2011 Dodge Caravan & Grand Caravan Service & Repair Manual

2011-2016 DODGE CARAVAN SERVICE AND REPAIR MANUAL

2014 ENGINE 2.8L Diesel - Service Information - C/V Tradesman, Grand Caravan, Town & Country DESCRIPTION DESCRIPTION The 2.8L (2777cc) four-cylinder "common rail" direct injection engine is an in-line overhead valve design. The engine utilize a cast iron cylinder block. The engine has a one piece aluminum cylinder head with four valves per cylinder and dual overhead camshafts. The 2.8L is turbocharged, intercooled and also equipped with a EGR cooler. The identification stamp for the 2.8L is located on the right side of the engine block, below the turbocharger. The engine code label is located on the front timing cover and is the same as the engine I.D. and serial number. There is also a fuel system label on the front timing cover used for fuel system identification during Powertrain Control Module (PCM) programming. STANDARD PROCEDURE DUST COVERS AND CAPS Fig. 1: Covers/Caps Courtesy of CHRYSLER GROUP, LLC Due to the high amounts of failures caused by dust, dirt, moisture and other foreign debris being introduced to the engine during service. Covers or caps are needed to reduce the possible damage that can be caused or created. 2014 Dodge Grand Caravan SE 2014 ENGINE 2.8L Diesel - Service Information - C/V Tradesman, Grand Caravan, Town & Country 2014 Dodge Grand Caravan SE 2014 ENGINE 2.8L Diesel - Service Information - C/V Tradesman, Grand Caravan, Town & Country

Fig. 2: Opening Cover Courtesy of CHRYSLER GROUP, LLC Covers over openings will reduce any possibilities for foreign materials to enter the engine systems. Using miller tool (special tool #10368, Set, Universal Protective Cap), Select the appropriated cover needed to the procedure. ENGINE GASKET SURFACE PREPARATION Fig. 3: Proper Tool Usage For Surface Preparation Courtesy of CHRYSLER GROUP, LLC 1 - ABRASIVE PAD 2 - 3M ROLOC™ BRISTLE DISC 3 - PLASTIC SCRAPER 2014 Dodge Grand Caravan SE 2014 ENGINE 2.8L Diesel - Service Information - C/V Tradesman, Grand Caravan, Town & Country

To ensure engine gasket sealing, proper surface preparation must be performed, especially with the use of aluminum engine components and multi-layer steel cylinder head gaskets. Never use the following to clean gasket surfaces:  Metal scraper  Abrasive pad or paper to clean cylinder block and head  High speed power tool with an abrasive pad (1), or a wire brush Only use the following for cleaning gasket surfaces:  Solvent or a commercially available gasket remover  High speed power tool with an 3M Roloc™ Bristle Disc (2), Plastic scraper (3)  Sealing surfaces must be free of grease or oil residue. Clean surfaces with Mopar® brake parts cleaner (or equivalent) FORM-IN-PLACE GASKETS AND SEALERS There are numerous places where form-in-place gaskets are used on the engine. Care must be taken when applying form-in-place gaskets to assure obtaining the desired results.Do not use form-in-place gasket material unless specified. Bead size, continuity, and location are of great importance. Too thin a bead can result in leakage while too much can result in spill-over which can break off and obstruct fluid feed lines. A continuous bead of the proper width is essential to obtain a leak-free gasket. There are numerous types of form-in-place gasket materials that are used in the engine area. Mopar® Engine RTV GEN II, Mopar® ATF-RTV, and Mopar® Gasket Maker gasket materials, each have different properties and can not be used in place of the other. MOPAR® ENGINE RTV GEN II Mopar® Engine RTV GEN II is used to seal components exposed to engine oil. This material is a specially designed black silicone rubber RTV that retains adhesion and sealing properties when exposed to engine oil. Moisture in the air causes the material to cure. This material is available in three ounce tubes and has a shelf life of one year. After one year this material will not properly cure. Always inspect the package for the expiration date before use. MOPAR® ATF RTV Mopar® ATF RTV is a specifically designed black silicone rubber RTV that retains adhesion and sealing properties to seal components exposed to automatic transmission fluid, engine coolants, and moisture. This material is available in three ounce tubes and has a shelf life of one year. After one year this material will not properly cure. Always inspect the package for the expiration date before use. MOPAR® GASKET MAKER NOTE: Multi-Layer Steel (MLS) head gaskets require a scratch free sealing surface. 2014 Dodge Grand Caravan SE 2014 ENGINE 2.8L Diesel - Service Information - C/V Tradesman, Grand Caravan, Town & Country

