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

Cylinder Head

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Removal & Installation



3.0L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Right inner splash shield
     
    Accessory drive belts
     
    Alternator
     
    A/C compressor and bracket
     
    Right motor mount
     
    Front cover
     
    Timing belt.
     
    Camshaft sprockets
     
    Rear timing cover
     
    Alternator bracket
     
    Spark plug wires
     
    Distributor
     
    Valve covers
     
    Intake manifold
     
    Exhaust front pipe
     
    Exhaust crossover pipe
     
    Exhaust manifolds
     
    Cylinder heads
     

  8.  

To install:

Click image to see an enlarged view

Fig. Cylinder head torque sequence-3.0L engine

  1. Install or connect the following:

    Cylinder heads. Tighten the bolts in sequence and in several passes to 80 ft. lbs. (108 Nm).
     
    Exhaust manifolds
     
    Exhaust crossover pipe
     
    Exhaust front pipe
     
    Intake manifold
     
    Valve covers
     
    Distributor
     
    Spark plug wires
     
    Alternator bracket
     
    Rear timing cover
     
    Camshaft sprockets. Tighten the bolts to 70 ft. lbs. (95 Nm).
     
    Timing belt
     
    Front cover
     
    Right motor mount. Tighten the frame rail bolts to 50 ft. lbs. (68 Nm), the vertical fastener to 75 ft. lbs. (102 Nm) and the horizontal fastener to 111 ft. lbs. (150 Nm).
     
    A/C compressor and bracket
     
    Alternator
     
    Accessory drive belts
     
    Right inner splash shield
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine, check for leaks and repair if necessary.
  6.  

3.3L & 3.8L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:
    CAUTION
    The intake manifold gaskets are made of a very thin metal and can cause injury if not properly handled.


    NOTE
    Keep all valvetrain components in order for assembly



    Negative battery cable
     
    Wiper module if removing the right cylinder head
     
    Upper and lower intake manifolds
     



    Valve covers.
     
    Spark plugs
     
    Dipstick tube
     
    Exhaust manifolds
     



    Rocker arm and shaft assemblies
     
    Cylinder head bolts, heads and gaskets
     

  8.  
  9. Clean all gasket mating surfaces.
  10.  

To install:

  1. Examine the cylinder head bolts and replace any that have stretched.

    Click image to see an enlarged view

    Fig. Cylinder head torque sequence-3.3L and 3.8L engines

  2.  
  3. Install the cylinder head with a new gasket. The left bank gasket has an L on it and is located at the front of the engine. The right gasket has an R stamped on it and is located at the rear of the engine. Tighten the bolts in sequence, as follows:


    1. Step 1: Tighten bolts 1-8 to 45 ft. lbs. (61 Nm).
    2.  
    3. Step 2: Tighten bolts 1-8 to 65 ft. lbs. (88 Nm).
    4.  
    5. Step 3: Tighten bolts 1-8 to 65 ft. lbs. (88 Nm).
    6.  
    7. Step 4: Bolts 1-8 plus 90 degrees.
    8.  
    9. Step 5: Tighten bolt 9 to 25 ft. lbs. (33 Nm).
    10.  

  4.  
  5. Check that the torque on bolts 1-8 has exceeded 90 ft. lbs. (122 Nm). If not, replace the bolt.
  6.  
  7. Install or connect the following:

    Pushrods
     
    Rocker arm and shaft assemblies
     
    Valve covers
     
    Exhaust manifolds
     
    Dipstick tube with a new O-ring
     
    Spark plugs
     
    Intake manifolds
     
    Wiper module, if removed
     
    Negative battery cable
     

  8.  
  9. Fill the cooling system.
  10.  
  11. Start the engine and check for leaks.
  12.  

 
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