2.4l 4-cyl. Engine - VIN [b] Dodge Grand Caravan III

ENGINE IDENTIFICATION

Note. For repair procedures not covered in this article, see ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION article in GENERAL INFORMATION.

2.4L DOHC engines are equipped with 2 balance shafts installed in a carrier attached to lower crankcase. The shafts are interconnected by gears to rotate in opposite directions. Gears are chain driven by the crankshaft at twice crankshaft speed, to counterbalance engine reciprocating masses. (Scheme 47)

ENGINE IDENTIFICATION CODES

Scheme 47

VALVE CLEARANCE ADJUSTMENT

Hydraulic valve lash adjusters are used. Valve adjustment is not required.

TROUBLE SHOOTING

Note. To trouble shoot engine mechanical components, see appropriate table in TROUBLE SHOOTING article in GENERAL INFORMATION.

REMOVAL & INSTALLATION

Note. For reassembly reference, label all electrical connectors, vacuum hoses and fuel lines before removal. Also place mating marks on engine hood and other major assemblies before removal.

FUEL PRESSURE RELEASE

1. Disconnect negative battery cable. Remove filler cap. Remove protective cap from fuel pressure test port on fuel rail. Place open end of Fuel Pressure Release Hose (C-4799-1), into an approved container. Connect fitting end of hose to fuel pressure test port. Fuel pressure will bleed off through hose into container.

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#24l-4-cyl-engine-vin-b__fuel-pressure-release) . Disconnect and remove battery and tray. Set Power Control Module (PCM) aside. Drain cooling system. Remove upper radiator hose and remove radiator fan module. Remove lower radiator hose. Disconnect A/T cooler line and plug, if equipped.
2. Disconnect transmission shift linkage. Disconnect throttle body linkage. Disconnect engine wiring harness. Disconnect heater hoses. Discharge A/C system using approved refrigerant recovery/recycling equipment.
3. Raise vehicle and remove right inner splash shield. Remove accessory drive belts. Remove axle shafts. For 1996 vehicles, see «FWD AXLE SHAFTS»(ref-56036) article in DRIVE AXLES. For 1997 vehicles, see «AXLE SHAFTS - FRONT»(/dodge/grand-caravan/iii-1995-2000/remont/axle-shafts/#axle-shafts-front) article in DRIVE AXLES. Disconnect exhaust pipe from manifold. Remove front and rear engine mount brackets from body. Lower vehicle.
4. Remove air cleaner assembly. Remove P/S pump and reservoir and set aside. Remove A/C compressor. Remove ground straps to body. Raise vehicle to allow Dolly and Cradle (6135 and 6710) to be installed under vehicle. Loosen cradle engine mounts to allow movement for positioning into engine locating holes on engine bedplate. Lower vehicle and position cradle mounts until engine is resting on mounts. Tighten cradle frame mounts to prevent movement when removing or installing engine and transmission.
5. Lower vehicle until only the weight of engine and transmission is on the cradle. Remove engine and transmission mount bolts. Raise vehicle slowly. It may be necessary to move engine/transmission assembly on cradle to allow passage past body flanges. To install, reverse removal procedure.

INTAKE MANIFOLD

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#24l-4-cyl-engine-vin-b__fuel-pressure-release). Disconnect negative battery cable. Remove air intake resonator. Disconnect fuel supply line quick-connect at fuel tube assembly. Remove fuel rail assembly attaching screws and remove fuel rail from engine. Cover injector holes to prevent entry of foreign material.
2. Remove accelerator, kickdown and speed control cables from throttle lever and bracket. Disconnect Idle Air Control (IAC) motor and Throttle Position (TP) sensor wiring connectors. Disconnect vacuum hoses from throttle body. Disconnect Manifold Absolute Pressure (MAP) sensor, Inlet Air Temperature (IAT) sensor, and Knock Sensor (KS) connectors. Disconnect vapor and brake booster hoses and wiring harness from tab located on intake manifold.
3. Remove transmission-to-throttle body support bracket fasteners at throttle body and loosen fastener at transmission end. Remove EGR tube bolts at valve and at intake manifold. Remove tube from engine. Remove intake manifold support bracket. Remove 10 intake manifold bolt and washer assemblies. Remove intake manifold.
4. To install, reverse removal procedure. Use NEW gaskets and tighten all fasteners to specification. (Scheme 48) See «TORQUE SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#24l-4-cyl-engine-vin-b__torque-specifications).