Mopar® Gasket Maker is an anaerobic type gasket material. The material cures in the absence of air when squeezed between two metallic surfaces. It will not cure if left in the uncovered tube. The anaerobic material is for use between two machined surfaces. Do not use on flexible metal flanges. MOPAR® GASKET SEALANT Mopar® Gasket Sealant is a slow drying, permanently soft sealer. This material is recommended for sealing threaded fittings and gaskets against leakage of oil and coolant. Can be used on threaded and machined parts under all temperatures. This material is used on engines with multi-layer steel (MLS) cylinder head gaskets. This material also will prevent corrosion. Mopar® Gasket Sealant is available in a 13 oz. aerosol can or 4oz./16 oz. can with applicator. MOPAR® THREEBOND ENGINE RTV SEALANT MOPAR® THREEBOND ENGINE RTV SEALANT is a unique gasket material that is specially made to retain adhesion and sealing properties when used to seal components exposed to engine oil. FORM-IN-PLACE GASKET AND SEALER APPLICATION Assembling parts using a form-in-place gasket requires care but it's easier than using precut gaskets. Mopar® Gasket Maker material should be applied sparingly 1 mm (0.040 in.) diameter or less of sealant to one gasket surface. Be certain the material surrounds each mounting hole. Excess material can easily be wiped off. Components should be torqued in place within 15 minutes. The use of a locating dowel is recommended during assembly to prevent smearing material off the location. Mopar® Engine RTV GEN II or ATF RTV gasket material should be applied in a continuous bead approximately 3 mm (0.120 in.) in diameter. All mounting holes must be circled. For corner sealing, a 3.17 or 6.35 mm (1/8 or 1/4 in.) drop is placed in the center of the gasket contact area. Uncured sealant may be removed with a shop towel. Components should be torqued in place while the sealant is still wet to the touch (within 10 minutes). The usage of a locating dowel is recommended during assembly to prevent smearing material off the location. Mopar® Gasket Sealant in an aerosol can should be applied using a thin, even coat sprayed completely over both surfaces to be joined, and both sides of a gasket. Then proceed with assembly. Material in a can with applicator can be brushed on evenly over the sealing surfaces. Material in an aerosol can should be used on engines with multi-layer steel gaskets. COMPRESSION TEST 2014 Dodge Grand Caravan SE 2014 ENGINE 2.8L Diesel - Service Information - C/V Tradesman, Grand Caravan, Town & Country

Fig. 4: Compression Tester Courtesy of CHRYSLER GROUP, LLC 1. Warm up the engine to operating temperature (approximately 80 degrees C). 2. Shut off the engine. 3. Disable the low pressure fuel pump. 4. Remove the fuel injectors. Refer to INJECTOR(S), FUEL, REMOVAL . 5. Cranks the engine with the starter to remove combustion residue in the cylinders. 6. Install the (special tool #VM.10010, Adapter, Compression Test) into the fuel injector bore of the cylinder to be tested. Install the fuel injector retainer, bolt and securely tighten. 7. Test compression pressure by cranking the engine with the starter for at least eight revolutions. 8. Measure the pressure in all of the cylinders. 9. Remove the (special tool #VM.10010, Adapter, Compression Test). 10. Install the fuel injectors. Refer to INJECTOR(S), FUEL, INSTALLATION . SPECIFICATIONS ENGINE SPECIFICATIONS Cylinder compression Difference Between Cylinders 10 Bar (145 psi) 2.8L Engine Specifications Engine 2.8L RT Engine Type 2.8L - 16 Valves 2014 Dodge Grand Caravan SE 2014 ENGINE 2.8L Diesel - Service Information - C/V Tradesman, Grand Caravan, Town & Country

