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

Engine

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Removal & Installation



2.4L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Relieve the fuel system pressure.
  8.  
  9. Recover the A/C refrigerant.
  10.  
  11. Remove or disconnect the following:
    NOTE
    When the transaxle lines are removed from the fittings at the transaxle damage to the inner wall of the hose will occur. To prevent leakage, cut the cooler hoses off flush at the transaxle fitting and use a service cooler hose splice kit upon installation.



    Negative battery cable
     
    Air cleaner and hoses
     
    Fuel line
     
    Vacuum hoses
     
    Radiator fans
     
    Radiator hoses
     



    Transaxle cooler lines, cut the lines flush at the transaxle fittings
     
    Transaxle shift linkage
     
    Throttle body linkage
     
    Engine wiring harness
     
    Heater hoses
     
    Front wheels
     
    Right inner splash shield
     
    Drive belts
     
    Axle halfshafts
     
    Crossmember cradle plate
     
    Exhaust front pipe
     
    Front motor mount
     
    Structural collar
     
    Rear motor mount
     
    Power steering pump. Pinch off the supply hose at the pump, disconnect the hose but leave the pressure line attached and then set the pump assembly aside.
     
    A/C compressor lines
     
    Body ground straps
     

  12.  
  13. Raise the vehicle enough to position dolly 6135, cradle tool 6710 with posts 6848 under vehicle.
  14.  
  15. Loosen the cradle posts to allow movement for proper positioning. Position the two rear posts (right side of engine) into the engine bedplate holes. Position the two front posts (left side of engine) on the oil pan rails. Lower the vehicle and position the cradle mounts until the engine is resting on the mounts and then tighten the mounts to the cradle frame to prevent mounts from moving when removing/installing the powertrain assembly.
  16.  
  17. Attach safety straps around the engine-to-cradle assembly. Lower the vehicle so the weight of the powertrain assembly, not the vehicle are on the cradle.

    Click image to see an enlarged view

    Fig. Chrysler powertrain support tools

  18.  
  19. Remove the engine and transmission bolts.
  20.  
  21. Raise the vehicle away from the powertrain.
  22.  

To install:

  1. Lower the vehicle over the powertrain.
  2.  
  3. Align the engine and transmission mounts to their attaching points. Install and tighten the right mount-to-rail and engine and left mount-to-frame brackets as shown in the two accompanying illustrations.
  4.  
  5. Remove the safety straps and the dolly.
  6.  
  7. Install the rear mount bracket and through bolt.

    Click image to see an enlarged view

    Fig. Right mount-to-rail and engine installation-2.4L engine



    Click image to see an enlarged view

    Fig. Left mount-to-frame bracket installation-2.4L engine

  8.  
  9. Install or connect the following:

    Torque converter
     
    Axle halfshafts

    Click image to see an enlarged view

    Fig. Structural collar and bending strut torque sequence-2.4L engine



    Click image to see an enlarged view

    Fig. Exploded view of the right side engine hydro-type mount-2.4L engine



    Click image to see an enlarged view

    Fig. Exploded view of the front mount and bracket assembly-2.4L engine



    Click image to see an enlarged view

    Fig. Exploded view of the left mount and bracket assembly-2.4L engine

     

  10.  
  11. Install the bending struts and structural collar, as follows:
    1. Step 1: Position the collar between the transaxle and oil pan and install bolts hand tight.
    2.  
    3. Step 2: Position the collar to oil pan bolts and install bolts hand tight.
    4.  
    5. Step 3: Tighten collar to transaxle bolts to 75 ft. lbs. (101 Nm).
    6.  
    7. Step 4: Tighten collar to oil pan bolts to 40 ft. lbs. (54 Nm).
    8.  
    9. Step 5: Install the engine front mount assembly.
    10.  

  12.  
  13. Install or connect the following:

    Exhaust front pipe
     
    Crossmember cradle plate
     
    Power steering pump and lines
     
    A/C compressor lines
     
    Drive belts
     
    Right inner splash shield
     
    Axle halfshafts
     
    Front wheels
     
    Transaxle cooler lines using a splice service kit
     
    Transaxle shift linkage
     
    Heater hoses
     
    Body ground straps
     
    Engine wiring harness
     
    Vacuum lines
     
    Throttle body linkage
     
    Engine cooling fans
     
    Fuel line
     
    Radiator hoses
     
    Air cleaner and hoses
     
    Negative battery cable
     

  14.  
  15. Fill the cooling system.
  16.  
  17. Fill the engine with clean oil.
  18.  
  19. Recharge the A/C system.
  20.  
  21. Start the engine and check for leaks.
  22.  

3.3L & 3.8L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Relieve the fuel system pressure.
  8.  
  9. Recover the A/C refrigerant.
  10.  
  11. Remove or disconnect the following:

    Battery and tray
     
    Air cleaner and hoses
     
    Fuel line from the rail
     
    Wiper module
     

  12.  
  13. Block off the heater hoses to the rear system by using pinch off pliers, if equipped.
    NOTE
    When the transaxle lines are removed from the fittings at the transaxle damage to the inner wall of the hose will occur. To prevent leakage, cut the cooler hoses off flush at the transaxle fitting and use a service cooler hose splice kit upon installation.