Scheme 48

Remove exhaust pipe from manifold, (it may be necessary to remove entire exhaust system). Remove exhaust manifold heat shield. Remove O2 sensor. Remove 8 exhaust manifold bolts and remove manifold. To install, reverse removal procedure. (Scheme 49) See TORQUE SPECIFICATIONS.

Scheme 49

Removal

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#24l-4-cyl-engine-vin-b__fuel-pressure-release) . Disconnect negative battery cable. Drain cooling system. Remove air cleaner and disconnect all vacuum lines, electrical wiring and fuel lines from throttle body. Remove throttle linkage. Remove accessory drive belts. Remove power brake vacuum hose from intake manifold.
2. Raise vehicle and remove exhaust pipe from manifold. Remove P/S pump assembly and lay aside. Disconnect coil pack wiring connector and remove coil pack and bracket from engine. Remove wiring connectors for cam sensor and fuel injectors. Remove timing belt and camshaft sprockets. See «TIMING BELT»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#24l-4-cyl-engine-vin-b__timing-belt) . Remove cam cover. Remove cylinder head bolts. Remove cylinder head.

Inspection

Remove all gasket material from head and block without scratching sealing surface. Inspect camshaft bearing journals for scoring. Ensure head flatness is within .004 (0.1 mm).

Installation

To install, reverse removal procedure. Clean and oil bolt threads before installation. Tighten head bolts in sequence using 4-step torque turn method. (Scheme 50)

1. 1st: Tighten to 25 Ft. Lbs. (34 N.m).
2. 2nd: Tighten to 50 Ft. Lbs. (68 N.m).
3. 3rd: Tighten to 50 Ft. Lbs. (68 N.m).
4. 4th: Tighten an additional 1/4 turn. (DO NOT use a torque wrench for 4th step).

Scheme 50

Remove timing belt. See TIMING BELT . Using Sprocket Puller (6793) and Puller Insert (C4685), remove crankshaft sprocket. Using Seal Puller (6771), remove front oil seal. Ensure front cover remains undamaged.

Using Seal Installer (6780), install NEW seal until flush with cover. Using Sprocket Installer (6792), install crankshaft sprocket. To complete installation, reverse removal procedure.

TIMING BELT

Note. Early engines are equipped with hydraulic tensioners. Late engines are equipped with mechanical tensioners. Late mechanical tensioner has a hydraulic retrofit kit. Kit consists of Tensioner Package (5010371-AA) and Cover (4694318-AB).

Removal (Hydraulic Tensioner)

1. Remove No. 1 spark plug. Set No. 1 cylinder at TDC on compression stroke. Remove upper timing belt cover. Check timing marks on camshaft sprockets. (Scheme 51)
2. Raise and support vehicle. Remove right splash shield. Remove accessory belts. Remove crankshaft damper bolt. Using Puller (1026) and Insert (6827), remove damper. Remove engine mount bracket. Remove timing cover bolts and remove cover. Ensure timing marks are aligned. Loosen timing belt tensioner screws and remove timing belt.

Installation (Hydraulic Tensioner)

1. Place tensioner in vise and slowly compress plunger. With plunger compressed into tensioner body, install a pin through body and plunger to retain plunger in body until tensioner is installed. CAUTION: DO NOT attempt to compress tensioner plunger with tensioner assembly installed on engine. Damage to tensioner and other components will occur. Tensioner MUST be compressed using a vise. Index tensioner in vise the same as installed on engine. This ensures proper pin orientation when tensioner is installed on engine.
2. Set crankshaft sprocket to TDC. (Scheme 52) Set camshaft timing marks. (Scheme 51) Install timing belt, starting at crankshaft, go around water pump sprocket, idler pulley, camshaft sprockets and then around tensioner pulley. Install tensioner to block but DO NOT tighten bolts.
3. Using torque wrench on tensioner pulley, apply 21 ft. lbs. (28 N.m) to tensioner. (Scheme 53) With torque applied, move tensioner up against timing belt and tighten tensioner mounting bolts. Pull tensioner pin. Pre-tension is correct when pin can be removed and installed freely. Rotate crankshaft 2 revolutions and check alignment of timing marks. Recheck tensioner pin installation. To complete installation, reverse removal procedure.

