Chrysler Town, Dodge Caravan. Manual — part 299
(18) Remove axle shafts. (Refer to 3 - DIFFEREN-
TIAL & DRIVELINE/HALF SHAFT - REMOVAL)
(19) Drain engine oil and remove oil filter. (Refer
to 9 - ENGINE/LUBRICATION/OIL - STANDARD
PROCEDURE)
(20) Remove crossmember cradle plate (Fig. 6).
(21) Disconnect exhaust pipe from manifold (Fig.
7).
(22) Remove engine front mount and bracket from
engine. (Refer to 9 - ENGINE/ENGINE MOUNTING/
FRONT MOUNT - REMOVAL)
(23) Remove
structural
collar.
(Refer
to
9
-
ENGINE/ENGINE BLOCK/STRUCTURAL COVER -
REMOVAL)
(24) Remove rear engine mount bracket. (Refer to
9 - ENGINE/ENGINE MOUNTING/REAR MOUNT -
REMOVAL)
(25) Mark flex plate to torque converter and
remove torque converter bolts.
(26) Pinch-off power steering supply hose at pump.
Remove hose from pump.
(27) Remove and set aside the power steering
pump and bracket. Do not disconnect pressure line.
(28) Lower vehicle.
(29) Remove A/C lines at compressor and cap open-
ings.
(30) Remove engine ground straps (strap at engine
right mount and at starter).
(31) Raise vehicle enough to allow engine dolly
Special Tool 6135, cradle Special Tool 6710 with
Posts Special Tool 6848 to be installed under vehicle
(Fig. 8).
(32) Loosen cradle posts to allow movement for
proper positioning. Locate two rear posts (right side
of engine) into the holes on the engine bedplate.
Locate the two front posts (left side of engine) on the
oil pan rails (Fig. 8). Lower vehicle and position cra-
dle mounts until the engine is resting on mounts.
Tighten mounts to cradle frame. This will keep
mounts from moving when removing or installing
engine and transmission.
(33) Install safety straps around the engine to cra-
dle. Tighten straps and lock.
(34) Lower vehicle so the weight of ONLY THE
ENGINE AND TRANSMISSION are on the cradle.
(35) Remove engine and transmission mount bolts.
(36) Raise vehicle slowly. It may be necessary to
move the engine/transmission assembly with the
dolly to allow for removal around the body.
Fig. 6 Crossmember Cradle Plate
1 - CRADLE PLATE
Fig. 7 Catalytic Converter to Exhaust Manifold
1 - CATALYTIC CONVERTER
2 - BOLT
3 - GASKET
4 - FLAG NUT
9 - 14
ENGINE 2.4L
RS
ENGINE 2.4L (Continued)
Fig. 8 Positioning Engine Cradle Support Post Mounts
1 - SPECIAL TOOL POSTS 6848
4 - SPECIAL TOOL 6710 CRADLE
2 - SPECIAL TOOL 6135 DOLLY
5 - SPECIAL TOOL 6848 - POST CONTACT ON PAN RAIL
3 - SPECIAL TOOL POSTS 6848
RS
ENGINE 2.4L
9 - 15
ENGINE 2.4L (Continued)
INSTALLATION - ENGINE ASSEMBLY
(1) Position engine and transmission assembly
under vehicle and slowly lower the vehicle over the
engine and transmission.
(2) Align
engine
and
transmission
mounts
to
attaching points. Install mounting bolts at the right
(Fig. 9) and left mounts (Fig. 10).
(3) Remove safety straps.
(4) Slowly raise vehicle enough to remove the
engine dolly and cradle Special Tools 6135 and 6710.
(5) Install rear mount bracket and rear mount
through
bolt.
(Refer
to
9
-
ENGINE/ENGINE
MOUNTING/REAR MOUNT - INSTALLATION)
(6) Install the flex plate to torque converter bolts.
(7) Install structural collar. (Refer to 9 - ENGINE/
ENGINE BLOCK/STRUCTURAL COVER - INSTAL-
LATION)
(8) Install front mount bracket and front mount
through
bolt.
(Refer
to
9
-
ENGINE/ENGINE
MOUNTING/FRONT MOUNT - INSTALLATION)
(9) Connect exhaust system to manifold (Fig. 7).
(10) Install crossmember cradle plate (Fig. 6).
(11) Install new oil filter.
(12) Install power steering pump and bracket.
(13) Connect power steering supply line to pump
and remove pinch-off pliers.
(14) Connect A/C compressor hoses to compressor.
(15) Install accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
INSTALLATION)
(16) Install axle shafts. (Refer to 3 - DIFFEREN-
TIAL & DRIVELINE/HALF SHAFT - INSTALLA-
TION)
(17) Install accessory drive belt splash shield.
