2000 - 2007 Dodge Caravan 2.4L Engine Torque Specs

2002 Dodge Caravan 2.4L Complete Torque Specs List

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Dodge Caravan 2.4L DOHC Repair Information

Dodge Caravan 2.4L DOHC Engine Repair Information

Here you can find information regarding the assembly of the Dodge 2.4L DOHC engine. In this guide we will start from the inside of the engine including the crankshaft, connecting rods, and piston ring installation and then move outwards all the way to the pulley belt system. Along the way correct procedures and torque specs will be given to aid in the assembly of the engine. Feel free to start from the beggining and work your way outwards or skip ahead to your current position in the engine for what you may need.

Crankshaft Main Caps Installation

Dodge 2.4L engine block
The 2.4L engine block main bearing caps should be inspected for any defects or flaws before installation. Be sure to lubricate the bearing surfaces prior to installation. Once prepared you can place the caps onto the crankshaft and begin tightening the bolts down in a multi stage process. The larger main bearing bolts can be torqued down to 60 ft-lbs in a cross pattern starting from the middle of the engine and working outwards. The smaller of the bearing cap bolts can be torqued down to 22 ft-lbs in a similar method. Be sure to go through each bolt during each step and work your way from the inside or middle caps to the outside or outwards bearing caps. Once finished you should be good to continue with the rest of the engine.

Dodge Caravan 2.4L Main Cap Bolts Torque Specs (M11): 60 ft-lbs

Dodge Caravan 2.4L Main Cap Bolts Torque Specs (M8): 22 ft-lbs

 

Piston and Connecting Rod Installation

Dodge 2.4L DOHC piston ring installation
To install the pistons and connecting rods you must first install the piston rings into each piston. Be careful not to stretch the rings or break them during installation. Make sure to put the correct rings in the correct positions, this can be determined by looking at the instructions given with the new rings. Each ring manufacturer is different so be sure to check for your specific rings. Once the rings have been installed you can now fit the connecting rod bearings into the end caps and lube them up with oil or lithium grease. The piston can now be lowered into the cylinder, make sure the dot or mark is facing the front of the engine and that you don't scratch the cylinder. Once installed you can match the connecting rod caps with the correct rods and start to torque the connecting rod bolts to 10 ft-lbs and then to 20 ft-lbs followed by an additional 90 degree turn for each bolt. After all are done rotate the crank to ensure all pistons move smoothly in and out of their cylinders and nothing binds.

Dodge Caravan 2.4L DOHC Connecting Rod Torque Specs : 20 ft-lbs + 90°

 

Oil Pump Installation

Dodge 2.4L DOHC oil pump installation
When installing the oil pump be sure to use the proper sealant around the pump base if neccessary to ensure that oil pressure doesn't drop due to leakage. Both surfaces should be cleaned and preped prior to installing. After preparing the contact surfaces carefully install the oil pump onto the engine and torque down the pump mounting bolts to 20 ft-lbs. Be sure to tighten down the bolts in a cross pattern to ensure that even torque is applied to the pump. From here we can install the oil pump cover and torque down its bolts to 8 ft-lbs.

Dodge Caravan 2.4L Oil Pump Mounting Bolts Torque Specs : 20 ft-lbs

Dodge Caravan 2.4L Oil Pump Cover Bolts Torque Specs : 8 ft-lbs

Dodge Caravan 2.4L Oil Pump Pickup Tube Torque Specs : 20 ft-lbs

 

Cylinder Head Installation

Dodge 2.4L DOHC cylinder head installation
The first thing you must do when installing cylinder heads is to ensure both the block and head surfaces are completely clean from dust, oil, and any debris. The next thing you must to is to set the camshafts to their correct positions to prevent any valves from hitting pistons during installation and torquing of the head bolts. Much the same you have to set the pistons to their correct locations, typically this means putting the #1 piston to TDC or Top Dead Center. Once everything is ready you can install the head gasket onto the engine block by aligning the alignment dowels. Something I usually do is spray down the head gasket with some engine copper spray from permatex which you can find here, this ensures that any gaps that could be present between the 2 surfaces gets filled with the spray. It also helps to transfer heat between the 2 metals. With the gasket in place you can set the cylinder head onto the gasket and block, if needed have someone assist with this process as the head can be heavy and you don't want to scratch anything or drop it! Once the head has been set in place you will want to start installing the head bolts to make sure it doesn't move. Be sure to buy new head bolts as many manufacturers use TTY or Torque to Yield head bolts meaning they stretch during torqueing and cannot be used twice. Also make sure to lubricate the bolts in clean engine oil before installing them into the head. On Dodge DOHC engines there is occasionally bolt holes on the engine block that cross into water passages. Any hole that does this should be installed with some silicon sealant. A little goes a long way in this step and you can check holes by shining a flashlight down them and looking in the water jackets. Once all the head bolts have been installed and finger tightened you can start the torqueing process, almost all head bolts have a multi-step process for torqueing. The 2.4L DOHC engine uses a single size of cylinder head bolts with a total of 10 bolts being installed into the cylinder head. These head bolts should be tightened down to 22 ft-lbs and then 60 ft-lbs followed by an additional 90 degree turn. Make sure to now overturn or underturn any bolt as this can cause an unbalance of surface pressure between the gasket and head.