Note. If pretension is incorrect and pin is removed, it may be necessary to remove timing belt tensioner to reinstall pin.

Scheme 51

Scheme 52

Scheme 53

Scheme 54

1. Remove No. 1 spark plug. Set No. 1 cylinder at TDC on compression stroke. Remove upper timing belt cover. Check timing marks on camshaft sprockets. (Scheme 51)
2. Raise and support vehicle. Remove right splash shield. Remove accessory belts. Remove crankshaft damper bolt. Using 3-jaw puller, remove damper. Remove engine mount bracket. Remove timing cover bolts and remove cover. Ensure timing marks are aligned. Lower vehicle.
3. Install 6-mm allen wrench in tensioner pulley. (Scheme 54) Using allen wrench, rotate tensioner pulley counter-clockwise slightly. Insert a 1/8" or 3-mm allen wrench in pinhole on front of tensioner pulley to lock in place. Remove timing belt.

Installation (Mechanical Tensioner)

Note. If timing belt is damaged due to alignment problems, replace tensioner assembly and idler pulley. On 1996 models, see technical service bulletin 09-11-96 Rev. A, dated 11/29/1996. See TENSIONER ASSEMBLY (MECHANICAL TENSIONER) .

1. Set crankshaft sprocket to TDC. (Scheme 55) Set camshaft timing marks with exhaust camshaft sprocket mark one half tooth below intake camshaft sprocket mark. (Scheme 56) Ensure arrows are up.
2. Install timing belt, starting at crankshaft, go around water pump sprocket, idler pulley, camshaft sprockets and then around tensioner pulley. Move exhaust camshaft counter clockwise to tighten up slack in belt. Ensure at this time all timing marks are aligned. Remove allen wrench from tensioner pulley (or pin from new tensioner). At crankshaft rotate crankshaft 2 revolutions and check alignment of timing marks. To complete installation, reverse removal procedure. Assemble with engine mount installed, but top timing belt cover off. Start engine for a few seconds. Turn ignition off. Measure distance between outer edge of timing belt and edge of intake camshaft sprocket. Belt should 0.08-0.24" (2-6 mm) from edge of sprocket. NOTE: Procedure revised. On 1996 models, see technical service bulletin 09-11-96 Rev. A, dated 11/29/1996.

Scheme 55

Scheme 56

Tensioner Assembly (Mechanical Tensioner)

Note. Tensioner pulley and bracket are machined as an assembly for proper timing belt alignment. Replace as an assembly only. On 1996 models, see technical service bulletin 09-11-96 Rev. A, dated 11/29/1996.

Remove timing belt. Remove timing belt idler pulley. Using Tool (6847), hold camshaft sprocket to remove bolt. Remove camshaft sprockets. Remove rear timing belt cover. Remove tensioner assembly. (Scheme 57) To install, reverse removal procedure.

Scheme 57

1. Remove cam cover. See «CAMSHAFT»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#24l-4-cyl-engine-vin-b) . Remove timing belt, sprockets and covers. See «TIMING BELT»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#24l-4-cyl-engine-vin-b__timing-belt) . Remove camshaft(s). See CAMSHAFT. Remove cam follower assemblies from cylinder head. Keep cam followers and lash adjusters in order of removal for reassembly. Inspect followers for wear or damage. Replace as necessary. Lash adjusters are serviced as an assembly and cannot be rebuilt.
2. Check for dry lash (the amount of clearance between base circle of cam and rocker arm roller when adjuster is drained of oil and completely collapsed). Dry lash should be .046" (1.17 mm) for intake and .050" (1.28 mm) for exhaust. After performing dry lash check, refill adjuster with oil and allow 10 minutes for adjuster(s) to bleed down before rotating cam.
3. To install, reverse removal procedure. Lubricate cam follower and lash adjuster with clean oil. When installing lash adjusters, ensure they are at least partially full of oil. This is indicated by little or no plunger travel when adjuster is depressed.

