Chrysler Caravan/Voyager/Town and Country 1996-1999

Cylinder Head

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REMOVAL & INSTALLATION




CAUTION
The fuel injection system remains under pressure, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

2.4L Engine

See Figure 1



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Fig. Fig. 1: Cylinder head bolt tightening sequence-2.4L engine

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Place a large drain pan under the radiator drain plug. Open up the drain plug and drain the cooling system.
  6.  
  7. Remove the air cleaner assembly and disconnect all vacuum lines, electrical wiring and fuel lines from the throttle body.
  8.  
  9. Disconnect the throttle linkage.
  10.  
  11. Remove the accessory drive belts.
  12.  
  13. Disconnect the power brake vacuum hose from the intake manifold.
  14.  
  15. Raise and safely support the vehicle. Disconnect the exhaust pipe from the exhaust manifold.
  16.  
  17. Lower the vehicle as required to remove the power steering pump. Do not disconnect the fluid lines. Set the pump aside.
  18.  
  19. Label the spark plug wires for correct installation. Detach the coil pack wiring connector and remove the coil pack and spark plug wires from the engine.
  20.  
  21. Detach the cam sensor and fuel injector wiring connectors.
  22.  
  23. Remove the timing belt covers, timing belt and camshaft sprockets.
  24.  
  25. Remove the timing belt idler pulley and rear timing belt cover.
  26.  
  27. Remove the cylinder head cover mounting fasteners and cylinder head cover. Remove the ground strap.
  28.  
  29. Identify the camshafts, if they are to be reused, for later installation. The camshafts are not interchangeable. Remove the camshaft bearing caps and the camshafts.
  30.  
  31. Remove the camshaft followers. Any components that are to be reused must be installed in their original locations. Use care to identify and mark the positions of any removed valvetrain components so they may be reinstalled correctly.
  32.  
  33. Remove the intake and exhaust manifolds.
  34.  
  35. Remove the cylinder head bolts.
  36.  
  37. Remove the cylinder head from the vehicle, using care not to damage the aluminum gasket surfaces.
  38.  
  39. Remove all gasket material from the sealing surfaces of the cylinder head and engine block. Be careful not to gouge or scratch the surface of the aluminum head. The cylinder head should be checked for warpage using a good straightedge and feeler gauges. Place the straightedge on the bottom of the cylinder head from front to back, then try to insert the feeler gauge between the head and the straightedge in several places. If a feeler gauge larger than 0.004 in. (0.1mm) fits between the head and straightedge, take the cylinder head to a machine shop for service before installing it.
  40.  
  41. Inspect the camshaft bearing oil feed holes in the cylinder head for clogging. Inspect the camshaft bearing journals for wear or scoring. Check the cam surface for abnormal wear and damage. A visible worn groove in the roller path or on the cam lobes is cause for replacement. Valve service may be performed at this time.
  42.  

To install:
  1. Clean all parts well. Note that the cylinder head bolts are tightened using a new procedure. The cylinder head bolts should be checked carefully BEFORE reuse. If the threads are necked down the bolts should be replaced with new bolts. Necking can be checked by holding a steel scale or straightedge against the threads. If all the threads do not contact the scale, the bolt should be replaced. New cylinder head bolts are recommended for any engine rebuild, especially if known that the engine has been disassembled before.
  2.  

  1. Be sure both the top of the engine block and the bottom of the cylinder head are clean. Install a new gasket making sure all holes align with the openings in the engine block. Carefully set the cylinder head in place.
  2.  
  3. Apply clean engine oil to the threads and under the heads of the bolts. Install the bolts and tighten them in sequence using the following four substeps:
    1. Tighten all bolts to 25 ft. lbs. (34 Nm).
    2.  
    3. Tighten all bolts to 50 ft. lbs. (68 Nm).
    4.  
    5. Tighten all bolts again to 50 ft. lbs. (68 Nm).
    6.  

  4.  

Do not use a torque wrench for the fourth step.