Dodge Caravan 2.4L DOHC Cylinder Head Torque Specs : 60 ft-lbs + 90°

 

Timing Belt and Camshaft Installation

Dodge 2.4L Timing chain installation
On the Dodge 2.4 DOHC engine the timing system is ran by the use of a timing belt. This belt system consists of a sprocket on each of the camshafts along with 2 idler sprockets and the water pumps sprocket. To install the timing system on this engine you must start with installing the idler sprocket and the tensioner sprocket by torqueing down the idler sprocket to 20 ft-lbs and the tensioner sprocket to 50 ft-lbs. From here you can install the camshafts onto the cylinder head and torque down the camshaft bearing cap bolts to 8 ft-lbs starting from the middle caps and working your way outwards. Be sure that the engines number 1 piston is at TDC prior to torqueing down the camshafts otherwise engine damage could occur. Once both of the camshafts have been installed we can install the camshaft timing sprockets and torque down the sprocket bolts to 85 ft-lbs. From here we can slide the crankshaft sprocket onto the crank by aligning the woodruff key slot and sliding it on. Make sure that you have the water pump installed as its pulley is apart of the timing belt system. For more information regarding the water pump installation please refer to the water pump portion on this web page. From here we can align the timing sprockets up with the corresponding marks shown in the picture. The belt can now be set in place by tensioning the tensioner and aligning the sprocket grooves with the belt grooves. Once aligned properly you can release the tensioner and the belt should stay in place. With that we can move onto installing the timing cover.

Dodge Caravan 2.4L Camshaft Sprocket Bolts Torque Spec: 85 ft-lbs

Dodge Caravan 2.4L Camshaft Bearing Cap Bolts Torque Spec : 8 ft-lbs

Dodge Caravan 2.4L Timing Belt Idler Bolt Torque Spec : 20 ft-lbs

Dodge Caravan 2.4L Timing Belt Tensioner Bracket Torque Spec : 20 ft-lbs

Dodge Caravan 2.4L Timing Belt Tensioner Sprocket Bolt Torque Spec : 50 ft-lbs

Dodge Caravan 2.4L Crankshaft Position Sensor Torque Spec: 8 ft-lbs

 

Timing Cover Installation

Dodge 2.4L Timing cover installation
The timing cover on the 2.4L engine is not as critical as other engines timing covers as it does not retain any engine oil from leaking outside of the system. Instead the timing cover on this engine protects the timing belt system from dirt and debris that can be picked up while driving. While less critical of a job it is still important to install the timing belt cover correctly otherwise belt damage will occur and you will be replacing it often. The timing belt cover can be installed without any additional silicon but rather just the stock standard gasket provided. The timing cover bolts can be torqued down to 8 ft-lbs.

Dodge Caravan 2.4L Timing Cover Bolts Torque Specs : 8 ft-lbs

 

Oil Pan Installation

Dodge 2.4L Oil Pan installation
Much like the timing cover on the 2.4L the oil pan plays an important role in keeping the engine oil inside the engine. For this reason I recommend using a new gasket as well as some silicone sealant during installation. Using the same technique as before with the cover you clean the surfaces of both the oil pan and the engine block and then install the new gasket onto the block and then follow it up with some silicone sealant. Be sure to follow your sealants instructions to ensure you get the best seal from your application. The oil pan bolts can be torqued down to 8 ft-lbs in a cross pattern. Along with the pan is the oil pan drain plug, this gets removed and reinstalled quite frequently and can be torqued down to 25 ft-lbs.