Remove ignition coil pack. Remove cam cover bolts. Remove cam cover and ground strap. Remove timing belt, sprockets and covers. See TIMING BELT. Remove camshaft bearing caps in sequence, one cam at a time. Remove outside bearing caps first. (Scheme 58) Camshafts are not interchangeable. Identify for installation.

1. Inspect camshaft bearing journals for damage and binding. If journals are binding, check cylinder head bearing surface for damage and the camshaft bearing oil feed holes in cylinder head for clogging.
2. Check cam surface for abnormal wear and damage. Replace if defective. A visible worn groove in roller path or on cam lobes is cause for replacement. Lubricate camshaft journals with fresh oil and install camshaft without cam follower assemblies. Install rear cam caps and tighten bolts to specification.
3. Install a dial indicator with its probe in-line with camshaft and against camshaft nose. Move camshaft as far as it will go in one direction and zero indicator. Move camshaft as far in the opposite direction as it will go and read indicator. Acceptable end play is .002-.010" (.05-.15mm).

1. Lubricate bearing journal and cam followers with clean oil and install camshafts. Install right and left camshaft bearing caps No. 2-5 and right cap No. 6. Tighten 6 mm bearing cap bolts to 106 INCH lbs. (12 N.m) in sequence. (Scheme 59)
2. Apply Mopar Gasket Maker to bearing caps No. 1 and 6. (Scheme 60) Install bearing caps and tighten 8 mm bolts to 21 ft. lbs. (28 N.m). Bearing caps must be installed before seals can be installed. To complete installation, reverse removal procedure.

Scheme 58

Scheme 59

Scheme 60

1. Remove engine. See «ENGINE»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#24l-4-cyl-engine-vin-b) . Remove timing belt. See «TIMING BELT»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#24l-4-cyl-engine-vin-b__timing-belt) . Remove oil pump. See «OIL PUMP»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#24l-4-cyl-engine-vin-b) under ENGINE OILING. Remove rear timing belt cover. Remove oil pan. Remove balance shaft chain cover, chain guide and tensioner. Remove balance shaft gear and chain sprocket retaining screws. Using wide pry bars, remove chain and sprocket assembly.
2. Remove front balance shaft cover and balance shaft gears. Remove rear balance shaft cover and balance shafts. Remove 4carrier-to-crankcase bolts and separate balance shaft carrier from engine. Check bearing surfaces and gears for scuffing and wear. Replace as necessary.

1. To install, reverse removal procedure. Ensure crankshaft to balance shaft timing is established. With balance shafts installed in carrier, position carrier on crankcase and install 4 attaching bolts. Tighten attaching bolts to 40 ft. lbs. (54 N.m).
2. Turn balance shafts until both shaft keyways are up. Install short hub (drive) gear on right hand balance shaft. Install long hub (driven) gear on left hand balance shaft. Ensure keyways are up and gear alignment dots are meshed after installation. (Scheme 61)
3. Install gear cover and tighten double ended stud/washer to 105 INCH lbs. (12 N.m). Using Installer (6052), install crankshaft sprocket. Turn crankshaft until No. 1 cylinder is at TDC. Timing marks on chain sprocket should align with parting line on left side of No. 1 main bearing cap. (Scheme 62)
4. Place chain over crankshaft sprocket so nickel plated link of chain is over No. 1 cylinder timing mark on crankshaft sprocket. (Scheme 62) Place balance shaft sprocket into timing chain so timing mark (Yellow dot) mates with lower nickel plated link on chain. (Scheme 63)
5. With balance shaft keyways pointed at 12 o'clock, slide balance shaft sprocket onto nose of balance shaft. Balance shaft may need to be pushed in slightly to provide clearance. NOTE: Timing mark on sprocket, lower nickel plated link, and arrow on side of gear cover should align when balance shafts are timed correctly.
6. If sprockets are correctly timed, install balance shaft bolts and tighten to 21 ft. lbs. (28 N.m). Place a wood block between crankcase and crankshaft counterbalance to prevent crankshaft and gear rotation.
7. Install chain tensioner loosely. Position guide on double-ended stud,ensuring tab on guide fits into slot on gear cover. Install and tighten nut/washer assembly to 106 INCH lbs. (12 N.m).
8. Place a shim.039" (1 mm) thick by 2.75" (70 mm) long between tensioner and chain. (Scheme 64) Apply firm pressure (5.5-6.6 lbs) against tensioner directly behind adjustment slot. With load applied, tighten top tensioner bolt first then bottom bolt to 106 INCH lbs. (12 N.m). Remove shim stock. Install balance shaft carrier covers and tighten screws to 106 INCH lbs. (12 N.m). To complete installation, reverse removal procedure.

