Caravan, Town & Country 2006-2007

Oil Pump

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Inspection



  1. Inspect mating surface of the chain case cover. Surface should be smooth. Replace cover if scratched or grooved.
  2.  
  3. Lay a straightedge across the pump cover surface. If a 0.025 mm (0.001 in.) feeler gauge can be inserted between cover and straight edge, cover should be replaced.
  4.  
  5. Measure thickness and diameter of outer rotor. If outer rotor thickness measures 7.64 mm (0.301 in.) or less, or if the diameter is 79.95 mm (3.148 in.) or less, replace outer rotor.
  6.  
  7. If inner rotor thickness measures 7.64 mm (0.301 in.) or less, replace inner rotor.
  8.  
  9. Install outer rotor into chain case cover. Press rotor to one side with fingers and measure clearance between rotor and chain case cover. If measurement is 0.39 mm (0.015 in.) or more, replace chain case cover, only if outer rotor is in specification.
  10.  
  11. Install inner rotor into chain case cover. If clearance between inner and outer rotors is 0.203 mm (0.008 in.) or more, replace both rotors.
  12.  
  13. Place a straightedge across the face of the chain case cover, between bolt holes. If a feeler gauge of 0.10 mm (0.004 in.) or more can be inserted between rotors and the straightedge, replace pump assembly.
  14.  
  15. Remove oil pressure relief valve.
  16.  
  17. Inspect oil pressure relief valve and bore. Inspect for scoring, pitting and free valve operation in bore. Small marks may be removed with 400-grit wet or dry sandpaper.
  18.  
  19. The relief valve spring has a free length of approximately 49.5 mm (1.95 inches) it should test between 19.5 and 20.5 pounds when compressed to 34 mm (1-11/32 inches). Replace spring that fails to meet specifications.
  20.  
  21. If oil pressure is low and pump is within specifications, inspect for worn engine bearings or other reasons for oil pressure loss.
  22.  

Overhaul



  1. Inspect mating surface of the chain case cover. Surface should be smooth. Replace cover if scratched or grooved.
  2.  
  3. Lay a straightedge across the pump cover surface. If a 0.025 mm (0.001 in.) feeler gauge can be inserted between cover and straight edge, cover should be replaced.
  4.  
  5. Measure thickness and diameter of outer rotor. If outer rotor thickness measures 7.64 mm (0.301 in.) or less, or if the diameter is 79.95 mm (3.148 in.) or less, replace outer rotor.
  6.  
  7. If inner rotor thickness measures 7.64 mm (0.301 in.) or less, replace inner rotor.
  8.  
  9. Install outer rotor into chain case cover. Press rotor to one side with fingers and measure clearance between rotor and chain case cover. If measurement is 0.39 mm (0.015 in.) or more, replace chain case cover, only if outer rotor is in specification.
  10.  
  11. Install inner rotor into chain case cover. If clearance between inner and outer rotors is 0.203 mm (0.008 in.) or more, replace both rotors.
  12.  
  13. Place a straightedge across the face of the chain case cover, between bolt holes. If a feeler gauge of 0.10 mm (0.004 in.) or more can be inserted between rotors and the straightedge, replace pump assembly.
  14.  
  15. Remove oil pressure relief valve.
  16.  
  17. Inspect oil pressure relief valve and bore. Inspect for scoring, pitting and free valve operation in bore. Small marks may be removed with 400-grit wet or dry sandpaper.
  18.  
  19. The relief valve spring has a free length of approximately 49.5 mm (1.95 inches) it should test between 19.5 and 20.5 pounds when compressed to 34 mm (1-11/32 inches). Replace spring that fails to meet specifications.
  20.  
  21. If oil pressure is low and pump is within specifications, inspect for worn engine bearings or other reasons for oil pressure loss.
  22.  

Removal & Installation



2.4L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Timing belt.
     
    Rear timing belt cover
     
    Oil pan
     
    Crankshaft sprocket using puller 6793 and insert C-4685-C2
     
    Crankshaft key
     
    Oil pump pickup tube
     
    Oil pump

    Click image to see an enlarged view

    Fig. Remove the crankshaft timing sprocket using puller 6793 and insert C-4685-C2-2.4L engine



    Click image to see an enlarged view

    Fig. Exploded view of the oil pump-2.4L engine

     

  6.  

To install:

  1. Clean all mating surfaces of any remaining gasket material.
  2.  
  3. Apply gasket maker material to the oil pump and replace the O-ring in the oil pump discharge passage.
  4.  
  5. Prime the pump with oil prior to installation.
  6.  
  7. Install or connect the following:
    NOTE
    The front crankshaft seal must be out of the pump to align it or the pump may be damaged.



    Oil pump, align the flats on the rotor with the flats on the crankshaft. Torque the bolts to 21 ft. lbs. (28 Nm).
     