Dodge Caravan 2.4L Oil Pan Bolts Torque Spec : 8 ft-lbs

Dodge Caravan 2.4L Oil Drain Plug Torque Specs : 25 ft-lbs

 

Valve Covers Installation

Dodge 2.4L Valve Cover installation
The valve cover installation is rather simple, there are rubber seals for each bolt hole and a silicone gasket that prevents oil from leaking out of the engine. It is recommended to replace both the seals and the gaskets although if they are in good condition you can reuse them. If you do choose to reuse them I would use some silicone sealant along with the silicon gasket to ensure it does not leak. The valve cover bolts torque down to 106 in-lbs or about 8 ft-lbs in a criss cross order. Be sure not to miss any bolts to avoid having oil leak out onto the exhaust pipes and cause a lot of smoking.

Dodge Caravan 2.4L Valve Cover Torque Specs : 8 ft-lbs

 

Intake Manifold and Fuel Rail Installation

Dodge 2.4L Intake Manifold installation
When installing the intake manifold you want to make sure you have all the surfaces as well as intake holes cleaned out before placing the manifold into position. Once cleaned you can then place the intake manifold gaskets onto the alignment pins. If you want you can also use a little bit of sealant on the gaskets to help ensure there are no leaks. With the gaskets in place you can now put the manifold down onto the gaskets and begin to install the bolts. The intake manifold bolts torque to 20 ft-lbs and can be tightened in a cross pattern. The ignition coil assembly can be torque down to 8 ft-lbs and the spark plugs themselves can be torqued down to 13 ft-lbs, be careful not to overtorque these as they can snap and cause big problems. When installing the throttle body make sure that all of the gaskets are in good condition and will hold a seal as you do not want to be leaking gas fumes around the engine. If everything looks good you can tighten the throttle body bolts down to 8 ft-lbs.

Dodge Caravan 2.4L Intake Manifold Torque Specs : 20 ft-lbs

Dodge Caravan 2.4L Ignition Coil Assembly Torque Spec : 8 ft-lbs

Dodge Caravan 2.4L Spark Plug Torque Specs : 13 ft-lbs

Dodge Caravan 2.4L Throttle Body Torque Specs : 8 ft-lbs

 

Exhaust Manifold Installation

Dodge 2.4L Exhaust Manifold installation
The exhaust manifold can be installed by cleaning the surface areas on both the head an the manifold itself and then by using the exhaust manifold gasket and putting it in place. Once the gasket is in its location you can put the manifold onto the heads and begin to torque them down to 18 ft-lbs. I always use some copper spray from permatex on the exhaust manifold gaskets to ensure I do not end up with any exhaust leaks once done. When you go to install the engine into the vehicle or if it is already in the vehicle the torque specs for the exhaust manifold to the exhaust pipes or catalytic converter is 25 ft-lbs.

Dodge Caravan 2.4L Exhaust Manifold Torque Spec : 18 ft-lbs

Dodge Caravan 2.4L Exhaust Pipe Torque Specs : 25 ft-lbs

 

Water Pump and Thermostat Installation

Dodge 2.4L Water Pump installation
The water pump on the Dodge 2.4L engine gets tightened down to the engine block on the serpentine belt side and is ran off of the timing belt. When removing the old water pump be sure that you drain out the coolant prior to removal otherwise the coolant will spill all over. Once drained you can remove the water pump mounting bolts and remove the old pump from the vehicle. From here we can clean up the engine blocks mating surface and prepare the new water pump for installation. Be sure to use a new gasket and some silicon sealant to ensure that no coolant ends up leaking and causes further engine damage down the road. Once prepared you can install the pump onto the engine and hand tighten the bolts down. Once all of the bolts have been installed you can then torque down the bolts to 8 ft-lbs. Make sure to follow your sealants instructions as they often require you to wait an extended amount of time before torqueing down the bolts.