  1. Tighten all bolts an additional 1 / 4 turn.
  2.  

  1. The camshaft end-play should be checked using the following procedure:
    1. Oil the camshaft journals and install the camshaft WITHOUT the cam follower assemblies. Install the rear cam caps and tighten them to 250 inch lbs. (28 Nm).
    2.  
    3. Carefully push the camshaft as far rearward as it will go.
    4.  
    5. Set up a dial indicator to bear against the front of the camshaft (the sprocket end). Zero the indicator.
    6.  
    7. Move the camshaft forward as far as it will go. Read the dial indicator. End-play specification is 0.002-0.010 in. (0.05-0.15mm).
    8.  

  2.  
  3. When satisfied with the fit and condition of the camshafts, remove the camshafts for installation of the cam followers.
  4.  
  5. Lubricate the camshaft followers with clean engine oil. Install the cam followers in their original positions on the hydraulic adjuster and valve stem.
  6.  


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

  1. Lubricate the camshaft bearing journals and cam followers with clean engine oil and install the camshafts. Install right and left camshaft bearing caps No. 2 through No. 5 and right side No. 6. Tighten the M6 fasteners to 105 inch lbs. (12 Nm) in sequence.
  2.  

  1. Apply Mopar Gasket Maker or equivalent sealer to the No. 1 and No. 6 bearing caps. Install the bearing caps and tighten the M8 fasteners to 250 inch lbs. (28 Nm). The end caps must be installed before the seals may be installed.
  2.  
  3. Apply a light coating of clean engine oil to the lip of the new camshaft seal. Install the camshaft seal until it fits flush with the cylinder head.
  4.  

Refer to the timing belt Unit Repair Section (URS) for information on the timing belts and sprockets.

  1. Install the camshaft sprockets, if removed. Install the rear timing belt cover and timing belt using care to be sure all timing marks are properly aligned. Install the timing belt cover.
  2.  


WARNING
Verify that all timing marks are correct. If the timing belt or sprockets are incorrectly installed, engine damage will occur. Take time to be sure all timing marks are correctly aligned.

  1. Install the intake and exhaust manifolds.
  2.  
  3. Clean the cylinder head cover and cylinder head gasket rails (mating surfaces). Make certain the rails are flat.
  4.  
  5. Install new cylinder head cover gaskets. Use care; DO NOT allow oil or solvents to contact the timing belt as they can deteriorate the rubber and cause tooth skipping. Apply Mopar Silicone Rubber Adhesive Sealant, or equivalent, at the camshaft cap corners and at the top edge of the 1 / 2 round seal.
  6.  
  7. Install the cylinder head cover assembly to the head and tighten the fasteners in sequence using the following three substeps:
    1. Tighten all cylinder head cover fasteners to 40 inch lbs. (4.5 Nm).
    2.  
    3. Tighten all fasteners to 80 inch lbs. (9 Nm).
    4.  
    5. Tighten all fasteners to 105 inch lbs. (12 Nm).
    6.  

  8.  
  9. Install the ground strap.
  10.  
  11. Install the ignition coil pack and reconnect the spark plug wiring.
  12.  
  13. Connect the cam sensor and fuel injectors' wiring.
  14.  
  15. Install the power steering pump assembly.
  16.  
  17. Connect the exhaust pipe to the exhaust manifold.
  18.  
  19. Connect all vacuum lines and remaining wiring. Connect the throttle linkage and fuel lines.
  20.  
  21. Install and adjust the accessory drive belts.
  22.  
  23. Refill the cooling system. An oil and filter change is recommended since coolant can enter the oil system when a head is removed.
  24.  
  25. Connect the remaining air ducting. Connect the negative battery cable and test run the vehicle. Check for leaks and for proper operation.
  26.  

3.0L Engine

See Figures 2, 3, 4, 5, 6, 7, 8, 9 and 10



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Fig. Fig. 2: A breaker bar should be used to loosen the cylinder head bolts

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable. Drain the cooling system.
  4.  
  5. Remove the accessory drive belts and the air conditioning compressor from its mount and support it aside. Remove the alternator and power steering pump from the brackets and move them aside.
  6.  
  7. Raise the vehicle and support safely. Remove the right front wheel and the right inner splash shield.
  8.  
  9. Remove the crankshaft pulleys and the torsional damper.
  10.  



