Chrysler Town, Dodge Caravan. Manual — part 1100
(4) Disconnect coolant hoses at cooler (Fig. 78).
(5) Remove oil cooler retaining bolt at engine block
(Fig. 78).
(6) Remove oil cooler retaining stud and remove oil
cooler from engine block (Fig. 78).
INSTALLATION
(1) Clean oil cooler and engine block sealing sur-
faces.
(2) Install oil cooler, retaining bolt, and stud (Fig.
78). Torque retaining bolt to 47.1N·m and stud to
50N·m.
(3) Connect coolant hoses at cooler (Fig. 78).
(4) Install oil filter (Refer to 9 - ENGINE/LUBRI-
CATION/OIL FILTER - INSTALLATION).
(5) Lower vehicle.
(6) Refill cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(7) Start engine and check for leaks.
(8) Check and adjust oil level as necessary.
OIL FILTER
DESCRIPTION
The oil filter is a high quality, full flow, disposable
style. (Fig. 79).
REMOVAL
NOTE: Capture any residual oil spill while removing
filter and wipe any oil that comes in contact with
other components
(1) Raise vehicle on hoist.
(2) Twist oil filter counterclockwise with a suitable
oil filter wrench to remove.
INSTALLATION
(1) Lubracate oil filter seal with clean engine oil.
(2) Turning clockwise, seat the oil filter then
tighten the oil filter 1/2 turn more (Fig. 79).
(3) Lower vehicle from hoist.
(4) Start engine and check for leaks.
(5) Check and adjust oil level as necessary.
Fig. 78 WATER PUMP AND OIL COOLER
ASSEMBLIES
1 - WATER PUMP HOUSING STUDS
2 - WATER PUMP
3 - RETAINING NUTS
4 - OIL COOLER RETAINING STUD
5 - OIL COOLER TO ENGINE BLOCK RETAINING BOLT
6 - OIL COOLER COOLANT HOSE
7 - ENGINE BLOCK
Fig. 79 OIL FILTER
1 - OIL FILTER
2 - OIL COOLER
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ENGINE
9 - 53
OIL COOLER & LINES (Continued)
OIL JET
DESCRIPTION
There are four oil jets installed in the engine block.
These oil jets are used to cool and lubricate the pis-
ton assemblies (Fig. 80).
REMOVAL
CAUTION: Use caution when removing and install-
ing oil jets. Damage to oil jet nozzle could cause
severe engine damage.
NOTE: Remove oil jets Before removing pistons,
crankshaft or liners
(1) Disconnect negative battery cable.
(2) Raise vehicle on hoist.
(3) Remove oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - REMOVAL).
(4) Using special tool VM.1060 to hold oil jet.
Remove oil jet retaining bolt and remove oil jet from
engine block (Fig. 81).
INSTALLATION
CAUTION: Use caution when removing and installa-
ing oil jets. Damage to oil jet nozzle could cause
severe engine damage.
NOTE: Carefully install the oil jets After assembling
the engine liners, crankshaft and pistons.
(1) Lubricate o-ring on oil jet.
(2) Using special tool VM.1060, install oil jet in
engine block (Fig. 81).
(3) Install oil jet retaining bolt. Torque bolt to
10.8N·m.
(4) Install oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION).
(5) Refill engine oil to proper level.
(6) Connect negative battery cable.
INTAKE MANIFOLD
DESCRIPTION
(Refer to 9 - ENGINE/CYLINDER HEAD/CYLIN-
DER HEAD COVER(S) - DESCRIPTION)
REMOVAL
(1) (Refer to 9 - ENGINE/CYLINDER HEAD/CYL-
INDER HEAD COVER(S) - REMOVAL)
INSTALLATION
(1) (Refer to 9 - ENGINE/CYLINDER HEAD/CYL-
INDER HEAD COVER(S) - INSTALLATION)
Fig. 80 OIL JET ASSEMBLY
1 - RETAINING BOLT
2 - OIL JET
3 - O-RING
Fig. 81 OIL JET REMOVAL/INSTALLATION
1 - SPECIAL TOOL VM.1060
2 - OIL JET
3 - CONNECTING ROD
4 - CRANKSHAFT
9 - 54
ENGINE
RG
VALVE TIMING
STANDARD PROCEDURE - LOCKING ENGINE
90° AFTER TDC
(1) Disconnect negative battery cable.
