ENGINE OVERHAUL 2.6 4cyl

1984 Dodge Caravan
ENGINE OVERHAUL 1984 CHRYSLER CORP. ENGINES 2.6L 4-Cylinder
ENGINE OVERHAUL
1984 CHRYSLER CORP. ENGINES 2.6L 4-Cylinder
ENGINE IDENTIFICATION
NOTE: For engine repair procedures not covered in this article, see ENGINE
OVERHAUL PROCEDURES - GENERAL INFORMATION article in the GENERAL
INFORMATION section.
Engine may be identified from Vehicle Identification Number (VIN). VIN is stamped on Gray metal tab located
on upper left corner of instrument panel, near windshield. Engine Identification Number is located on left side
of block between core plug and rear of block (radiator side of vehicle).
Engine serial number is located on right side of block adjacent to exhaust manifold stud. In addition, VIN code
appears as part of production or unit number stamped on right side of engine forward facing surface, below
cylinder head. VIN consists of 17 characters. Eighth character identifies engine and 10th character establishes
model year.
ENGINE IDENTIFICATION CODES

Application VIN Code
2.6L 4-Cylinder 2-Bbl G
ADJUSTMENTS
VALVE CLEARANCE ADJUSTMENT
NOTE: After overhaul or other service procedures, perform all valve adjustments
AFTER checking hot torque on cylinder head bolts. Emission levels and engine
performance will be adversely affected by incorrect jet valve adjustment. Jet
valve adjustment must be done prior to intake valve adjustment.
Valve Arrangement
l Intake valves (Left side).

l Exhaust valves (Right side).
l Jet valves (Left side).
Jet Valves
1. Engine must be warm for correct adjustment. Rotate engine until No. 1 piston is at TDC on compression
stroke. Back off intake valve adjusting screws on No.1 and No. 2 cylinders at least 2 full turns.
2. Loosen lock nuts on jet valve adjusting screws of No. 1 and No. 2 cylinders. Back off jet valve adjusting
screw (counterclockwise) until .006" (.15 mm) feeler gauge fits between screw and top of jet valve stem.
3. Tighten adjusting screw (clockwise) until tip of screw just touches feeler gauge. If screw is hard to turn,
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1984 Dodge Caravan
be careful to avoid compressing spring. Jet valve could be forced down as jet valve spring tension is low.
4. Hold adjusting screw in place and tighten lock nut. Recheck jet valve clearances. Rotate engine until No.
4 piston is at TDC on compression stroke. Adjust jet valve clearances on No. 3 and No. 4 cylinders in the
same manner as described for cylinders No. 1 and No. 2.
Intake and Exhaust Valve
1. Be sure engine is warm. Position piston at TDC of compression stroke on cylinder at which valves are
being adjusted. Loosen valve adjuster lock nuts. Adjust valve clearance by turning adjusting screw while
measuring clearance with feeler gauge. Repeat for each cylinder.
2. Hot engine settings are .006" (.15 mm) for intake valves and .010" (.25 mm) for exhaust valves. After
adjustment, tighten lock nut securely while holding adjusting screw with screwdriver.
REMOVAL & INSTALLATION

ENGINE REMOVAL
See ENGINE REMOVAL - 4-CYL article at end of ENGINE Section.
CYLINDER HEAD & INTAKE MANIFOLD
Removal
1. Disconnect battery. Drain cooling system and remove upper radiator hose. Disconnect heater hoses.
Disconnect plug wires and remove distributor. Remove valve cover-to-carburetor bracket.
2. Remove fuel lines and fuel pump. Remove valve cover. Remove all vacuum hoses and wiring from
engine. Unhook accelerator linkage at carburetor. Remove water pump belt and pulley. Rotate crankshaft
to TDC on No. 1 cylinder.
3. Mark face of timing chain link that is in line with timing mark on camshaft sprocket. Use White paint to
make mark. Remove camshaft sprocket and distributor drive gear from camshaft. Disconnect pulse air
feeder hoses from underneath vehicle.
4. Unbolt power steering pump and place aside with hoses connected. Disconnect ground wire. Remove
dipstick tube. Remove exhaust manifold shield. Disconnect catalytic feeder pipe from exhaust manifold.
5. Undo cylinder head bolts in sequence shown in Fig. 1. Use sequence to avoid warping of cylinder head.
Remove bolts and lift cylinder head assembly out of vehicle.
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1984 Dodge Caravan
Fig. 1: Cylinder Head Bolt Removal Sequence
Installation
1. Clean gasket surfaces of cylinder block and head. Check head for flatness with straight edge. Maximum
allowable warp of cylinder head is .004" (.1 mm).
2. Install new cylinder head gasket, using no sealant. Install cylinder head assembly and tighten cylinder
head bolts in reverse order of that shown in Fig. 1. Tighten all head bolts, except 2 bolts to chain case
cover, to 30 ft. lbs. (40 N.m) on 1st step.
3. For cold engine, tighten bolts to 69 ft. lbs. (94 N.m) on 2nd step. For hot engine, tighten bolts to 76 ft. lbs.
(103 N.m) on 2nd step. Tighten cylinder head-to-chain case cover bolts to 159 INCH lbs. (18 N.m).
4. Check valve clearance with engine cold. Readjust valve clearance after checking hot torque setting of
cylinder head bolts. Hot intake and jet valve clearance is .006" (.15 mm) and hot exhaust valve clearance
is .010" (.25 mm).
5. To complete installation, reverse removal procedure. Install breather and semi-circular seal in back of
cylinder head and apply sealant to points shown in Fig. 2. Use new gasket for valve cover.
1984 Dodge Caravan
Fig. 2: Installing Breather & Semi-Circular Seal
VALVES
Valve Arrangement
l Intake valves (Left side).