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Fig. Fig. 3: After the cylinder head bolts are removed in the proper sequence, lift the cylinder heads from the engine block



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Fig. Fig. 4: Clean the cylinder head mating surfaces before installation

  1. Lower the vehicle. Using a floor jack and a block of wood positioned under the oil pan, raise the engine slightly. Remove the engine mount bracket from the timing cover end of the engine.
  2.  
  3. Remove the timing belt covers.
  4.  
  5. Remove the timing belt as described in the unit repair section in the beginning of this guide.
  6.  
  7. Hold the camshaft sprocket using a suitable tool and remove the camshaft sprocket retaining bolt. Remove the sprocket and the inner timing belt cover (left bank) and/or alternator bracket (right bank).
  8.  
  9. Label and disconnect the spark plug wires from the spark plugs.
  10.  
  11. If removing the left (front) cylinder head, remove the distributor cap and spark plug wires. Mark the position of the rotor and distributor in relation to the cylinder head and remove the distributor. Remove the distributor drive adapter.
  12.  
  13. Remove the valve cover.
  14.  
  15. Install the auto lash adjuster retainers on the rocker arms. Remove the camshaft bearing cap-to-cylinder head bolts (do not remove the bolts from the assembly). Remove the rocker arms, rocker shafts and bearing caps as an assembly. Remove the camshaft from the cylinder head.
  16.  
  17. Remove the intake manifold assembly.
  18.  
  19. Remove the exhaust manifold and crossover pipe.
  20.  
  21. Remove the cylinder head bolts starting from the outside and working inward. Remove the cylinder head from the engine.
  22.  
  23. Clean the gasket mounting surfaces and check the head gasket surface for leaks, damage or warpage; the maximum warpage allowed is 0.008 in. (0.20mm).
  24.  

To install:
  1. Clean all parts well. Install the new cylinder head gasket over the dowels on the engine block.
  2.  
  3. Install the cylinder head on the engine block and tighten the 10mm Allen cylinder head bolts in sequence, using three even steps, to 80 ft. lbs. (108 Nm).
  4.  

  1. Install the intake and exhaust manifolds.
  2.  
  3. Lubricate the camshaft with clean engine oil and install on the cylinder head.
  4.  
  5. Apply silicone sealant to the cylinder head at the front and rear cam bearing cap contact areas. Install the rocker arm shaft assembly and tighten the bearing cap bolts to 85 inch lbs. (10 Nm) in the following sequence: No. 3, No. 2, No. 1 and No. 4. Retighten to 180 inch lbs. (20 Nm) in the same sequence.
  6.  
  7. If removed, install the distributor drive adapter. Install a new camshaft seal.
  8.  
  9. Install the valve cover.
  10.  
  11. Install the inner timing belt cover (left bank) and/or alternator bracket (right bank).
  12.  
  13. Position the camshaft sprocket. Hold the sprocket using a suitable tool and install the camshaft sprocket bolt. Tighten the bolt to 70 ft. lbs. (95 Nm).
  14.  



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Fig. Fig. 5: Distributor drive extension-3.0L engine



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Fig. Fig. 6: Cylinder head and rocker arm shaft assemblies



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Fig. Fig. 7: Cylinder head bolt removal sequence

Be sure the timing belt sprocket timing marks are aligned.

  1. If removed, install the distributor, aligning the marks made during removal. Install the distributor cap and spark plug wires.
  2.  
  3. Install the timing belt.
  4.  
  5. Install the timing belt covers and the engine support bracket.
  6.  
  7. Install the torsional damper and tighten the bolt to 112 ft. lbs. (151 Nm). Install the crankshaft pulleys.
  8.  
  9. Install the inner splash shield and the right front wheel. Tighten the wheel lug nuts to 95 ft. lbs. (129 Nm). Lower the vehicle.
  10.  



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Fig. Fig. 8: Cylinder head bolt tightening sequence



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Fig. Fig. 9: Install the camshaft oil seal with the special tool



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Fig. Fig. 10: Use the special tool to install a new camshaft end seal (plug)

  1. Install the alternator, power steering pump and air conditioning compressor.
  2.  
  3. Install the accessory drive belts and adjust to the proper tension.
  4.  
  5. Refill the cooling system. Since coolant can contaminate the engine oil when a cylinder head is removed, an oil and filter change is recommended.
  6.  
  7. Reconnect the negative battery cable.
  8.  
  9. Start the engine and check for leaks. Check the ignition timing.
  10.  