    Front crankshaft seal using tool 6780

    Click image to see an enlarged view

    Fig. Install the front crankshaft seal using tool 6780-2.4L engine

     
    Crankshaft key
     
    Crankshaft sprocket using tool 6792

    Click image to see an enlarged view

    Fig. Install the crankshaft timing sprocket using tool 6792-2.4L engine

     
    Oil pump pickup tube. Torque the bolt to 21 ft. lbs. (28 Nm).
     
    Oil pan
     
    Rear timing belt cover
     
    Timing belt
     
    Negative battery cable
     

  8.  
  9. Fill the engine with clean oil.
  10.  
  11. Start the engine, check for leaks and repair if necessary.
  12.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Timing belt.
     
    Rear timing belt cover
     
    Oil pan
     
    Crankshaft sprocket using puller 6793 and insert C-4685-C2
     
    Crankshaft key
     
    Oil pump pickup tube
     
    Oil pump

    Click image to see an enlarged view

    Fig. Remove the crankshaft timing sprocket using puller 6793 and insert C-4685-C2-2.4L engine



    Click image to see an enlarged view

    Fig. Exploded view of the oil pump-2.4L engine

     

  6.  

To install:

  1. Clean all mating surfaces of any remaining gasket material.
  2.  
  3. Apply gasket maker material to the oil pump and replace the O-ring in the oil pump discharge passage.
  4.  
  5. Prime the pump with oil prior to installation.
  6.  
  7. Install or connect the following:
    NOTE
    The front crankshaft seal must be out of the pump to align it or the pump may be damaged.



    Oil pump, align the flats on the rotor with the flats on the crankshaft. Torque the bolts to 21 ft. lbs. (28 Nm).
     



    Front crankshaft seal using tool 6780

    Click image to see an enlarged view

    Fig. Install the front crankshaft seal using tool 6780-2.4L engine

     
    Crankshaft key
     
    Crankshaft sprocket using tool 6792

    Click image to see an enlarged view

    Fig. Install the crankshaft timing sprocket using tool 6792-2.4L engine

     
    Oil pump pickup tube. Torque the bolt to 21 ft. lbs. (28 Nm).
     
    Oil pan
     
    Rear timing belt cover
     
    Timing belt
     
    Negative battery cable
     

  8.  
  9. Fill the engine with clean oil.
  10.  
  11. Start the engine, check for leaks and repair if necessary.
  12.  

3.0L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove or disconnect the following:
    NOTE
    The oil pump bolts vary in length. Note their locations for assembly.



    Negative battery cable
     
    Drive belts
     
    Crankshaft damper
     
    Timing belt.
     
    Crankshaft sprocket and key
     
    Oil pump
     



    Click image to see an enlarged view

    Fig. Exploded view of the oil pump assembly-3.0L engine

  6.  

To install:

  1. Clean the engine black and oil pump mating surfaces of any remaining gasket material.
  2.  
  3. Install or connect the following:

    Oil pump and a new gasket. Tighten the bolts to 10 ft. lbs. (13 Nm).
     
    Crankshaft sprocket and key
     
    Timing belt
     
    Crankshaft damper
     
    Drive belts
     
    Negative battery cable
     

  4.  
  5. Fill the engine with clean oil.
  6.  
  7. Start the engine, check for leaks and repair if necessary.
  8.  

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. Remove or disconnect the following:

    Negative battery cable
     
    Oil pan
     
    Timing chain cover
     
    Oil pump from the case cover

    Click image to see an enlarged view

    Fig. Exploded view of the oil pump assembly-3.3L and 3.8L engines

     

  8.  

To install:

  1. Install or connect the following:

    Oil pump to the front cover. Torque the cover screws to 105 inch lbs. (12 Nm).
     
    Front cover. Torque the bolts to 20 ft. lbs. 927 Nm).
     
    Oil pan
     
    Negative battery cable
     

  2.  
  3. Fill the engine with clean oil.
  4.  
  5. Fill the cooling system.
  6.  
  7. Start the engine, check for leaks and repair if necessary.
  8.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Oil pan
     
    Timing chain cover
     
    Oil pump from the case cover

    Click image to see an enlarged view

    Fig. Exploded view of the oil pump assembly-3.3L and 3.8L engines

     

  8.  

To install:

  1. Install or connect the following:

    Oil pump to the front cover. Torque the cover screws to 105 inch lbs. (12 Nm).
     
    Front cover. Torque the bolts to 20 ft. lbs. (27 Nm).
     
    Oil pan
     
    Negative battery cable
     

  2.  
  3. Fill the engine with clean oil.
  4.  
  5. Fill the cooling system.
  6.  
  7. Start the engine, check for leaks and repair if necessary.
  8.  

 
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