l Exhaust valves (Right side).
l Jet valves (Left side).
Valve Guide Servicing
1. Check valve stem-to-guide clearance. If clearance exceeds service limits, check valve guide and valve
stem for wear. If guide is to be replaced, 3 oversizes are available. Guide should be driven out from top of
head through combustion chamber.
2. With head at room temperature, press old guide out with push rod of installing tool (MD998115).
Inserting hole in cylinder head must be bored to size for outside diameter of new guide.
3. Press new guide into head from top. Use valve guide installing tool (MD998115) with collar. Use of tool
will press guide into head to correct installed height. Properly installed guide will have .55" (13.9 mm) of
length remaining above head boss surface. See Fig. 3.
4. Put new valve into guide and make sure that valve moves freely in guide. Guide may need to be reamed if
valve does not move freely.
1984 Dodge Caravan
VALVE GUIDE OVERSIZES

Oversize Guide Oversize: In. (mm) Cylinder Head Bore: In. (mm)
1st .002 (.05) .5138-.5145 (13.050-13.068)
2nd .010 (.25) .5217-.5224 (13.250-13.268)
3rd .020 (.50) .5315-.5322 (13.500-13.518)
VALVE STEM-TO-GUIDE CLEARANCE

Valve Standard: In. (mm) Service Limit: In. (mm)
Intake .0012-.0024 (.031-.061) .004 (.10)
Exhaust .002-.0035 (.05-.089) .006 (.15)
Fig. 3: Valve Guide Installation & Height
Valve Stem Oil Seals
1. Cylinder head must be removed from engine. After installing valve spring seat, lubricate new valve stem
oil seal with engine oil and place on valve guide.
2. Using installer tool (MD998005), lightly tap seal into correct position as tool bottoms on head. DO NOT
use old seals or twist seals when installing. See Fig. 4.
1984 Dodge Caravan
Fig. 4: Valve Stem Oil Seal Installation & Height
Valve Seat Servicing
1. Check valve seat for damage or wear. Replace or rework seat, as necessary. If reworking seat, check
valve guide first. Make proper replacement, if required, then check seat for necessary corrections.
2. Recondition valve seat with grinder or cutter to specified contact width. After rework, valve should be
lapped into seat. Use valve grinding compound.
3. Valve seat sink (wear of seat inward allowing valve to seat too deep in head) must be checked by
measuring installed height of valve spring. Measure between spring seat and retainer with all spring
components installed.
4. Remove valve seat by thinning down with cutter. Machine seat bore to proper size for oversize seat. Cool
new oversize seat insert with liquid nitrogen. Quickly press chilled insert into head. Replacement seats
are available in .012" (.30 mm) and .024" (.60 mm) oversizes, which are marked "30" and "60"
respectively.
CAUTION: DO NOT try to press seat insert into head when both are at same
temperature. Valve seat bore of cylinder head will be damaged and seat
insert will have loose fit.
JET VALVES
Removal
Remove jet valve assembly with jet valve socket wrench (MD998310). Remove jet valve spring retainer lock,
1984 Dodge Caravan
using jet valve spring pliers (MD998309). Remove valve spring retainer and valve spring.
CAUTION: Make sure jet valve socket wrench (MD998310) is not tilted in relation to
center of jet valve. Valve stem may be bent by pressure against valve
spring retainer and cause incorrect jet valve operation.
Inspection
1. Make sure valve slides freely in jet body but has no play. Check face of jet valve and jet body seat for
damage. Check jet valve spring for cracks or damage. Replace jet valve and jet valve body as assembly if
either part is defective.
2. Jet valve stem diameter should be .169" (4.29 mm). Angle of face and seat is 45°. Valve spring free
length is 1.165" (29.59 mm). Spring load should be 5.50 lbs at .846" (2.5 kg at 21.49 mm).
Installation
1. Install new jet valve stem seal on jet body, using seal installer (MD998308). DO NOT reuse old seal. Oil
jet valve stem and insert valve in body, using care not to damage stem seal lips. Make sure valve slides
smoothly in body.
2. Place spring and retainer on valve body. Compress with spring pliers (MD998309) and install retainer
lock. Install new "O" ring seal in groove of jet body. Oil "O" ring and threaded portion of jet body. Screw
jet valve assembly into head by hand and tighten with socket wrench (MD998310).
VALVE SPRINGS
1. Remove rocker arm assemblies. Note which shaft is on intake side and which is on exhaust side for
correct reassembly. Remove camshaft. Compress valve springs and remove retainer locks. Remove all
retainers, springs, spring seals and valves, keeping all parts in proper order for assembly. See Fig. 5.
1984 Dodge Caravan
Fig. 5: Rocker Arm and Valve Assembly
NOTE: Mark rocker arm shafts for reassembly and note number of oil holes at
bottom of shafts.
2. Check valve spring free length and pressure. Check valve springs for out of square with 90° straightedge.
Valve spring out of square service limit is 3° maximum.
3. If beyond limit, replace spring. Installed height of new intake or exhaust valve spring should be
1.590" (40.4 mm). Maximum installed height is 1.629" (41.4 mm). If maximum height limit is exceeded,