Dodge Caravan 2.4L Water Pump to Block Torque Specs : 8 ft-lbs

 

Front Dress and Pulley belt Installation

Dodge 2.4L Pulley and Belt installation
Most of what is left on the engine is just place and tighten objects such as the belt pulleys, belt tensioner, throttle body, oil filter neck, crankshaft pulley, and motor mounts. If the items have a gasket and hold either oil or coolant inside the engine then feel free to add some sealant along with the gasket. Always be sure to inspect your gaskets and replace them if there is any deteriation or flaws with them. For the belt system the crankshaft pulley gets tightened down to the crankshaft at 105 ft-lbs. The drive belt tensioner can be tightened to 33 ft-lbs and the idler pulley can be torqued down to 16 ft-lbs. When installing be sure they both turn smoothly and if they do not then replace them with new ones as the bearings can go bad. The engine motor mount can be installed onto the engine block if it hasn't been already, the torques for the mount to the block is 59 ft-lbs and then when installing the mount to the vehicle or frame it can be torqued to 35 ft-lbs. Finally the throttle body can be installed on top of the intake manifold with a good gasket and some added sealant using 7 ft-lbs in a criss cross pattern. For installing the belt you can use a tool to move the tensioner into its springed state and install the belt as shown in the picture. The generator or alternator can be tightened down to the engine block using 17 ft-lbs of force. The power steering pump can be installed and torqued down to 18 ft-lbs and finally the A/C compressor can be torqued down to 15 ft-lbs of force.

Dodge Caravan 2.4L Crankshaft Pulley Torque Specs : 105 ft-lbs

Dodge Caravan 2.4L Idler Pulley Bolt Torque Spec : 16 ft-lbs

Dodge Caravan 2.4L Drive Belt Tensioner Torque Specs : 33 ft-lbs

Dodge Caravan 2.4L Motor Mount to Engine Torque Specs : 59 ft-lbs

Dodge Caravan 2.4L Motor Mount to Frame Torque Specs : 35 ft-lbs

Dodge Caravan 2.4L Alternator to Block Torque Specs : 17 ft-lbs
Dodge Caravan 2.4L Power Steering Pulley Torque Specs : 18 ft-lbs
Dodge Caravan 2.4L A/C Compressor to Block Torque Specs : 15 ft-lbs

 


Timing Torque Specs
Timing Belt Cover Bolts Torque spec 8 ft-lbs
Camshaft Timing Sprocket Bolts Torque Specs 85 ft-lbs
Camshaft Bearing Cap Bolts Torque Specs 8 ft-lbs
Timing Belt Idler Bolt Torque Specs 20 ft-lbs
Timing Belt Tensioner Bracket Bolts Torque Specs 20 ft-lbs
Timing Belt Tensioner Sprocket Bolt Torque Specs 50 ft-lbs
Crankshaft Position Sensor Torque spec 8 ft-lbs
Cylinder Head Torque Specs
Cylinder Head Bolts Torque Specs 60 ft-lbs + 90°
Valve Cover Torque specs 8 ft-lbs
Exhaust Manifold Bolts Torque specs 18 ft-lbs
Exhaust Manifold to Pipe Torque 25 ft-lbs
Bottom End Torque's
Main Bearing Large Cap Bolts Torque Spec 60 ft-lbs
Main Bearing Small Cap Bolts Torque Spec 22 ft-lbs
Connecting Rod Bolts Torque Spec 20 ft-lbs + 90°
Oil Pump Mounting Bolts Torque Spec 20 ft-lbs
Oil Pump Cover Bolts Torque Spec 8 ft-lbs
Oil Pump Pickup Tube Torque Spec 20 ft-lbs
Oil Pan Bolts Torque Spec 8 ft-lbs
Oil Pan Drain Plug Torque Spec 25 ft-lbs
Intake Manifold and Fuel Rail Torque Spec
Intake Manifold 20 ft-lbs
Fuel Rail Torque Specs 5 ft-lbs
Spark Plugs Torque Specs 13 ft-lbs
Throttle Body Torque Specs 8 ft-lbs
Ignition Coil Assembly Torque Spec 8 ft-lbs
Water Pump & Pulley Torque Specs
Water Pump to Block Torque Specs 13 ft-lbs
Water Pump Pulley Bolts Torque Specs 19 ft-lbs
Crankshaft Pulley Bolt Torque Spec 105 ft-lbs
Drive Belt Tensioner Bolt Torque Spec 33 ft-lbs
Belt Idler Pulley Bolt Torque Spec 16 ft-lbs
Motor Mount (Engine Side) Torque 59 ft-lbs
Motor Mount (Frame Side) Torque 35 ft-lbs
Alternator to Block Bolts Torque Spec 17 ft-lbs
Power Steering Pump Bolts Torque Spec 18 ft-lbs
A/C Compressor to Block Torque Spec 15 ft-lbs