Caravan, Town & Country 2006-2007

Engine 2

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Removal & Installation



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
     
    Transaxle case cover
     
    Engine-to-transaxle struts
     
    Rear motor mount bracket
     
    Front motor mount and bracket
     
    PTO, if equipped
     
    Axle halfshafts
     
    Exhaust front pipe to the manifold
     
    Crossmember cradle plate
     
    Transaxle shift linkage and electrical connectors
     
    Transaxle cooler lines using a splice kit
     
    Transaxle dipstick tube and
     
    Electrical connector at the transaxle dipstick tube
     
    A/C compressor electrical connectors and hoses
     
    CMP and CKP position sensor connectors
     
    Fuel injector connectors and clip to the bracket
     
    ECT sensor connector
     
    Ignition coil connectors
     
    Ground strap to the rear of the cylinder head
     
    Power steering reservoir
     
    Wiring harness clip to the right side mount
     
    Vacuum lines to the throttle body, brake booster and speed control
     
    EGR transducer connector
     
    TPS sensor connector
     
    IAC valve connector
     
    MAP sensor connector
     
    Throttle body linkage
     
    Engine cooling fan
     
    Radiator upper hose
     
    Heater hoses
     
    Radiator upper support crossmember
     
    Wiper module
     
    Fuel line to the rail
     
    Air cleaner and hoses
     
    Battery and tray
     

  8.  
  9. Fill the cooling system.
  10.  
  11. Fill the engine with clean oil.
  12.  
  13. Recharge the A/C system.
  14.  
  15. Start the engine and check for leaks.
  16.  

  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 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
     
    Transaxle case cover
     
    Engine-to-transaxle struts
     
    Rear motor mount bracket
     
    Front motor mount and bracket
     
    PTO, if equipped
     
    Axle halfshafts
     
    Exhaust front pipe to the manifold
     
    Crossmember cradle plate
     
    Transaxle shift linkage and electrical connectors
     
    Transaxle cooler lines using a splice kit
     
    Transaxle dipstick tube and
     
    Electrical connector at the transaxle dipstick tube
     
    A/C compressor electrical connectors and hoses
     
    CMP and CKP position sensor connectors
     
    Fuel injector connectors and clip to the bracket
     
    ECT sensor connector
     
    Ignition coil connectors
     
    Ground strap to the rear of the cylinder head
     
    Power steering reservoir
     
    Wiring harness clip to the right side mount
     
    Vacuum lines to the throttle body, brake booster and speed control
     
    EGR transducer connector
     
    TPS sensor connector
     
    IAC valve connector
     
    MAP sensor connector
     
    Throttle body linkage
     
    Engine cooling fan
     
    Radiator upper hose
     
    Heater hoses
     
    Radiator upper support crossmember
     
    Wiper module
     
    Fuel line to the rail
     
    Air cleaner and hoses
     
    Battery and tray
     

  8.  
  9. Fill the cooling system.
  10.  
  11. Fill the engine with clean oil.
  12.  
  13. Recharge the A/C system.
  14.  
  15. Start the engine and check for leaks.
  16.  

 
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