Chrysler Town, Dodge Caravan. Manual - part 300

DESCRIPTION

SPECIFICATION

Bore Diameter—Piston
Pin

20.96–20.98 mm

(0.8252–0.8260 in.)

Bore Diameter—
Crankshaft End

53.007–52.993 mm

(2.0868–2.0863 in.)

Side Clearance

0.13–0.38 mm

(0.005–0.015 in.)

Wear Limit

0.40 mm

(0.016 in.)

Weight—Total (Less
Bearing)

565.8 grams

(19.96 oz.)

Crankshaft

Connecting Rod Journal
Diameter

49.984–50.000 mm

(1.968–1.9685 in.)

Main Bearing Journal
Diameter

59.992–60.008 mm

(2.362–2.3625 in.)

Journal Out-of-Round
(Max.)

0.0035 mm

(0.0003 in.)

Journal Taper (Max.)

0.007 mm

(0.0001 in.)

End Play

0.09–0.24 mm

(0.0035–0.0094 in.)

Wear Limit

0.38 mm

(0.015 in.)

Main Bearing Diametrical
Clearance

0.018–0.062 mm

(0.0007–0.0024 in.)

Hydraulic Lash Adjuster

Body Diameter

15.901–15.913 mm

(0.626–0.6264 in.)

Plunger Travel Minimum
(Dry)

3.0 mm

(0.118 in.)

Cylinder Head Camshaft Bearing Bore Diameter

Journals No.1–6

26.020–26.041 mm

(1.024–1.025 in.)

Camshaft

Journal Diameter No. 1–6

25.951–25.970 mm

(1.021–1.022 in.)

Bearing Clearance—
Diametrical

0.069–0.071 mm

(0.0027–0.003 in.)

End Play

0.05–0.17 mm

(0.0019–0.0066 in.)

Lift (Zero Lash)

Intake

8.25 mm

(0.324 in.)

DESCRIPTION

SPECIFICATION

Exhaust

6.60 mm

(0.259 in.)

Intake Valve Timing*

Closes (ABDC)

51°

Opens (BTDC)

1°

Duration

232°

Exhaust Valve Timing*

Closes (ATDC)

7°

Opens (BBDC)

47°

Duration

234°

Valve Overlap

8°

*All readings in crankshaft degrees. Timing points @

4° from top of Ramps.

Cylinder Head

Material

Cast Aluminum

Gasket Thickness
(Compressed)

0.71 mm

(0.028 in.)

Valve Seat

Angle

44.5–45°

Seat Diameter—Intake

34.37–34.63 mm

(1.353–1.363 in.)

Seat Diameter—Exhaust

27.06–27.32 mm

(1.065–1.075 in.)

Runout (Max.)

0.05 mm

(0.002 in.)

Valve Seat Width—Intake
and Exhaust

0.9–1.3 mm

(0.035–0.051 in.)

Service Limit—Intake

2.0 mm

(0.079 in.)

Service Limit—Exhaust

2.5 mm

(0.098 in.)

Valve Guide

Diameter I.D.

5.975–6.000 mm

(0.235–0.236 in.)

Guide Bore Diameter

11.0–11.02 mm

(0.4330–0.4338 in.)

Guide Height (spring seat
to guide tip)

13.25–13.75 mm

(0.521–0.541 in.)

Valves

Face Angle—Intake and
Exhaust

44.5—45°

Head Diameter—Intake

34.67–34.93 mm

1.364–1.375 in.)

9 - 18

ENGINE 2.4L

RS

ENGINE 2.4L (Continued)

DESCRIPTION

SPECIFICATION

Head Diameter—Exhaust

28.32–28.52 mm

(1.114–1.122 in.)

Valve Length (Overall)

—Intake

112.76–113.32 mm

(4.439–4.461 in.)

—Exhaust

110.89–111.69 mm

(4.365–4.397 in.)

Valve Stem Diameter

—Intake

5.934–5.952 mm

(0.2337–0.2344 in.)

—Exhaust

5.906–5.924 mm

(0.2326–0.2333 in.)

Valve Margin

Intake

1.2–1.7 mm

(0.047–0.066 in.)

Service Limit

0.95 mm

(1/32 in.)

Exhaust

0.985–1.315 mm

(0.038–0.051 in.)

Service Limit

1.05 mm

(3/64 in.)

Valve Stem Tip Height

Intake

48.04 mm

(1.891 in.)

Exhaust

47.99 mm

(1.889 in.)

Valve Stem to Guide Clearance

Intake

0.048–0.066 mm

(0.0018–0.0025 in.)

Max. Allowable

0.076 mm

(0.003 in.)

Service Limit

0.25 mm

(0.010 in.)

Exhaust

0.0736–0.094 mm

(0.0029–0.0037 in.)