(2) Remove starter motor (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - REMOVAL).
NOTE: Crankshaft hub retaining bolt is left hand
thread.
(3) Rotate engine untill notch in hub is in the fol-
lowing position (Fig. 82).
(4) Special tool VM.1068 can be install in engine
block as shown at this time (Fig. 83). This will lock
the engine at 90° after TDC.
(5) Remove front wiper unit (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER
MODULE
-
REMOVAL).
(6) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(7) Remove plug in cylinder head cover/intake
manifold and insert VM.1053 to lock exhaust cam-
shaft in position (Fig. 84).
(8) Remove generator (Refer to 8 - ELECTRICAL/
CHARGING/GENERATOR - REMOVAL).
Fig. 82 CRANKSHAFT HUB ALIGNMENT
1 - VIBRATION DAMPER/CRANKSHAFT PULLEY
2 - CRANKSHAFT HUB NOTCH
3 - VIBRATION DAMPER/CRANKSHAFT PULLEY TO
CRANKSHAFT HUB BOLTS
4 - ACCESSORY DRIVE BELT
Fig. 83 90 DEGREES AFTER TDC ALIGNMENT PIN
LOCATION
1 - ENGINE BLOCK
2 - VM.1051 TDC PIN OR VM.1068 90 DEGREES ATDC PIN
3 - FLYWHEEL
Fig. 84 EXHAUST CAMSHAFT LOCKING PIN
VM.1053
1 - EXHAUST MANIFOLD HEAT SHIELD
2 - EXHAUST CAMSHAFT LOCKING PIN VM.1053
3 - COOLANT TUBE FROM THERMOSTAT HOUSING TO UPPER
RADIATOR HOSE
4 - CYLINDER HEAD COVER/INTAKE MANIFOLD
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ENGINE
9 - 55
(9) Remove plug in cylinder head cover/intake
manifold and insert VM.1052 to lock intake camshaft
in position (Fig. 85).
(10) At this point the timing belt can be removed
for service.
(11) After engine service is completed and timing
belt reinstalled, remove both camshaft locking pins
from cylinder head cover/intake manifold.
(12) Install both camshaft access plugs.
(13) Remove 90° after TDC engine locking pin.
(14) Install starter motor (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - INSTALLA-
TION).
(15) Install generator (Refer to 8 - ELECTRICAL/
CHARGING/GENERATOR - INSTALLATION).
(16) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
(17) Install front wiper unit (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER
MODULE
-
INSTALLATION).
(18) Connect negative battery cable.
BALANCE SHAFT
DESCRIPTION
The 2.5L Common Rail Diesel engine is equipped
with two nodular cast iron balance shafts in a cast
aluminum carrier. The balance shaft assembly is
mounted to the engine block (Fig. 86).
OPERATION
The balance shaft is driven by the crankshaft. The
balance shafts are connected by heelical gears. The
dual-counter rotating shafts decrease second order ver-
tical shaking forces caused by component movement.
REMOVAL
(1) Disconnect negative battery cable.
(2) Raise vehicle on hoist.
(3) Before installation of the balance shaft assem-
bly, the # 1 cylinder must be brought to TDC. Using
special tool VM.1051, roll engine over by hand until
tool can be inserted into engine block locking fly-
wheel from turning.
(4) Remove oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - REMOVAL).
(5) Remove balance shaft assembly (Fig. 86).
Fig. 86 OIL PUMP PICKUP TUBE ASSEMBLY
1 - BALANCE SHAFT
2 - OIL JET RETAINING BOLT
3 - OIL JET
4 - ENGINE BLOCK
5 - CRANKSHAFT
6 - O- RING(S)
7 - BALANCE SHAFT RETAINING BOLTS
8 - OIL DIPSTICK TUBE RETAINER
9 - RUBBER BUSHING
10 - RETAINING BOLT
Fig. 85 INTAKE CAMSHAFT LOCKING PIN VM.1052
1 - TIMING BELT INNER COVER
2 - GLOW PLUG ELECTRICAL CONNECTOR
3 - CYLINDER HEAD COVER/INTAKE MANIFOLD
4 - FUEL RAIL
5 - INTAKE CAMSHAFT LOCKING PIN VM.1052
9 - 56
ENGINE
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VALVE TIMING (Continued)
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