(18) Install front wheels and tires.
(19) Remove plugs from transmission cooler hoses
and install transaxle oil cooler line service splice kit.
Refer to instructions included with kit.
(20) Connect the transaxle shift linkage and elec-
trical connectors.
(21) Connect heater hoses (Fig. 5).
(22) Install ground straps.
(23) Connect all engine and throttle body electrical
connections.
(24) Connect all vacuum lines.
(25) Connect the throttle cables.
(26) Connect the fuel line. (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY/QUICK CONNECT FIT-
TING - STANDARD PROCEDURE)
(27) Connect radiator lower and upper hoses.
(28) Install radiator fans. (Refer to 7 - COOLING/
ENGINE/RADIATOR FAN - INSTALLATION)
(29) Fill cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(30) Connect battery cables.
(31) Install air cleaner and inlet hose.
(32) Fill engine crankcase with proper oil to cor-
rect level.
Fig. 9 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
Fig. 10 LEFT MOUNT TO FRAME BRACKET
1 - FRAME BRACKET
2 - FRAME RAIL - LEFT
3 - BOLT
4 - TRANSAXLE MOUNT
9 - 16
ENGINE 2.4L
RS
ENGINE 2.4L (Continued)
(33) Start engine and run until operating temper-
ature is reached.
(34) Adjust transmission linkage, if necessary.
SPECIFICATIONS
SPECIFICATIONS - 2.4L ENGINE
DESCRIPTION
SPECIFICATION
General Specification
Type
In-Line OHV, DOHC
Number of Cylinders
4
Displacement
2.4 Liters
(148 cu. in.)
Bore
87.5 mm
(3.445 in.)
Stroke
101.0 mm
(3.976 in.)
Compression Ratio
9.4:1
Firing Order
1-3-4-2
Compression Pressure
690 kPa (Minimum)
(100 psi Minimum)
Max. Variation Between
Cylinders
25%
Cylinder Block
Cylinder Bore Diameter
87.4924–87.5076 mm
(3.4446–3.4452 in.)
Out-of-Round (Max.)
0.051 mm
(0.002 in.)
Taper (Max.)
0.051 mm
(0.002 in.)
Pistons
Piston Diameter
87.463–87.481 mm
(3.4434–3.4441 in.)
Clearance @ 14 mm
(9/16 in.) from bottom of
skirt
0.024–0.057 mm
(0.0009–0.0022 in.)
Weight
346–356 grams
(12.20–12.56 oz.)
Land Clearance
(Diametrical)
0.614–0.664 mm
(0.024–0.026 in.)
Piston Length
66.25 mm
(2.608 in.)
Piston Ring Groove
Depth No. 1
4.640–4.784 mm
(0.182–0.188 in.)
DESCRIPTION
SPECIFICATION
Piston Ring Groove
Depth No. 2
4.575–4.719 mm
(0.180–0.185 in.)
Piston Ring Groove
Depth No. 3
4.097–4.236 mm
(0.161–0.166 in.)
Piston Pins
Clearance in Piston
0.005–0.018 mm
(0.0002–0.0008 in.)
Clearance in Connecting
Rod
Interference
Diameter
21.998–22.003 mm
(0.8660–0.8662 in.)
End Play
None
Length
72.75–73.25 mm
(2.864–2.883 in.)
Piston Rings
Ring Gap—Top
Compression Ring
0.25–0.51 mm
(0.0098–0.020 in.)
Wear Limit
0.8 mm
(0.031 in.)
Ring Gap—2nd
Compression Ring
0.23–0.48 mm
(0.009–0.018 in.)
Wear Limit
0.8 mm
(0.031 in.)
Ring Gap—Oil Control
Steel Rails
0.25–0.64 mm
(0.0098–0.025 in.)
Wear Limit
1.0 mm
(0.039 in.)
Ring Side Clearance—
Compression Rings
0.030–0.080 mm
(0.0011–0.0031 in.)
Wear Limit
0.10 mm
(0.004 in.)
Ring Side Clearance—Oil
Ring Pack
0.012–0.178 mm
(0.0004–0.0070 in.)
Ring Width—
Compression Rings
1.47–1.50 mm
(0.057–0.059 in.)
Ring Width—Oil Ring
Pack
2.72–2.88 mm
(0.107–0.1133 in.)
Connecting Rod
Bearing Clearance
0.025–0.071 mm
(0.0009–0.0027 in.)
Wear Limit
0.075 mm
(0.003 in.)
RS
ENGINE 2.4L
9 - 17
ENGINE 2.4L (Continued)
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