Max. Allowable

0.101 mm

(0.004 in.)

Service Limit

0.25 mm

(0.010 in.)

DESCRIPTION

SPECIFICATION

Valve Springs

Free Length (Approx.)

48.4 mm

(1.905 in.)

Nominal Force (Valve
Closed)

338 N @ 38.0 mm

(75.98 lbs. @ 1.496 in.)

Nominal Force (Valve
Open)

607 N @ 29.75 mm

(136 lbs. @ 1.172 in.)

Installed Height

38.00 mm

(1.496 in.)

Number of Coils

7.82

Wire Diameter

3.86 mm

(1.496 in.)

Oil Pump

Clearance Over Rotors
(Max.)

0.10 mm

(0.004 in.)

Cover Out-of-Flat (Max.)

0.025 mm

(0.001 in.)

Inner Rotor Thickness
(Min.)

9.40 mm

(0.370 in.)

Outer Rotor Thickness
(Min.)

9.40 mm

(0.370 in.)

Outer Rotor Clearance
(Max.)

0.039 mm

(0.015 in.)

Outer Rotor Diameter
(Min.)

79.95 mm

(3.148 in.)

Tip Clearance Between
Rotors (Max.)

0.20 mm

(0.008 in.)

Oil Pressure

At Curb Idle Speed*

25 kPa

(4 psi)

At 3000 rpm

170–550 kPa

(25–80 psi)

CAUTION:
*If pressure is ZERO at curb idle, DO NOT run engine

at 3000 rpm.

RS

ENGINE 2.4L

9 - 19

ENGINE 2.4L (Continued)

SPECIFICATIONS - TORQUE

DESCRIPTION

N·m

Ft.

Lbs.

In.

Lbs.

Balance Shaft Carrier to
Block—Bolts

54

40

—

Balance Shaft Gear
Cover—Double Ended
Fastener

12

—

105

Balance Shaft Sprocket—
Bolt

28

—

250

Balance Shaft Chain
Tensioner—Bolts

12

—

105

Balance Shaft Carrier
Cover—Bolts

12

—

105

Camshaft Sprocket—Bolt

101

75

—

Connecting Rod
Cap—Bolts

27 +

1

⁄

4

turn

20

+

1

⁄

4

turn

—

Crankshaft Main Bearing
Cap/Bedplate

—M8 Bolts

28

250

—M11 Bolts

41 +

1

⁄

4

Turn

30

+

1

⁄

4

Turn

—

Crankshaft Damper

136

100

—

Cylinder Head—Bolts

(Refer to 9 - ENGINE/

CYLINDER HEAD -

INSTALLATION)

Cylinder Head Cover—
Bolts

12

—

105

Flex Plate to Crankshaft

95

70

—

Engine Mount Bracket
Right—Bolts

61

45

—

Engine Mounting—Bolts

(Refer to 9 ENGINE/

ENGINE MOUNTING)

Exhaust Manifold to
Cylinder Head—Bolts

19

—

170

DESCRIPTION

N·m

Ft.

Lbs.

In.

Lbs.

Exhaust Manifold Heat
Shield—Bolts

12

—

105

Intake Manifold - Lower
—Bolts

28

—

250

Intake Manifold -
Upper—Bolts

28

—

250

Oil Filter

12

—

105

Oil Pan—Bolts

12

—

105

Oil Pan Drain—Plug

28

20

—

Oil Pressure Switch

21

—

190

Oil Pump to Block—Bolts

28

20

—

Oil Pump Cover
Plate—Bolts

12

—

105

Oil Pump Pick-up
Tube—Bolt

28

20

—

Oil Pump Relief
Valve—Cap

41

30

—

Spark Plugs

18

13

—

Structural Collar

(Refer to 9 - ENGINE/

ENGINE BLOCK/

STRUCTURAL COVER -

INSTALLATION)

Timing Belt Covers

- Front Covers to Rear

Cover—Bolts

6

—

50

- Rear Cover—M6 Bolts

12

—

105

—M8 Bolts

28

—

250

Timing Belt Idler Pulley

61

45

—

Timing Belt Tensioner
Lock Bolt

25

—

220

Timing Belt Tensioner
Assembly—Bolts

61

45

—

9 - 20

ENGINE 2.4L

RS

ENGINE 2.4L (Continued)

SPECIAL TOOLS

2.4L ENGINE

Puller 1026

Crankshaft Damper Removal Insert 6827A

Dolly 6135

Cradle 6710A

Post Kit Engine Cradle 6848

Camshaft Sprocket Holder 6847

Camshaft Seal Remover C-4679A

Camshaft Seal Installer MD-998306

Crankshaft Damper/Sprocket Installer 6792

RS

ENGINE 2.4L

9 - 21

ENGINE 2.4L (Continued)