Scheme 61

Scheme 62

Scheme 63

Scheme 64

1. Remove engine from vehicle. See «ENGINE»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#24l-4-cyl-engine-vin-b) . Remove transaxle from engine. Remove clutch and drive plate from crankshaft. Remove transaxle upper cover. Using a screwdriver, carefully pry rear seal out. DO NOT nick or damage crankshaft flange seal surface or retainer bore.
2. Polish shaft seal lip surface with 400 grit paper, if necessary, to eliminate varnish, dirt or nicks. Place seal, with self contained installation sleeve, on crankshaft journal. Using a plastic hammer, lightly tap NEW seal into place until seal is flush with cylinder block surface. To install, reverse removal procedure.

1. Drain cooling system down below the thermostat level.
2. Remove thermostat housing bolts and housing (Scheme 66)
3. Remove thermostat, discard gasket and clean both gasket sealing surfaces.

Installation - 2.4L Engine

1. Place a new gasket (dipped in clean water) on water box surface, center thermostat in water box on gasket.
2. Place housing over gasket and thermostat making sure thermostat is in the thermostat housing.
3. Bolt housing to water box (Scheme 66) Tighten bolts to 28 N.m (250 in. lbs.).
4. Reill the cooling system to the proper level.

1. Raise vehicle on hoist. Remove right inner splash shield. Remove accessory drive belts and P/S pump. Drain cooling system. Support engine from bottom and remove right engine support. Remove P/S pump bracket bolts and set pump and bracket assembly aside (P/S lines need not be disconnected).
2. Remove right engine mount bracket. Remove timing belt. See «TIMING BELT»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#24l-4-cyl-engine-vin-b__timing-belt) . Remove inner timing belt cover. Remove water pump-to-engine attaching screws. Remove water pump.

Inspect water pump and replace if it has one or more of the following defects

1. Cracks or damage on body.
2. Coolant leaks from shaft seal weep hole (evident by coolant traces on pump body).
3. Loose or rough bearing.
4. Impeller rubs either pump body or engine block.
5. Impeller loose or damaged.
6. Sprocket or sprocket flange loose or damaged.

Install NEW "O" ring in water pump body "O" ring groove. Assemble pump body to block and tighten to 106 INCH lbs. (12 N.m). Pressurize cooling system to 15 psi (1.05 kg/cm 2 ) and check pump shaft seal and "O" ring for leaks. Rotate pump by hand to ensure freedom of movement. To complete installation, reverse removal procedure.

Drain oil and remove oil pan. Clean oil pan and engine gasket surfaces. Apply silicone rubber adhesive to engine block parting line. Install oil pan gasket to block. Install pan and tighten bolts to 106 INCH lbs. (12 N.m).

Cylinder Head

1. Inspect cylinder head for cracks and warpage. Repair or replace head if warpage exceeds specification. See «CYLINDER HEAD»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#24l-4-cyl-engine-vin-b) table under ENGINE SPECIFICATIONS. After grinding valves or valve seats, install valve into cylinder head and measure distance from spring seat of cylinder head to tip of valve.
2. Distance should be 1.889" (47.99 mm) for exhaust and 1.891" (48.04 mm) for intake. Grind valve tip and rechamfer if necessary.