valve or valve seat is worn excessively.
OIL PAN
See ENGINE OIL PAN REMOVAL - 4-CYL article at end of ENGINE Section.
OVERHAUL
PISTON & CONNECTING ROD ASSEMBLY
Removal
1. Remove cylinder head and oil pan. With piston at bottom of stroke, check top of cylinder bore for ridge.
Cover piston with cloth to catch cuttings and remove ridge with ridge reamer.
2. Mark piston and rod assemblies for installation in original locations. Check to be sure connecting rods
and rod caps are marked for reassembly in their original locations.
1984 Dodge Caravan
3. Rotate engine until connecting rod is straight down. Remove connecting rod caps and bearings. Push
connecting rod and piston assembly upward through top of cylinder block.
Installation
1. Lubricate all internal surfaces with engine oil before installing. Make sure arrows on top of pistons point
toward timing chain. Matching marks on connecting rods and caps must align and be on right side of
engine.
2. Use ring compressor to compress rings. Be careful that piston ring end gaps are positioned properly. See
Fig. 6. Apply light coat of engine oil to pistons and rings. Rotate crankshaft so connecting rod journal is
at center of bore.
3. Cover rod bolts before installing piston and rod assembly in bore. This will protect crankshaft journals
from damage. Tap lightly on piston dome with wood drift while guiding connecting rod onto crankshaft.
4. Install rod cap onto proper piston and connecting rod assembly. Make sure cap and rod markings are on
same side. Tighten attaching bolts. Install cylinder head and oil pan.
Fitting Pistons
1. After checking block for distortion, cracks or scratches, measure cylinder bores at 3 levels (90° apart).
Top and bottom levels should be .38" (10 mm) into cylinder.
2. If any cylinder bore is distorted from standard size, block must be rebored and oversize pistons installed.
Standard bore size is 3.587" (91.10 mm). Maximum out-of-round or taper is .0008" (.02 mm).
NOTE: Pistons are available in standard, .010" (.25 mm), .020" (.50 mm), .030" (.75
mm) and .040" (1.00 mm) oversizes. Oversize pistons are stamped on
crown to indicate amount of oversize.
3. Check outside diameter of piston by measuring at point .08" (2 mm) from bottom of skirt and 90° to pin
bore (across thrust face). Determine amount of cylinder reboring required to meet specified clearance.
NOTE: When removing or installing piston pin, connecting rod should be in firm
contact with body of pin setting tool (MD998184 & MD998183).
Fitting Piston Pins
1. Inspect and replace any piston pin showing signs of fracture, etching or wear. Check piston pin-to-rod
bore fit. Lubricate pin and small end of rod bore with engine oil.
2. Set connecting rod and piston with arrow on piston and mark on connecting rod facing up. Using correct
guide bar (marked 4G54) and push rod, press piston pin into bore, using 1600-3800 lbs. (720-1710 kg)
force at normal room temperature.
NOTE: Upper and intermediate (No. 1 and No. 2) piston rings have same thickness, but
different cross section. Oil ring expander end gap should be at least 45° from
side rail gaps, but not on piston pin center or on thrust direction.
1984 Dodge Caravan
Fitting Piston Rings
1. Measure piston ring side and end gap clearance for all pistons. Replace rings as necessary. Check ring
end gap after using piston to position ring in cylinder bore at least .63" (16 mm) from bottom of bore.
2. Install rings on pistons with end gaps staggered at 120° intervals. Ensure ring gap is not in line with thrust
face of pin bore. See Fig. 6. Be sure manufacturer's marks face up when rings are installed.
Fig. 6: Piston Ring End Gap Positions
3. Install oil ring expander first, then upper oil ring side rail followed by lower side rail. DO NOT use ring
expander on side rails. When installing upper side rail, place one end between piston ring groove and
expander.
4. Hold end firmly and press down portion to be installed until side rail is in position. Install lower side rail.
Using ring expander, install intermediate and upper rings. Piston rings are available in standard and
oversize to match piston size.
CONNECTING ROD BEARINGS
NOTE: Following procedures are performed with oil pan and oil pump removed.
Whenever crankshaft must be rotated, access plug covering hole in right front
fender inner splash shield should be removed. Socket, extension and ratchet
may then reach crankshaft sprocket bolt to turn crankshaft.
1. Inspect bearings for seizure, improper contact, or other damage. Replace defective bearings. Measure
1984 Dodge Caravan
outside diameter of crankshaft connecting rod bearing journals to determine if out-of-round or tapered.
2. Turn crankshaft until connecting rod to be checked starts moving toward top of engine. Use Plastigage
method to measure bearing clearances. If clearance exceeds specifications, replace bearing.
3. Undersize bearings are available in .010" (.25 mm), .020" (.50 mm), and .030" (.75 mm) undersizes. After
inspection and/or replacement, tighten rod bearing caps. Check connecting rod-to-crankshaft side
clearance. Clearance should be .004-.010" (.10-.25 mm).
CONNECTING ROD JOURNALS