    Heater hoses
     
    Radiator upper support crossmember
     
    Engine cooling fan
     
    Throttle body linkage
     
    Manifold Absolute Pressure (MAP) sensor connector
     
    Idle Air Control (IAC) valve connector
     
    Throttle Position (TPS) sensor connector
     
    Exhaust Gas Recirculation (EGR) transducer connector
     
    Vacuum lines from the throttle body, brake booster and speed control
     
    Wiring harness clip from the right side mount
     
    Power steering reservoir and set aside without disconnecting the lines
     
    Ground strap from the rear of the cylinder head
     
    Engine Coolant Temperature (ECT) sensor connector
     
    Ignition coil connectors
     
    Fuel injector connectors and clip from the bracket
     
    Camshaft (CMP) and Crankshaft (CKP) position sensor connectors
     
    A/C compressor electrical connectors and hoses. Cap the lines to avoid system contamination.
     
    Radiator upper hose
     
    Electrical connector at the transaxle dipstick tube
     
    Transaxle dipstick tube and seal the opening to avoid system contamination
     



    Transaxle cooler lines, cut the lines flush at the transaxle fittings
     
    Transaxle shift linkage and electrical connectors
     
    Axle halfshafts
     
    Crossmember cradle plate
     
    Power Transfer Unit (PTO), if equipped
     
    Exhaust front pipe from the manifold
     
    Front motor mount and bracket
     
    Rear motor mount bracket
     
    Engine-to-transaxle struts
     
    Transaxle case cover
     
    Torque converter
     
    Power steering pressure hose clip bolt
     
    Knock sensor connector, if equipped
     
    Engine block heater connector, if equipped
     
    Drive belt splash shield
     
    Accessory drive belt
     
    Lower radiator hose
     
    A/C compressor
     
    Alternator
     
    Water pump pulley bolts and position the pulley between the pump and the housing
     
    Oil pressure switch connector
     
    Wiring harness clip from the dipstick tube
     

  14.  
  15. Install adapter tools on the right side of the engine block as illustrated

    Power steering pump and set aside
     

  16.  
  17. Raise the vehicle enough to position dolly 6135, cradle tool 6710 with posts 6848 and adapter tool 6909 under vehicle.
  18.  
  19. Loosen the cradle posts to allow movement for proper positioning. Lower the vehicle and position the cradle/post mounts until the engine is resting on the posts and then tighten the mounts to the cradle frame to prevent mounts from moving when removing/installing the powertrain assembly.
  20.  
  21. Attach safety straps around the engine-to-cradle assembly. Lower the vehicle so the weight of the powertrain assembly, not the vehicle are on the cradle.
  22.  
  23. Remove or disconnect the following:

    Engine right side mount-to-engine bolts
     
    Left mount through bolt

    Click image to see an enlarged view

    Fig. Adapter tools 6912 and 8444 mounted on the block-3.3L and 3.8L engines



    Click image to see an enlarged view

    Fig. Position tool 6848 for use with adapters 8444 and 6912-3.3L and 3.8L engines

     

  24.  
  25. Raise the vehicle away from the powertrain.
  26.  

To install:

  1. Lower the vehicle over the powertrain.
  2.  
  3. Align the engine and transmission mounts to their attaching points. Install and tighten the right mount and left transmission mounts as shown in the two accompanying illustrations.
  4.  
  5. Remove the safety straps and the dolly and adapters.
  6.  
  7. Install or connect the following:

    Power steering pump and pressure line

    Click image to see an enlarged view

    Fig. Exploded view of the front engine mounting-3.3L and 3.8L engines



    Click image to see an enlarged view

    Fig. Exploded view of the right side hydro-type engine mounting-3.3L and 3.8L engines



    Click image to see an enlarged view

    Fig. Exploded view of the rear engine mounting-3.3L and 3.8L engines



    Click image to see an enlarged view

    Fig. Exploded view of the left engine mounting-3.3L and 3.8L engines



    Click image to see an enlarged view

    Fig. Exploded view of the left engine mounting on models equipped with a 31TH transaxle-3.3L and 3.8L engines



    Click image to see an enlarged view

    Fig. Exploded view of the left engine mounting on models equipped with a 41TE transaxle-3.3L and 3.8L engines



    Click image to see an enlarged view

    Fig. Exploded view of the right engine mounting-3.3L and 3.8L engines

     
    Alternator
     
    Wiring harness clip to the dipstick tube
     
    Oil pressure switch connector
     
    A/C compressor
     
    Water pump pulley
     
    Lower radiator hose
     
    Accessory drive belt
     
    Drive belt splash shield
     
    Engine block heater connector, if equipped
     
    Knock sensor connector, if equipped
     
    Power steering pressure hose clip bolt
     
    Torque converter