Valve Springs

Measure valve spring free length, out-of-square and spring pressure. Measure installed height from valve spring lower edge to upper edge. DO NOT include spring seat or retainer flange. Replace valve spring if not within specification. See VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS.

Valve Stem Oil Seals

Ensure oversize valve stem seals are used when oversize valves are installed. Ensure oil seal lower edge is against valve guide after installation.

Valve Guides

1. Check valve stem oil clearance. Ensure valve stem diameter is within specification. See «VALVES & VALVE SPRINGS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#24l-4-cyl-engine-vin-b) table under ENGINE SPECIFICATIONS. Ream valve guide for valve with oversize valve stem if clearance exceeds specification. See «CYLINDER HEAD»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#24l-4-cyl-engine-vin-b) table under ENGINE SPECIFICATIONS. NOTE: DO NOT ream valve guides from standard to maximum in one step. Ream guides to oversize in gradual steps, so guides are reamed true in relation to valve seat.
2. Valves are available with oversize valve stems of .006" (.15 mm), .016" (.40 mm) and .031" (.80 mm). Replace guides if they cannot be repaired using a .031" (.80 mm) oversize reamer.

Valve Seat

If valve face and/or valve seats have been ground, measure valve tip-to-valve spring seat dimension. Grind valve tip (if necessary) to give a an installed height of 1.889" (47.99 mm) for exhaust valves or 1.891" (48.04 mm) for intake valves when measured from spring seat.

Valves

After grinding valves, inspect remaining margin. Intake valves with less than .047" (1.2 mm) margin and exhaust valves with less than .035" (0.9 mm) margin should be replaced.

Valve Seat Correction Angles

If seat width is too wide after grinding, use a 15-degree or 65-degree stone to alter seat width. A 15-degree stone will lower valve seat and a 65-degree stone will raise valve seat. For valve seat width, see CYLINDER HEAD table under ENGINE SPECIFICATIONS.

Piston & Rod Assembly

Install piston with notch or arrow on top of piston toward timing belt end of engine. Note direction of connecting rod installation on piston before removing. Install connecting rod in original direction. Other information for connecting rod-to-piston installation is not available from manufacturer.

Fitting Pistons

1. To determine if piston-to-cylinder clearance is within specification, measure piston skirt diameter .551" (14.0 mm) from bottom of piston skirt, at 90-degree angle to piston pin. Ensure piston diameter is within specification. See «PISTONS, PINS & RINGS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#24l-4-cyl-engine-vin-b) table under ENGINE SPECIFICATIONS.
2. Measure cylinder bore .394" (10.0 mm) below top of cylinder bore, at middle of bore and .394 " (10.0 mm) from bottom of cylinder bore.

Piston Rings

Ensure ring end gap and side clearance are within specification. See PISTONS, PINS & RINGS table under ENGINE SPECIFICATIONS. Position ring gaps in proper locations before installing pistons. (Scheme 66)

Scheme 65

Rod Bearings

Note direction of connecting rod and cap installation before removing. Install connecting rod in original direction.

Crankshaft & Main Bearings

1. Ensure crankshaft end play is within specification. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#24l-4-cyl-engine-vin-b) table under ENGINE SPECIFICATIONS. Install main bearing shells with oil holes aligned with oil holes in block and tabs seated in block tab slots. CAUTION: DO NOT allow oil on bedplate mating surface. Oil will adversely effect ability of sealer to seal bedplate to cylinder block.
2. Using fresh, clean oil, lubricate bearings and crankshaft journals and install crankshaft. Apply.059-.078" (1.5-2 mm) bead of anaerobic sealer to cylinder block. (Scheme 67) CAUTION: Use only Anaerobic Sealer (4773257) on bedplate or damage may occur to engine.
3. Install lower main bearings into main bearing cap/bedplate. Ensure bearing tabs are seated into bedplate slots. Install main bearing cap/bedplate onto engine. Clean and oil main bearing bolts before installation. Install main bearing bolts No. 11, 17 and 20 finger tight. Tighten these bolts together until bedplate contacts cylinder block uniformly. Tighten bolts No. 11, 17 and 20 to 20 ft. lbs. (28 N.m). (Scheme 68)
4. Install main bearing bolts No. 1-10 and tighten in sequence to 30 ft. lbs. (41 N.m). (Scheme 68) Install main bearing bolts No. 11-20 and tighten in sequence to 20 ft. lbs. (28 N.m). (Scheme 68) After main bearing bedplate is installed, check crankshaft turning torque. Turning torque should not exceed 50 INCH lbs. (5.6 N.m).