Size (1) Diameter: In. (mm)
Standard 2.0860-2.0866 (52.985-53.000)

1st Undersize 2.0762-2.0767 (52.735-52.750)
2nd Undersize 2.0663-2.0669 (52.485-52.500)
3rd Undersize 2.0565-2.0571 (52.235-52.250)
(1) Maximum out-of-round is .0004" (.010 mm).
MAIN BEARINGS
NOTE: No. 1 main bearing is at timing chain end and No. 5 bearing is at transmission
end of block. When using Plastigage to check main bearings, remove weight
from crankshaft by supporting counterweight with jack or preferably by
shimming adjacent bearings. DO NOT turn crankshaft with Plastigage installed.
NOTE: Following procedures are performed with oil pan and oil pump removed.
Whenever crankshaft must be rotated, access plug covering hole in right front
fender inner splash shield should be removed. Socket, extension and ratchet
may then reach crankshaft sprocket bolt to turn crankshaft.
1. Inspect each bearing for seizure, improper contact, or damage. Replace defective bearings. Measure
outside diameter of crankshaft main bearing journals to determine if out-of-round or tapered.
2. Use Plastigage method to measure bearing clearance. Always install caps with arrow facing toward
timing chain end. If clearance exceeds limits, replace bearing. U
CAMSHAFT
Removal
1. Disconnect negative battery cable. Drain cooling system. Remove upper radiator hose and disconnect
heater hoses. Remove breather hoses, purge hose and vacuum hoses. Remove air cleaner and duct
assembly.
2. Remove fuel line and fuel pump. Disconnect spark plug cables and remove distributor. Remove
carburetor-to-valve cover bracket and separate carburetor linkage. Remove water pump pulley shield,
valve cover and breather. Remove semi-circular seal.
3. Remove water pump belt and pulley. Turn crankshaft until No. 1 piston is at TDC on compression stroke.
Make mating mark on timing chain in line with timing mark on camshaft sprocket using White paint.
1984 Dodge Caravan
Remove camshaft sprocket bolt, washer and distributor drive gear. See Fig. 7.
Fig. 7: Camshaft, Timing Chain, & Silent Shaft Assemblies
NOTE: DO NOT remove rocker arm mount bolts from camshaft bearing caps.
Remove rocker arms, rocker shafts and bearing caps as an assembly. If
wave washer is replaced for any reason, dished portion of washer must
face front of engine.
4. Remove camshaft sprocket with timing chain and place on sprocket holder. Remove rocker arm mount
bolts with rocker arms, rocker shafts, and bearing caps as an assembly. Remove camshaft.
Installation
1. Check camshaft journals for wear, scratches or seizure. Check lobes, rocker arms and bearing caps for
damage or wear. Limit of camshaft lobe wear is 1.64" (41.7 mm) or wear of .020" (.5 mm).
2. If cylinder head bearing surfaces are excessively worn, scratched or binding, replace cylinder head
assembly. Lubricate camshaft lobes and bearing journals. Install camshaft onto cylinder head.
3. Install complete rocker arm shaft assembly with mating marks on bearing caps and rocker shafts in proper
position. Marks on cap are .08" (12 mm) diameter castings while marks on shafts are .12" (3 mm) holes.
Position camshaft so dowel pin on front end is positioned at top center. See Fig. 8.
1984 Dodge Caravan
Fig. 8: Camshaft Installation Position
NOTE: Note bearing cap-rocker arm shaft mating marks.
4. Install camshaft bearing caps with arrows pointing towards timing chain end and in numerical order.
Starting at center, tighten all bolts to 85 INCH lbs. (10 N.m) in sequence of center (No. 3), No. 2, No. 4,
front (No. 1), and rear (No. 5) caps. Repeat sequence, tightening to 175 INCH lbs. (20 N.m).
5. Install camshaft sprocket and distributor drive gear onto camshaft. Carefully set camshaft timing. Tighten
camshaft sprocket locking bolt. Set valve clearance temporarily to cold engine setting.
6. Fit gasket to valve cover. Temporarily install breather, semi-circular seal and valve cover. Start engine
and run at idle speed until warm. Reset valves to specified hot settings.
7. Install breather and semi-circular seal to cylinder head with sealant. See Fig. 2. Install and tighten valve
cover. Complete installation by reversing removal procedure.
TIMING CHAIN
Removal
1. Disconnect negative battery cable. Remove alternator belt, alternator and distributor. Remove and set
aside A/C compressor (if equipped) with hoses attached. Remove power steering belt, pump and bracket.
2. Raise vehicle and remove right inner splash shield. Drain oil from crankcase and remove crankshaft drive
pulley. Lower vehicle and place jack under engine. Remove right front engine mounting bolt and raise
1984 Dodge Caravan
engine slightly.
3. Remove engine oil dipstick, air cleaner assembly and spark plug wires. Remove cylinder head vacuum
connections. Remove valve cover. Remove ONLY 2 front cylinder head bolts (threaded into chain case
cover). DO NOT touch other cylinder head bolts.
4. Remove oil pan, timing indicator, and engine mounting plate. Remove bolts holding chain case cover and
lift off cover. Remove bolts holding chain guides in position. Remove silent shaft and crankshaft sprocket
bolts. Remove drive chain, outer crankshaft sprocket and silent shaft sprockets.
5. Remove camshaft sprocket bolt, distributor drive gear, camshaft sprocket holder and both timing chain
guides. Depress tensioner to remove timing chain. Remove inner crankshaft sprocket and camshaft
sprocket.
Installation
1. Inspect all parts for cracks, wear or other damage. Check chain tensioner spring free length. Standard free