3.3L and 3.8L Engines

See Figures 11, 12, 13 and 14



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Fig. Fig. 11: Cylinder head assembly-3.3L and 3.8L engines

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable and drain the cooling system.
  4.  
  5. Remove the intake manifold with the throttle body.
  6.  
  7. Disconnect the coil wires, sending unit wire, heater hoses and bypass hose.
  8.  
  9. Remove the closed ventilation system, evaporation control system and cylinder head cover(s).
  10.  
  11. Remove the exhaust manifold(s).
  12.  
  13. Remove the rocker arm and shaft assemblies. Remove the pushrods and identify them to ensure installation in their original positions.
  14.  
  15. Loosen the cylinder head bolts in the reverse order of the torque sequence. Remove the cylinder head bolts and remove the cylinder head(s) from the block.
  16.  
  17. Clean all gasket mating surfaces.
  18.  



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Fig. Fig. 12: Cylinder head gasket installation-3.3L and 3.8L engines



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Fig. Fig. 13: Checking the cylinder head mounting bolts for stretching (necking)-3.3L and 3.8L engines



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Fig. Fig. 14: Cylinder head tightening sequence-3.3L and 3.8L engines

To install:
  1. Clean the gasket mounting surfaces and install a new head gasket to the block.
  2.  

The cylinder head bolts are tightened using the torque yield method. The bolts should be examined before they are reused. If the threads are stretched, the bolts should be replaced. Stretching can be checked by holding a straightedge against the threads. If all the threads do not contact the straightedge, the bolt should be replaced.

  1. Install the cylinder head to the block with the bolts.
  2.  
  3. Tighten cylinder head bolts Nos. 1 through 8 in sequence as follows:
    1. Tighten each bolt to 45 ft. lbs. (61 Nm).
    2.  
    3. Repeat the sequence and tighten the bolts to 65 ft. lbs. (88 Nm).
    4.  
    5. Repeat the sequence again, making sure the bolts are at 65 ft. lbs. (88 Nm).
    6.  
    7. Finally, turn each bolt, in sequence, 1 / 4 turn. Do not use a torque wrench for this step.
    8.  
    9. Check the torque of each bolt after the 1 / 4 turn. The torque should be over 90 ft. lbs. (122 Nm). If not, replace the bolt.
    10.  

  4.  
  5. Tighten head bolt No. 9 to 25 ft. lbs. (33 Nm) after the other eight bolts have been properly tightened.
  6.  
  7. Install the pushrods, rocker arms and shafts, and tighten the bolts to 250 inch lbs. (28 Nm).
  8.  
  9. Place a drop of silicone sealer onto each of the four manifold-to-cylinder head gasket corners.
  10.  


CAUTION
The intake manifold gasket is composed of very thin and sharp metal. Handle this gasket with care or damage to the gasket or personal injury could result.

  1. Install the intake manifold gasket and tighten the end retainers to 105 inch lbs. (12 Nm).
  2.  
  3. Install the intake manifold and tighten the bolts in sequence to 10 inch lbs. (1 Nm). Repeat the sequence, increasing the torque to 200 inch lbs. (22 Nm). Recheck each bolt, making sure it is at 200 inch lbs. (22 Nm) of torque. As the bolts are tightened, inspect the seals to ensure that they have not become dislodged.
  4.  
  5. Install the valve cover with a new gasket. Tighten the valve cover bolts to 105 inch lbs. (12 Nm). Install the exhaust manifold and crossover pipe. Tighten the bolts to 20 ft. lbs. (27 Nm) and the nuts to 15 ft. lbs. (20 Nm).
  6.  
  7. Install the closed ventilation system and the evaporation control system.
  8.  
  9. Reconnect the coil wires, sending unit wire, heater hoses and bypass hose.
  10.  
  11. Ensure all wiring connections, cables, hoses, vacuum and fuel lines have been reattached.
  12.  
  13. Refill the cooling system to the correct level. Coolant can contaminate the engine oil when performing cylinder head service. An oil and filter change is recommended.
  14.  
  15. Reconnect the negative battery cable. Start the engine and check for leaks.
  16.  

 
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