Displacement 2776 cc Bore 94.00 Stroke 100.00 Power (VGT) 120 kW (163 CV) @ 3800 RPM Torque (ATX) 360 N.m @ 1800 RPM ±2000 RPM Cylinders 4 In line Injection Order 1-3-4-2 Compression Ratio 16.5:1 Vacuum at idle 600 mm/HG (27.5 In/HG) @ 800 RPM Idle Speed (ATX) 815 ± 100 RPM Maximum RPM in Gear 4600 RPM ± 80 RPM Maximum RPM in neutral ATX 3000 ± 50 RPM Belt tension Automatic Belt Tensioner Thermostat opening 90°C ± 2°C Generator Rating Denso 12V-220A Glow Plug 4.4V Emissions Level EU5 Block configuration/Material Open/Cast Iron Cylinder Head Dual Overhead Cam Timing System Belt Fuel System CP1H HP 1800 bar (26.106 psi) Fuel Pump, Piezo Injectors Fuel Supply Electric Fuel Pump In the Fuel Tank Electronic Control Unit EDC 17 Timing System Belt Driven DOHC Overhead Camshaft Air Intake Dry Filter With turbocharger and Charge Air Cooler Fuel System Direct Fuel Injection Common Rail System Emission devices Cooled EGR (electric DC motor) Electric Intake Throttle Fast Metallic Glow plugs Combustion Cycle 4 Stroke Cylinder Compression Difference Between Cylinders 10 bar (145 psi) Cooling System Water Cooling Pressure Cap Setting 14 psi Turbocharger Single VGT with REA Intake Ports Aluminum heads with traditional dual side intake and exhaust ports. One intake port is helical and the other has a directed entry. Crankshaft 8 Counterweights with an incorporated balance shaft gear. 2 overhead camshafts with axial front bearings 2014 Dodge Grand Caravan SE 2014 ENGINE 2.8L Diesel - Service Information - C/V Tradesman, Grand Caravan, Town & Country

Camshafts and identical camshaft caps, finger followers, and hydraulic lifters. Intake AND Exhaust Valves Flat with fire deck face. Intake Manifold Plastic, with integrated swirl control flap and actuator Lubrication Pressure Lubricated By Rotary Pump Minimum Oil Pressure (warm) 0.7 BAR (10 psi) at idle / 2.5 BAR (36 psi) at 3800 RPM Engine Rotation Clockwise Viewed From Front Cover Engine Oil Capacity with Oil Filter 6.5 Liters (6.9 Quarts) 2.8L Engine Specifications Cylinder Head Cylinder head height 135.5 mm (5.334 in.) Cylinder head flatness deformation tolerance 0.075 mm (0.003 in.) Cylinder Head Gasket Thickness 0 Hole 1.10 mm (0.043 in) 1 Hole 1.20 mm (0.047 in) 2 Holes 1.30 mm (0.051 in) Intake Manifold Intake manifold flatness deformation tolerance 0.15 mm (0.006 in.) Exhaust Manifold Exhaust manifold flatness deformation tolerance 0.1 mm (0.004 in.) Tappets Hydraulic tappet outside diameters 11.994 mm ± 0.06 mm (0.472 in ± 0.002) Valves Intake valve face angle 45°30' Exhaust valve face angle 45°30' Intake Valve Head Diameter 32 mm (1.25 in.) Exhaust Valve Head Diameter 29.4 mm (1.15 in.) Intake Valve Stem Diameter 5.97 mm (0.235 in.) Exhaust Valve Stem Diameter 5.96 mm (0.235 in.) Intake Valve Guide Stem Clearance Min 0.030 mm (0.0012 in.) Max 0.060 mm (0.0024 in.) Exhaust Valve Guide Stem Clearance Min 0.040 mm (0.0016 in.) Max 0.070 mm (0.0028 in.) Valve Springs Free Length 50.8 mm (2 in.) Closed Valve 38 mm (1.49 in.) 2014 Dodge Grand Caravan SE 2014 ENGINE 2.8L Diesel - Service Information - C/V Tradesman, Grand Caravan, Town & Country