length is 2.587" (65.70 mm). Spring load is 4.4 lbs. at 1.453" (2.0 kg at 36.9 mm).
2. With camshaft bearing caps tightened to specification, rotate camshaft so that dowel hole is on upper
vertical centerline. See Fig. 8. Install sprocket holder and right and left chain guides.
3. Rotate crankshaft until No. 1 piston is at TDC on compression stroke. Install tensioner spring and shoe on
oil pump body. Install timing chain on camshaft and crankshaft sprockets.
4. Be sure timing marks are aligned. Timing marks on sprockets are punch marks near gear teeth. Timing
marks on chain are middle of each PLATED link. See Fig. 9. Holding chain and sprocket assembly in
both hands, align crankshaft sprocket to keyway and slide into place.
1984 Dodge Caravan
Fig. 9: Camshaft Sprocket Alignment & Installation
5. Align camshaft sprocket dowel hole with camshaft dowel hole. Install dowel pin and distributor drive
gear. Install sprocket bolt on camshaft and tighten. Install silent shaft chain drive sprocket on crankshaft.
6. Install silent shaft chain to oil pump sprocket and to silent shaft sprocket. Be sure timing marks on gear
teeth (punch marks) are aligned with marks (plated links) of chain. See Fig. 10.
7. Holding parts with both hands, align crankshaft sprocket timing mark with plated chain link. Install oil
pump and silent chain sprockets to their respective shafts.
1984 Dodge Caravan
Fig. 10: Silent Shaft Drive Chain Installation
NOTE: Timing marks on chain and sprockets must be aligned.
8. Install oil pump and silent shaft sprocket bolts. Loosely install three chain guides. Adjust silent shaft
tension by tightening chain guide "A" and "C". Then shake oil pump and silent shaft sprockets to collect
all chain slack at point "P" in Fig. 10.
9. Adjust position of chain guide "B" so that when chain is pressed inward with finger tips, clearance
between chain guide "B" and chain links will be .04-.14" (1.0-3.6 mm). Tighten chain guide "B"
mounting bolts.
10. Install new chain case cover gaskets to cover. Trim as required to fit at top and bottom. Coat cover and
gaskets with sealant. Install gasket and cover to cylinder block. Reinstall front 2 cylinder head bolts.
11. To adjust tension with engine installed, proceed as follows: Remove cover from access hole in chain case
cover. Loosen special bolt "B". See Fig. 11.
12. Apply finger pressure only (no tools) on boss in direction indicated. Tighten special bolt "B" to 175
INCH lbs. (20 N.m). Complete reassembly by reversing disassembly procedure.
1984 Dodge Caravan
Fig. 11: Silent Shaft Chain Adjustment With Engine Installed
SILENT SHAFTS
Right Silent Shaft
1. With chains removed, remove oil pump mounting bolts. See Fig. 12. Remove bolt holding oil pump
driven gear and silent shaft together. Remove oil pump and withdraw right silent shaft from bore.
2. Reverse removal procedure to install. Prime oil pump and make sure oil pump mating marks align and
that Woodruff key on shaft fits keyway in driven gear.
1984 Dodge Caravan
Fig. 12: Cutaway View Of Gear Type Oil Pump
NOTE: If bolt holding oil pump driven gear is difficult to remove, remove oil pump and
silent shaft as an assembly and then remove lock bolt.
Left Silent Shaft
1. Remove thrust plate supporting left silent shaft. Thrust plate is removed by threading two .31" (7.9 mm)
bolts evenly into tapped plate holes. Withdraw left silent shaft from cylinder block.
1984 Dodge Caravan
2. To install, reverse removal procedure. Install silent shafts into cylinder block taking care not to damage
inner bearings. Install thrust plate on left silent shaft using new "O" ring. Install oil pump.
3. If silent shaft inner bearings are worn, use Camshaft Bearing Remover (MD998251) to draw bearing from
cylinder block. For installation, use Camshaft Bearing Installer (MD998250) to press bearing straight into
block.
4. Silent shaft clearances are as follows: Outer diameter to outer bearing clearance is .0008-.0024" (.020-
.060 mm). Inner diameter to inner bearing clearance is .0020-.0035" (.050-.090 mm).
LUBRICATION
ENGINE OILING SYSTEM
Crankcase Capacity
Four and one half quarts (4.3L) without oil filter. Five quarts (4.7L) including filter.
Oil Filter
Oil filter should be replaced every 15,000 miles (every other oil change) or at 7,500 miles (every 12 months) on
low usage vehicles.
Normal Oil Pressure
Normal oil pressure should be 50-64 psi (3.5-4.4 kg/cm2 ) at 2000 RPM. Minimum at idle is 4 psi (28 kg/cm2 )
Pressure Regulator Valve
Valve is located in oil pump body and is not adjustable.
OIL PUMP
Gear-type oil pump is used on the 2.6L engine to provide force-feed lubrication system. Driven gear of oil
pump also drives right silent shaft. See Fig. 13. For removal of oil pump, refer to SILENT SHAFTS.
Disassembly is done as oil pump is removed from block.
Inspection
Check drive gear-to-housing clearance. Check drive and driven gear end play. Check drive and driven gear-to-
bearing clearance in body and at cover. Remove end cap and check oil pump relief valve spring free length is
1.85" (46.9 mm). Check spring load is 9.5 lbs. at 1.575" (4.3 kg at 40 mm).
Installation
Ensure new gasket is used. Refill oil pump assembly with oil before installation. Pump reassembly is done as
pump is installed on block. For installation of oil pump, see SILENT SHAFTS.
1984 Dodge Caravan
Fig. 13: Mating Marks For Oil Pump Gears
NOTE: Align marks and prime oil pump during installation.
OIL PUMP SPECIFICATIONS

