2003 CHRYSLER CARAVAN timing belt

CAUTION: Oil pump pressure relief valve must be
installed as shown in (Fig. 93) or serious engine
damage may occur.
(4) Install relief valve, spring, gasket and cap as
shown in (Fig. 93). 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. 98). 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. 92).
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. 99).
(6) Install crankshaft key (Fig. 91).
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. 100).
(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 Oil Pump Sealing
1 - O-RING
2 - SEALER LOCATION
Fig. 99 Front Crankshaft Seal - Installation
1 - PROTECTOR
2 - SEAL
3 - SPECIAL TOOL 6780
Fig. 100 Crankshaft Sprocket - Installation
1 - SPECIAL TOOL 6792
2 - TIGHTEN NUT TO INSTALL
RSENGINE 2.4L9-57
OIL PUMP (Continued)
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EXHAUST MANIFOLD
REMOVAL
(1) Raise vehicle and disconnect exhaust pipe from
the exhaust manifold.
(2) Disconnect upstream oxygen sensor connector
at the rear of exhaust manifold.
(3) Remove the bolts attaching the manifold to the
cylinder head.
(4) Remove exhaust manifold.
(5) Inspect the manifold. (Refer to 9 - ENGINE/
MANIFOLDS/EXHAUST MANIFOLD - INSPEC-
TION)
CLEANING
(1) Discard gasket (if equipped) and clean all sur-
faces of manifold and cylinder head.
INSPECTION
(1) Inspect manifold gasket 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 manifolds for cracks or distortion.
Replace manifold as necessary.
INSTALLATION
(1) Install exhaust manifold with a new gasket.
Tighten attaching nuts in the sequence shown in
(Fig. 109) to 19 N´m (170 in. lbs.).
(2) Attach exhaust pipe to exhaust manifold and
tighten fasteners to 37 N´m (27 ft. lbs.).
(3) Install and connect the oxygen sensor. (Refer to
14 - FUEL SYSTEM/FUEL INJECTION/O2 SENSOR
- COMPONENT LOCATION)
TIMING BELT COVER(S)
REMOVAL
FRONT COVER - UPPER
(1) Remove upper timing belt cover fasteners (Fig.
110) and remove cover.
FRONT COVER - LOWER
(1) Remove crankshaft vibration damper (Refer to
9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL).
(2) Remove generator drive belt tensioner assem-
bly (Refer to 7 - COOLING/ACCESSORY DRIVE/
BELT TENSIONERS - REMOVAL).
(3) Remove timing belt front cover bolts (Fig. 110)
and remove covers.
REAR COVER
(1) Remove front covers.
(2) Remove engine mount bracket (Fig. 111).
(3) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
REMOVAL).
Fig. 109 Exhaust Manifold Tightening Sequence
Fig. 110 Front Timing Belt Covers
1 - BOLTS - UPPER FRONT COVER 6 N´m (50 in. lbs.)
2 - BOLTS - LOWER FRONT COVER 6 N´m (50 in. lbs.)
RSENGINE 2.4L9-61
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(4) Remove camshaft sprockets. Hold camshaft
sprocket with Special Tool 6847 while removing cen-
ter bolt (Fig. 112).(5) Remove timing belt idler pulley (Fig. 113).
(6) Remove rear cover fasteners and remove cover
from engine (Fig. 114).
INSTALLATION
FRONT COVER - UPPER
(1) Install timing belt cover. Torque fasteners to 6
N´m (50 in. lbs.) (Fig. 110).
FRONT COVER - LOWER
(1) Install timing belt front covers (Fig. 110).
Tighten fasteners to 6 N´m (50 in. lbs.).
(2) Install generator drive belt tensioner (Refer to
7 - COOLING/ACCESSORY DRIVE/BELT TEN-
SIONERS - INSTALLATION).
(3) Install crankshaft vibration damper (Refer to 9
- ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
INSTALLATION).
REAR COVER
(1) Install rear timing belt cover and fasteners.
Torque fasteners to specified values (Fig. 114).
CAUTION: Do not use an impact wrench for tighten-
ing camshaft sprocket bolt. Damage to the timing
locating pin can occur. Hand tighten using a
wrench ONLY.
Fig. 111 Engine Mount Bracket
1 - ENGINE MOUNT BRACKET
2 - BOLTS - 61 N´m (45 ft. lbs.)
Fig. 112 Camshaft Sprocket - Removal/Installation
1 - SPECIAL TOOL 6847
Fig. 113 Timing Belt Idler Pulley
1 - IDLER PULLEY
2 - BOLT
9 - 62 ENGINE 2.4LRS
TIMING BELT COVER(S) (Continued)
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(2) Install camshaft sprockets. Hold sprockets with
Special Tool 6848 and tighten center bolt to 101 N´m
(75 ft. lbs.) (Fig. 112).
