Drive, remove the power transfer unit (Refer to 21 -
TRANSMISSION/TRANSAXLE/POWER TRANSFER
UNIT - REMOVAL).
(15) Remove the power steering fluid pressure and
return hoses from the power steering gear (Fig. 10).
(16) Remove the routing clamp bolt securing the
power steering fluid hoses to the rear of the cradle
crossmember (Fig. 11). Allow the hoses to hang down
out of the way.
(17) Remove the heat shield from the steering gear
(Fig. 10).
(18) Remove the 2 bolts and nuts mounting the
steering gear to the front suspension cradle.
Fig. 9 Removing Roll Pin From Intermediate Coupler
1 - INTERMEDIATE COUPLER
2 - KNURLED NUT
3 - SUSPENSION CRADLE
4 - REMOVER SPECIAL TOOL 6831A
5 - STEERING GEAR
6 - NUT
7 - ROLL PIN
8 - THREADED ROD
Fig. 10 RHD Gear Heat Shield And Hose Fittings
1 - HEAT SHIELD
2 - CRADLE CROSSMEMBER
3 - RETURN HOSE FITTING
4 - PRESSURE HOSE FITTING
5 - POWER STEERING GEAR
RSGEAR19-31
GEAR (Continued)
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REMOVAL
REMOVAL - PUMP (2.4L ENGINE)
(1) Remove the (-) negative battery cable from the
battery and isolate cable.
(2) Remove the cap from the power steering fluid
reservoir.
(3) Using a siphon pump, remove as much power
steering fluid as possible from the power steering
fluid reservoir.
(4) Raise the vehicle on jack stands or centered on
a frame contact type hoist. See Hoisting in Lubrica-
tion and Maintenance.
(5) Disconnect the oxygen sensor wiring harness
from the vehicle wiring harness at the rear engine
mount bracket.
NOTE: The exhaust system needs to be removed
from the engine to allow for an area to remove the
power steering pump from the vehicle.
(6) Remove the four bolts and flag nuts securing
the catalytic converter from the exhaust manifold
(Fig. 3).
(7) Disconnect all the exhaust system isolators/
hangers from the brackets on the exhaust system (2
at the mufflers and 1 at the resonator) (Fig. 4).
(8) Remove the exhaust system by moving it as far
rearward, then lowering the front below the cross-
member and out of the vehicle.
(9) Remove the power steering fluid supply hose
from the fitting on the power steering pump. Drain
off excess power steering fluid from hose.(10) Move the heat sleeve on the power steering
return hose to expose the hose connection at the
pump (Fig. 5). Remove the hose from the power
steering Pump. Allow the remaining power steering
fluid to drain from the power steering pump and res-
ervoir through the removed return hose.
Fig. 3 Catalytic Converter to Exhaust Manifold
1 - CATALYTIC CONVERTER
2 - BOLT
3 - GASKET
4 - FLAG NUT
Fig. 4 Exhaust System - Typical (All Vehicles)
1 - CATALYTIC CONVERTER 4 - SUPPORT - RESONATOR
2 - BAND CLAMP 5 - RESONATOR
3 - SUPPORTS - MUFFLER 6 - MUFFLER
19 - 38 PUMPRS
PUMP (Continued)
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(17) Remove the 3 bolts attaching the front
bracket to the power steering pump and separate the
power steering pump from the front bracket.
(18) If the power steering pump pulley needs to be
transferred, (Refer to 19 - STEERING/PUMP - DIS-
ASSEMBLY).
REMOVAL - PUMP (3.3L/3.8L ENGINE)
(1) Remove the (-) negative battery cable from the
battery and isolate cable.
(2) Remove the wiper module (unit)(Refer to 8 -
ELECTRICAL/WIPERS/WASHERS/WIPER MOD-
ULE - REMOVAL).
(3) Raise the vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(4) Remove the drive belt splash shield.
(5) Remove the pressure hose routing bracket bolt
(Fig. 9).
(6) lower the vehicle.
(7) Remove cap from power steering fluid reser-
voir.
(8) Using a siphon pump, remove as much power
steering fluid as possible from the power steering
fluid reservoir.
(9) Disconnect the pressure hose from the pump
(Fig. 10).
(10) Disconnect the fluid supply hose from the
pump (Fig. 10).
(11) Remove the three front mounting bolts
through the pulley (Fig. 11)
(12) Remove the pump (with pulley) through the
engine compartment rocking it over the aluminum
bracket.
REMOVAL - PUMP (2.5L DIESEL)
(1) Remove the negative (-) battery cable from the
battery and isolate cable.
(2) Remove the fill cap from the power steering
fluid reservoir.
Fig. 9 Pressure Hose Routing Clamp
1 - PRESSURE HOSE TUBE
2 - STEERING GEAR
3 - CRADLE CROSSMEMBER
4 - DRIVESHAFT
5 - ROUTING CLAMP BRACKET
Fig. 10 Supply And Pressure Hoses At Pump
1 - PRESSURE HOSE AND FITTING
2 - SUPPLY HOSE AND CLAMP
3 - POWER STEERING PUMP
Fig. 11 Pump Mounting
1 - PUMP REAR MOUNTING BOLT (2001 ONLY)
2 - PUMP FRONT MOUNTING BOLT (3)
3 - TIMING CHAIN COVER AND PUMP BRACKET THRU BOLT
(2001 ONLY)
4 - PUMP BELT PULLEY
5 - POWER STEERING PUMP
6 - BRACKET (2001 ONLY)
19 - 40 PUMPRS
PUMP (Continued)
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