Application Clearance: In. (mm)
Gears-to-Housing Clearance .004-.006 (.11-.15)
Gears-to-Bearing Clearance
Oil Pump Body .0008-.002 (.020-.05)
Driven Gear End Play .0016-.0039 (.040-.100)
Drive Gear End Play .0020-.0043 (.050-.110)
ENGINE COOLING
WATER PUMP
Removal
1. Drain cooling system. Remove radiator hose, by-pass hose and heater hose from water pump. Remove
drive pulley cover. Remove locking bolt and pivot bolts. Pull up on slotted side (front of car) of water
pump to relieve belt tension.
1984 Dodge Caravan
2. Remove drive belt. Remove water pump assembly from engine. Remove 4 bolts holding pump to body.
Discard gasket and clean all gasket surfaces. Remove and discard "O" ring and clean "O" ring groove.
Installation
1. Install new gasket on water pump body. Position pump assembly on body and tighten 4 bolts. Use new
"O" ring and position pump on engine with drive belt. Install pivot and locking bolts. Adjust belt tension
and tighten bolts.
2. Reverse removal procedure to complete reassembly. When refilling cooling system, check anti-freeze
freezing point and fill cooling system with required amount of anti-freeze (Mopar-4106794 or Prestone
II).
3. If, after repair, radiator coolant level must be checked, install pressure cap and start engine. Run until
upper radiator hose feels hot. Stop engine and add more coolant, as necessary, to completely fill system.
NOTE: For further information on cooling system capacities and other cooling system
components, see ENGINE COOLING FAN and COOLING SYSTEM
SPECIFICATIONS article.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
Camshaft Sprocket Bolt 40 (54)
Connecting Rod Cap Bolt 34 (46)
Crankshaft Drive Pulley Bolt 87 (118)
Cylinder Head Bolt
Step 1 (Cold or Hot) 34 (46)
Step 2
Cold 69 (93)
Hot 76 (103)
Main Bearing Cap Bolt (1) 58 (78)
Oil Pump Sprocket Bolt 25 (34)
Silent Chain Sprocket Bolt 25 (34)
Water Pump Drive Pulley Bolt 40 (54)
INCH Lbs. (N.m)
Camshaft Bearing Cap Bolt 175 (20)
Chain Case Cover Bolt 159 (18)
Chain Guide Bolt 159 (18)
Cylinder Head-to-Chain Case Cover Bolt 159 (18)
Engine Mount Plate Bolt 159 (18)
Exhaust Manifold Nut 150 (17)
Intake Manifold Nut 150 (17)
Jet Valve 168 (19)
1984 Dodge Caravan
Oil Pump Mount Bolt 71 (8)

