Caravan, Grand Voyager, Town and Country, Voyager, 2000-2004

Camshaft, Bearings & Lifters

Print

Inspection



  1. Inspect the camshaft bearing journals for wear or damage.
  2.  
  3. Inspect the cylinder head and check oil return holes.
  4.  
  5. Check the tooth surface of the distributor drive gear teeth of the right camshaft for wear or damage.
  6.  
  7. Check both camshaft surfaces for wear or damage.
  8.  
  9. Remove the distributor drive adaptor seal.
  10.  
  11. Check camshaft lobe height and replace if out of limit. Standard value is 1.61 in. (41mm).
  12.  

Removal & Installation



2.4L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    The bearing caps are marked for location, Remove the outside caps first. The caps are not interchangeable the intake cam # 6 thrust bearing face spacing is wider.



    Negative battery cable
     
    Valve cover
     
    Camshaft Position (CMP) sensor and camshaft target magnet
     
    Timing belt
     
    Camshaft sprockets
     
    Rear timing cover
     

  4.  
  5. Make sure to identify the caps before removal, then loosen the caps in the sequence illustrated one at a time and remove the camshafts and cam followers. Always make sure to remove the outside bearing caps first.

    Click image to see an enlarged view

    Fig. The camshaft bearing caps are marked for location-2.4L engines



    Click image to see an enlarged view

    Fig. Camshaft bearing caps removal sequence-2.4L engines

  6.  

To install:


NOTE
Make sure none of the pistons are at Top Dead Center (TDC) when installing the camshafts.

  1. Install or connect the following:

    Lubricate then install the cam followers in their original positions
     
    Lubricate then install the camshafts
     

  2.  
  3. Install right and left camshaft bearing caps 2-5 and right # 6. Tighten the M6 fasteners to 105 inch lbs. (12 Nm) in the sequence illustrated.
  4.  
  5. Apply a 0.060 (1-1.5mm) bead of gasket maker to the # 1 and # 6 bearing caps. Install the bearing caps in their original positions and tighten the M8 fasteners to 250 inch lbs. (28 Nm)

    Camshaft oil seals
     
    Camshaft target magnet and CMP sensor
     
    Valve cover
     
    Rear timing cover
     
    Timing belt idler pulley
     
    Camshaft sprockets. Tighten the bolts to 75 ft. lbs. (101 Nm).
     
    Timing belt
     
    Front cover
     
    Negative battery cable
     

  6.  
  7. Start the engine and check for proper operation.

    Click image to see an enlarged view

    Fig. Apply a 0.060 (1-1.5mm) bead of gasket maker to the # 1 and # 6 bearing caps-2.4L engines



    Click image to see an enlarged view

    Fig. Camshaft bearing caps tightening sequence-2.4L engines

  8.  

3.0L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner and hoses
     
    Accessory drive belts
     
    Front cover
     
    Timing belt.
     
    Valve covers
     

  4.  
  5. Install Lash Adjuster Retainers tools MD-998443.
    NOTE
    Keep all valvetrain components in order for assembly.

  6.  
  7. Remove or disconnect the following:

    Rocker arm and shaft assemblies
     
    Lash adjuster retainers
     
    Lash adjusters
     
    Camshaft sprockets
     
    Distributor
     
    Distributor drive adapter housing
     
    Camshaft oil seals
     
    Camshafts
     

  8.  

To install:

  1. Install or connect the following:

    Camshafts
     
    Lash adjusters
     
    Lash adjuster retainers
     

  2.  
  3. Install the rocker arm and shaft assemblies in their original positions and tighten the bearing cap bolts, as follows:


    1. Step 1: Cap No. 3 bolts to 85 inch lbs. (10 Nm).
    2.  
    3. Step 2: Cap No. 2 bolts to 85 inch lbs. (10 Nm).
    4.  
    5. Step 3: Cap No. 1 bolts to 85 inch lbs. (10 Nm).
    6.  
    7. Step 4: Cap No. 4 bolts to 85 inch lbs. (10 Nm).
    8.  
    9. Step 5: Cap No. 3 bolts to 15 ft. lbs. (20 Nm).
    10.  
    11. Step 6: Cap No. 2 bolts to 15 ft. lbs. (20 Nm).
    12.  
    13. Step 7: Cap No. 1 bolts to 15 ft. lbs. (20 Nm).
    14.  
    15. Step 8: Cap No. 4 bolts to 15 ft. lbs. (20 Nm).
    16.  
    17. Remove the lash adjuster retainers.
    18.  

  4.  
  5. Install or connect the following:

    Camshaft oil seals
     
    Distributor drive adapter housing
     
    Distributor
     
    Camshaft sprockets
     
    Timing belt.
     
    Front cover
     
    Accessory drive belts
     
    Air cleaner and hoses
     
    Negative battery cable
     

  6.  
  7. Start the engine and check for proper operation.
  8.  

3.3L & 3.8L Engines

NOTE
Keep all valvetrain components in order for assembly.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the engine from the vehicle and mount it on a stand.
  4.  
  5. Remove or disconnect the following:

    Valve covers
     
    Rocker arm and shaft assemblies
     
    Pushrods
     
    Intake manifold
     
    Cylinder heads
     
    Yoke retainer
     
    Aligning yokes
     
    Hydraulic lifters
     
    Oil pan
     
    Oil pump pickup tube
     
    Crankshaft pulley
     
    Front cover
     
    Timing chain and sprockets
     
    Camshaft thrust plate
     
    Camshaft
     

  6.  

To install:

  1. Install or connect the following:

    Camshaft
     
    Camshaft thrust plate. Torque the bolts to 105 inch lbs. (12 Nm).
     
    Timing chain and sprockets. Torque the camshaft sprocket bolt to 40 ft. lbs. (54 Nm).
     
    Front cover. Torque the bolts to 20 ft. lbs. (27 Nm).
     
    Crankshaft pulley. Torque the bolt to 40 ft. lbs. (54 Nm).
     
    Oil pump pickup tube
     
    Oil pan
     
    Hydraulic lifters
     
    Aligning yokes
     
    Yoke retainer. Torque the bolts to 105 inch lbs. (12 Nm).
     
    Cylinder heads
     
    Intake manifold
     
    Pushrods
     
    Rocker arm and shaft assemblies
     
    Valve covers
     

  2.  
  3. Install the engine to the vehicle.

    Click image to see an enlarged view

    Fig. Remove the thrust plate and withdraw the camshaft from the engine-3.3L and 3.8L engines

  4.  

 
label.common.footer.alt.autozoneLogo