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)
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