Water Pump Mounting Bolt 203 (23)
(1) Tighten in 3 even steps.
ENGINE SPECIFICATIONS
GENERAL ENGINE SPECIFICATIONS
GENERAL ENGINE SPECIFICATIONS

Application In. (mm)
Displacement
Cu. In. 156
Liters 2.6
Fuel System 2-Bbl.
HP @ RPM 99@4800
Torque Ft. Lbs. @ RPM 137@2800
Compression Ratio 8.7:1
Bore 3.59 (91.1)
Stroke 3.86 (98.0)
VALVE SPECIFICATIONS
VALVE SPECIFICATIONS
Application (1) In. (mm)
Intake
Head Diameter 1.81 (45.72)
Face Angle 45°
Seat Angle 45°
Seat Width .035-.015 (2) (.90-1.29)
Stem Diameter .315 (8.00)
Stem Clearance .0012-.0024 (.03-.06)
Valve Lift .413 (10.5)
Exhaust
Head Diameter 1.50 (38.10)
Face Angle 45°
Seat Angle 45°
Seat Width .035-.015 (3) (.90-1.29)
Stem Diameter .315 (8.00)
Stem Clearance 0020-.0035 (.05-.09)
Valve Lift 413 (10.5)
1984 Dodge Caravan
(1) If jet valve or body are bad, replace both as assembly only.
(2) Margin for new valve is .047" (1.2 mm) service limit is .028" (.7 mm).
(3) Margin for new valve is .079" (2 mm), service limit is .039" (1 mm).
PISTONS, PINS & RINGS SPECIFICATIONS
PISTONS, PINS & RINGS SPECIFICATIONS