Scheme 66

Scheme 67

Cylinder Block

Measure cylinder bore .394" (10.0 mm) below top of cylinder bore, at middle of bore and .394" (10.0 mm) from bottom of cylinder bore. Check cylinder block deck surface warpage. Resurface cylinder block if warpage exceeds specification. See CYLINDER BLOCK table under ENGINE SPECIFICATIONS. DO NOT grind more than .008" (.20 mm) total from surface of cylinder head and deck surface of cylinder block.

ENGINE LUBRICATION SYSTEM

System is a full-flow, filtered, pressure-fed type oil system. Oil pump is mounted in front engine cover and is driven by crankshaft. Pressurized oil is routed through main oil gallery, running length of the cylinder block, supplying main and rod bearings through secondary passages. Pistons are lubricated from slots in connecting rod assemblies and from rod bearing throw off. Camshaft and valve mechanisms are lubricated from a full length oil gallery supplied via crankcase main gallery.

Crankcase Capacity

Oil capacity is 4.5 qts. (4.25L) with filter.

Oil Pressure Specifications

Oil pressure is 14 psi (.28 k/cm 2 ) at curb idle and25-80 psi (1.75-5.62 k/cm 2 ) at 3000 RPM.

Removal & Disassembly

1. Remove timing belt. See «TIMING BELT»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#24l-4-cyl-engine-vin-b__timing-belt) under REMOVAL & INSTALLATION. Remove oil pan. See OIL PAN under REMOVAL & INSTALLATION. Remove oil pump bolts and oil pump.
2. Remove relief valve threaded plug, gasket, spring and valve. see scheme 23 Remove oil pump cover screws and lift off cover.
3. Remove pump rotors. Wash all parts in solvent and inspect for wear or damage. See «OIL PUMP SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#24l-4-cyl-engine-vin-b) table.

Scheme 68

OIL PUMP SPECIFICATIONS

Note. Install inner rotor with chamfer facing cast iron oil pump cover.

Reassembly & Installation

1. Using NEW parts as required, assemble pump. Install cover and tighten screws to 106 INCH lbs. (12 N.m). Install relief valve, spring, gasket and threaded plug. see scheme 23 Tighten plug to 30 ft. lbs. (41 N.m).
2. Prime pump by filling rotor cavity with clean engine oil. Install "O" ring into counterbore on oil pump discharge passage. Apply Mopar Gasket Maker to oil pump mating surface.
3. Install oil pump slowly onto crankshaft until seated to engine block. Tighten bolts to 17 ft. lbs. (23 N.m). To complete installation, reverse removal procedure.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

CRANKSHAFT, MAIN BEARINGS & CONNECTING ROD BEARINGS SPECIFICATIONS

CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS

CONNECTING RODS SPECIFICATIONS

CONNECTING RODS

PISTONS, PISTON PINS & PISTON RINGS SPECIFICATIONS

PISTONS, PINS & RINGS

CYLINDER BLOCK SPECIFICATIONS

CYLINDER BLOCK

ENGINE VALVES & VALVE SPRINGS SPECIFICATIONS

VALVES & VALVE SPRINGS

CYLINDER HEAD SPECIFICATIONS

CYLINDER HEAD

CAMSHAFT SPECIFICATIONS

CAMSHAFT

See also:
• ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION
• AXLE SHAFTS - FRONT
• FUEL PRESSURE RELEASE
• TORQUE SPECIFICATIONS
• TIMING BELT
• TENSIONER ASSEMBLY (MECHANICAL TENSIONER)
• CAMSHAFT
• REMOVAL & INSTALLATION