(3) Install timing belt idler pulley and tighten
mounting bolt to 61 N´m (45 ft. lbs.) (Fig. 113).
(4) Install timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
INSTALLATION).
(5) Install engine mount bracket and tighten bolts
to 61 N´m (45 ft. lbs.) (Fig. 111).
(6) Install front covers.
TIMING BELT AND
SPROCKET(S)
REMOVAL
REMOVAL - TIMING BELT
(1) Remove air cleaner upper cover, housing, and
clean air tube.
(2) Remove make-up air hose from cylinder head
cover.
(3) Raise vehicle on hoist.
(4) Remove right front wheel.
(5) Remove right inner splash shield.(6) Remove accessory drive belts (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(7) Remove crankshaft vibration damper (Refer to
9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL).
(8) Remove air conditioner/generator belt tensioner
and pulley assembly (Refer to 7 - COOLING/ACCES-
SORY DRIVE/BELT TENSIONERS - REMOVAL).
(9) Remove timing belt lower front cover bolts and
remove cover (Refer to 9 - ENGINE/VALVE TIMING/
TIMING BELT COVER(S) - REMOVAL).
(10) Lower vehicle.
(11) Remove bolts attaching timing belt upper
front cover and remove cover (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT COVER(S) -
REMOVAL).
(12) Remove right engine mount (Refer to 9 -
ENGINE/ENGINE MOUNTING/RIGHT MOUNT -
REMOVAL).
(13) Remove engine mount bracket (Fig. 115).
Fig. 114 Rear Timing Belt Cover Fasteners
1 - M6 BOLTS - 12 N´m (105 in. lbs.)
2 - M8 BOLTS - 28 N´m (250 in. lbs.)
3 - TIMING BELT TENSIONER
Fig. 115 Engine Mount Bracket
1 - ENGINE MOUNT BRACKET
2 - BOLTS - 61 N´m (45 ft. lbs.)
RSENGINE 2.4L9-63
TIMING BELT COVER(S) (Continued)
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CAUTION: When aligning crankshaft and camshaft
timing marks always rotate engine from crankshaft.
Camshaft should not be rotated after timing belt is
removed. Damage to valve components may occur.
Always align timing marks before removing timing
belt.
(14) Before the removal of the timing belt, rotate
crankshaft until the TDC mark on oil pump housing
aligns with the TDC mark on crankshaft sprocket
(trailing edge of sprocket tooth) (Fig. 116).
NOTE: The crankshaft sprocket TDC mark is
located on the trailing edge of the sprocket tooth.
Failure to align trailing edge of sprocket tooth to
TDC mark on oil pump housing will cause the cam-
shaft timing marks to be misaligned.
(15) Loosen timing belt tensioner lock bolt (Fig.
117).
(16) Inserta6mmAllen wrench into the hexagon
opening located on the top plate of the belt tensioner
pulley (Fig. 117). Rotate the top plateCLOCKWISE
until there is enough slack in timing belt to allow for
removal.
(17) Remove timing belt.CAUTION: If timing belt was damaged due to incor-
rect tracking (alignment), the belt tensioner pulley
and bracket must be replaced as an assembly
(Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT
TENSIONER & PULLEY - REMOVAL).
REMOVAL - CAMSHAFT SPROCKETS
(1) Disconnect negative battery cable.
(2) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
REMOVAL).
(3) Hold camshaft sprockets with Special Tool 6847
while removing center bolts (Fig. 118).
REMOVAL - CRANKSHAFT SPROCKET
(1) Disconnect negative battery cable.
(2) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
REMOVAL).
(3) Remove crankshaft sprocket using Special
Tools 6793 and insert C-4685-C2 (Fig. 119).
CLEANING
Do Not attempt to clean a timing belt. If contami-
nation from oil, grease, or coolants have occurred, the
timing belt should be replaced.
Clean all sprockets using a suitable solvent. Clean
all sprocket grooves of any debris.
Fig. 116 Crankshaft and Camshaft Timing
1 - CAMSHAFT TIMING MARKS
2 - CRANKSHAFT TDC MARKS
3 - TRAILING EDGE OF SPROCKET TOOTH
Fig. 117 Timing Belt Tensioner
1 - LOCK BOLT
2 - TOP PLATE
9 - 64 ENGINE 2.4LRS
TIMING BELT AND SPROCKET(S) (Continued)
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INSTALLATION
INSTALLATION - CRANKSHAFT SPROCKET
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.
(1) Install crankshaft sprocket using Special Tool
6792 (Fig. 120).
(2) Install timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION)
INSTALLATION - CAMSHAFT SPROCKETS
(1) Install camshaft sprockets. Hold camshaft
sprockets with Special Tool 6847 while tightening
center bolts to 115 N´m (85 ft. lbs.) (Fig. 118).
(2) Install timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
INSTALLATION).
(3) Connect negative battery cable.