Opened Valve 29 mm (1.14 in.) Camshafts Camshaft End Play Min 0.150 mm (0.006 in.) Max 0.350 mm (0.013 in.) Outer Journal Diameter (at crankshaft) 25.95 mm ± 0.01 mm (1.021 mm ±.0004 in) Inner Journal Diameter (at cylinder head) 26.00 mm + 0.015 mm (1.027 in =.0006 in) Crankshaft Journal Clearance Max 0.075 mm (0.003 in.) Min 0.030 mm (0.0012 in) Connecting Rods Connecting Rod Diameter (Small End) 32 mm (1.26 in.) Connecting Rod Diameter (Large End) 57.563 mm (2.266 in.) Piston Pin Diameter 32 mm (1.26 in.) Length: Federal Mogul 74 mm ± 0.3 mm (2.9 in. ± 0.3 in.) Crankshaft End Play 0.1 mm - 0.34 mm (0.004 in. - 0.013 in.) Bearing Selection. Refer to BEARING(S), CRANKSHAFT, STANDARD PROCEDURE . Engine Block Cylinder Bore Internal Diameter 94 mm (3.700 in.) Cylinder Bore Out-Of-Round (Roundness) 0.009 mm (0.0003 in.) Oversized Piston +0.40 mm (+0.015 in.) Fuel System Injection Pressure 1800 Bar (26.106 psi) High Pressure Pump CP1H ECU EDU 17 Injectors Piezo CRI 3.2 Glow Plugs Make/Type Bosch / GLP2 HS Voltage 4.4V Lubrication System Oil Pump Outer Rotor End Play Min 0.01 (0.0004 in.) Max 0.09 (0.0036 in.) Oil Pump Inner Rotor End Play Max 0.01 mm (0.0004 in.) Min 0.09 mm (0.0036 in.) Oil Pump Outer Rotor to Body Diameter Clearance Max 0.130 mm (0.052 in.) Min 0.230 mm (0.0091 in) 2014 Dodge Grand Caravan SE 2014 ENGINE 2.8L Diesel - Service Information - C/V Tradesman, Grand Caravan, Town & Country

TORQUE ENGINE BLOCK Opening Pressure 5 Bar (73 psi) Oil Pressure Valve Spring Free Length 46.8 mm (1.84 in) Minimum Oil Pressure (Warm) at Idle 0.7 Bar (10 psi) at 3800 RPM 2.5 Bar (36 psi) Cooling System Thermostat Opening Temperature 90°C (194°F) Pressure Cap Setting 1.2 Bar (17 psi) Engine Oil Specification. Refer to CAPACITIES AND RECOMMENDED FLUIDS, DESCRIPTION . Coolant Specification. Refer to CAPACITIES AND RECOMMENDED FLUIDS, DESCRIPTION . Cylinder Head Gasket Selection Millimeters Inches DISTANCE FROM PISTON AT TDC TO CYLINDER BLOCK 0.300 - 0.399 0.0119 - 0.0158 CYLINDER HEAD GASKET THICKNESS 1.10 0.0434 PISTON CLEARANCE 0.700-0.800 0.0276 -0.0315 DISTANCE FROM PISTON AT TDC TO CYLINDER BLOCK 0.400 - 0.499 0.0158 - 0.0197 CYLINDER HEAD GASKET THICKNESS 1.20 0.0473 PISTON CLEARANCE 0.700-0.800 0.0276 -0.0315 DISTANCE FROM PISTON AT TDC TO CYLINDER BLOCK 0.500 - 0.600 0.0197 - 0.0237 CYLINDER HEAD GASKET THICKNESS 1.30 0.0512 PISTON CLEARANCE 0.700-0.800 0.0276 -0.0315 DESCRIPTION N.m Ft. Lbs. In. Lbs. Balance Shaft 33 24 - Connecting Rod Caps Specific fastener placement and torque pattern is required. Refer to ROD, PISTON AND CONNECTING, INSTALLATION . Dipstick Tube (block) 11 - 97 Dipstick Tube (sump) 11 - 97 Engine Mounts and Brackets Specific fastener placement and torque pattern is required (Refer to ENGINE MOUNTING ) Fuel Quantity Solenoid 7 - 62 2014 Dodge Grand Caravan SE 2014 ENGINE 2.8L Diesel - Service Information - C/V Tradesman, Grand Caravan, Town & Country

2011 Dodge Caravan & Grand Caravan Service & Repair Manual

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