Piston Clearance .0008-.0016 (.020-.040)
Pins
Piston Fit Slip Fit
Rod Fit Press Fit
Rings
Ring No. 1
End Gap .010-.018 (.25-.45)
Side Clearance .0024-.0039 (.061-.099)
Ring No. 2
End Gap .010-.018 (25-.45)
Side Clearance .0008-.0024 (.020-.061
Ring No. 3
End Gap .008-.035 (.20-.40)
Side Clearance (1)
(1) Free to rotate after assembly
CRANKSHAFT MAIN & CONNECTING ROD BEARINGS SPECS
CRANKSHAFT MAIN & CONNECTING ROD BEARINGS SPECS

Main Bearings
Journal Diameter 2.362 (59.99)
Clearance .0008-.0020 (.020-.050)
Thrust Bearing No. 3
Crankshaft End Play .002-.007 (.05-.18)
Connecting Rod Bearings
Clearance .0008-.0024 (.020-.060)
Side Play .004-.010 (.10-.25)
VALVE SPRINGS SPECIFICATIONS
1984 Dodge Caravan
VALVE SPRINGS SPECIFICATIONS

Application Specifications
Inner
Free Length 1.869 (1) (47.47)
Pressure (2)
Valve Closed [email protected] (271@40)
Valve Open N/A
(1) Valve spring free length service limit is 1.830" (46.88 mm).
(2) Lbs. @ In. (Kg @ mm)
CAMSHAFT SPECIFICATIONS
CAMSHAFT SPECIFICATIONS
Clearance .002-.004 (1) (.06-.10)
Lobe Lift .418 (10.5)
(1) Camshaft end play is .004-.008 (.10-.20 mm).

ENGINE OVERHAUL 2.6 4cyl

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ENGINE OVERHAUL 2.6 4cyl

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ENGINE OVERHAUL 2.6 4cyl

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1984 Dodge Caravan

ENGINE OVERHAUL 1984 CHRYSLER CORP. ENGINES 2.6L 4-Cylinder

1984 CHRYSLER CORP. ENGINES 2.6L 4-Cylinder

ENGINE IDENTIFICATION CODES

l Intake valves (Left side).

viernes, 29 de mayo de 2020 07:56:01

Intake and Exhaust Valve

REMOVAL & INSTALLATION

See ENGINE REMOVAL - 4-CYL article at end of ENGINE Section.

CYLINDER HEAD & INTAKE MANIFOLD

Fig. 1: Cylinder Head Bolt Removal Sequence

Fig. 2: Installing Breather & Semi-Circular Seal

l Intake valves (Left side).

Valve Guide Servicing

VALVE GUIDE OVERSIZES

VALVE STEM-TO-GUIDE CLEARANCE

Fig. 3: Valve Guide Installation & Height

Valve Stem Oil Seals

Fig. 4: Valve Stem Oil Seal Installation & Height

Valve Seat Servicing

Fig. 5: Rocker Arm and Valve Assembly

Fitting Piston Pins

Fitting Piston Rings

Fig. 6: Piston Ring End Gap Positions

CONNECTING ROD BEARINGS

CONNECTING ROD JOURNALS

Standard 2.0860-2.0866 (52.985-53.000)

Fig. 7: Camshaft, Timing Chain, & Silent Shaft Assemblies

Fig. 8: Camshaft Installation Position

NOTE: Note bearing cap-rocker arm shaft mating marks.

Fig. 9: Camshaft Sprocket Alignment & Installation

Fig. 10: Silent Shaft Drive Chain Installation

NOTE: Timing marks on chain and sprockets must be aligned.

Fig. 11: Silent Shaft Chain Adjustment With Engine Installed

Right Silent Shaft

Fig. 12: Cutaway View Of Gear Type Oil Pump

Left Silent Shaft

Normal Oil Pressure

Pressure Regulator Valve

Valve is located in oil pump body and is not adjustable.

Fig. 13: Mating Marks For Oil Pump Gears

NOTE: Align marks and prime oil pump during installation.

OIL PUMP SPECIFICATIONS

Oil Pump Mount Bolt 71 (8)

GENERAL ENGINE SPECIFICATIONS

PISTONS, PINS & RINGS SPECIFICATIONS

PISTONS, PINS & RINGS SPECIFICATIONS

(1) Free to rotate after assembly

CRANKSHAFT MAIN & CONNECTING ROD BEARINGS SPECS

CRANKSHAFT MAIN & CONNECTING ROD BEARINGS SPECS

VALVE SPRINGS SPECIFICATIONS

VALVE SPRINGS SPECIFICATIONS

(2) Lbs. @ In. (Kg @ mm)

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