INSTALLATION - TIMING BELT
(1) Set crankshaft sprocket to TDC by aligning the
sprocket with the arrow on the oil pump housing.
(2) Set camshafts timing marks so that the
exhaust camshaft sprocket is a 1/2 notch below the
intake camshaft sprocket (Fig. 121).
CAUTION: Ensure that the arrows on both camshaft
sprockets are facing up.
(3) Install timing belt. Starting at the crankshaft,
go around the water pump sprocket, idler pulley,
camshaft sprockets and then around the tensioner
(Fig. 122).
(4) Move the exhaust camshaft sprocket counter-
clockwise (Fig. 122) to align marks and take up belt
slack.
(5) Inserta6mmAllen wrench into the hexagon
opening located on the top plate of the belt tensioner
pulley. Rotate the top plateCOUNTERCLOCK-
WISE. The tensioner pulley will move against the
belt and the tensioner setting notch will eventually
start to move clockwise. Watching the movement of
the setting notch, continue rotating the top plate
counterclockwise until the setting notch is aligned
with the spring tang (Fig. 123). Using the allen
wrench to prevent the top plate from moving, torque
the tensioner lock bolt to 25 N´m (220 in. lbs.). Set-
Fig. 118 Camshaft Sprocket - Removal/Installation
1 - SPECIAL TOOL 6847
Fig. 119 Crankshaft Sprocket - Removal
1 - SPECIAL TOOL 6793
2 - SPECIAL TOOL C-4685±C2
3 - CRANKSHAFT SPROCKET
Fig. 120 Crankshaft Sprocket - Installation
1 - SPECIAL TOOL 6792
2 - TIGHTEN NUT TO INSTALL
RSENGINE 2.4L9-65
TIMING BELT AND SPROCKET(S) (Continued)
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ting notch and spring tang should remain aligned
after lock nut is torqued.
(6) Remove allen wrench and torque wrench.
NOTE: Repositioning the crankshaft to the TDC
position must be done only during the CLOCKWISE
rotation movement. If TDC is missed, rotate a fur-
ther two revolutions until TDC is achieved. DO NOT
rotate crankshaft counterclockwise as this will
make verification of proper tensioner setting impos-
sible.
(7) Rotate the crankshaft CLOCKWISE two com-
plete revolutions manually for seating of the belt,
until the crankshaft is repositioned at the TDC posi-
tion. Verify that the camshaft and crankshaft timing
marks are in proper position (Fig. 124).
Fig. 121 Camshaft Sprocket Alignment
1 - CAMSHAFT SPROCKET-EXHAUST
2 - CAMSHAFT SPROCKET-INTAKE
3 - 1/2 NOTCH LOCATION
Fig. 122 Timing Belt Installation
1 - CAMSHAFT TIMING MARKS 1/2 NOTCH LOCATION
2 - CRANKSHAFT AT TDC
3 - INSTALL BELT IN THIS DIRECTION
4 - ROTATE CAMSHAFT SPROCKET TO TAKE UP BELT SLACK
Fig. 123 Timing Belt Tension Adjustment
1 - ALIGN SETTING NOTCH WITH SPRING TANG
2 - TOP PLATE
3 - 6mm ALLEN WRENCH
4 - LOCK BOLT
5 - SETTING NOTCH
6 - SPRING TANG
9 - 66 ENGINE 2.4LRS
TIMING BELT AND SPROCKET(S) (Continued)
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(8) Check if the spring tang is within the tolerance
window (Fig. 125). If the spring tang is within the
tolerance window, the installation process is complete
and nothing further is required. If the spring tang is
not within the tolerance window, repeat Steps 5
through 7.
(9) Install engine mount bracket to engine (Fig.
115).
(10) Install timing belt front covers and bolts
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT COVER(S) - INSTALLATION).
(11) Install air conditioning/generator belt ten-
sioner and pulley (Refer to 7 - COOLING/ACCES-
SORY DRIVE/BELT TENSIONERS -
INSTALLATION).(12) Install right engine mount (Refer to 9 -
ENGINE/ENGINE MOUNTING/RIGHT MOUNT -
INSTALLATION).
(13) Install crankshaft vibration damper (Refer to
9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - INSTALLATION).
(14) Install accessory drive belts (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(15) Install drive belt splash shield.
(16) Install right front wheel.
(17) Connect make-up air hose to cylinder head
cover.
(18) Install air cleaner housing, upper cover, and
clean air tube.
Fig. 124 Crankshaft and Camshaft Timing
1 - CAMSHAFT TIMING MARKS
2 - CRANKSHAFT TDC MARKS
3 - TRAILING EDGE OF SPROCKET TOOTH
Fig. 125 Timing Belt Tension Verification
1 - SPRING TANG
2 - TOLERANCE WINDOW
RSENGINE 2.4L9-67
TIMING BELT AND SPROCKET(S) (Continued)
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