Chrysler Caravan/Voyager/Town and Country 1996-1999

Engine

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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.

REMOVAL & INSTALLATION



In the process of removing the engine, you will come across a number of steps which call for the removal of a separate component or system, such as disconnect the exhaust system'' or remove the radiator.'' In most instances, a detailed removal procedure can be found elsewhere in this manual.

It is virtually impossible to list each individual wire and hose which must be disconnected, simply because so many different model and engine combinations have been manufactured. Careful observation and common sense are the best possible approaches to any repair procedure.

Removal and installation of the engine can be made easier if you follow these basic points:



If you have to drain any of the fluids, use a suitable container.
 
Always tag any wires or hoses and, if possible, the components they came from before disconnecting them.
 
Because there are so many bolts and fasteners involved, store and label the retainers from components separately in muffin pans, jars or coffee cans. This will prevent confusion during installation.
 
After unbolting the transmission or transaxle, always make sure it is properly supported.
 
If it is necessary to disconnect the air conditioning system, have this service performed by a qualified technician using a recovery/recycling station. If the system does not have to be disconnected, unbolt the compressor and set it aside.
 
When unbolting the engine mounts, always make sure the engine is properly supported. When removing the engine, make sure that any lifting devices are properly attached to the engine. It is recommended that if your engine is supplied with lifting hooks, your lifting apparatus be attached to them.
 
Lift the engine from its compartment slowly, checking that no hoses, wires or other components are still connected.
 
After the engine is clear of the compartment, place it on an engine stand or workbench.
 
After the engine has been removed, you can perform a partial or full teardown of the engine using the procedures outlined in this manual.
 

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the battery cables from the battery, negative cable first.
  4.  
  5. Detach the fuel line-to-fuel rail quick-disconnect fittings by squeezing the retainer tabs together and pulling back on the fitting.
  6.  
  7. Scribe the hood hinge outlines on the hood and remove the hood.
  8.  
  9. Remove the wiper arm and blade assemblies.
  10.  
  11. Remove the cowl cover from the vehicle.
  12.  
  13. Detach the positive lock on the wiper unit electrical connector.
  14.  
  15. Detach the wiper unit electrical connector from the engine compartment wiring harness.
  16.  
  17. Disconnect the windshield washer hose from the hose coupling inside the wiper unit.
  18.  
  19. Remove the drain tubes from the bottom of the wiper unit.
  20.  
  21. Remove the sound absorbers from the ends of the wiper unit.
  22.  
  23. Remove the attaching nuts securing the wiper unit to the lower windshield fence.
  24.  
  25. Remove the attaching bolts securing the wiper unit to the dash panel.
  26.  
  27. Raise the wiper unit from the weld-studs on the lower windshield fence and remove the wiper unit from the vehicle.
  28.  
  29. Remove the air cleaner assembly and related hoses.
  30.  
  31. Remove the battery cover, battery, battery tray and integral vacuum reservoir from the vehicle.
  32.  
  33. If equipped, block off the rear heater to the rear heater unit.
  34.  
  35. Drain the cooling system. Remove the upper and lower radiator hoses from the radiator.
  36.  
  37. Disconnect and plug the heater hoses from the engine.
  38.  
  39. Remove the radiator and cooling fan assembly.
  40.  
  41. Disconnect the transaxle shift linkage.
  42.  
  43. Disconnect the throttle body linkage and all vacuum hoses to the throttle body.
  44.  
  45. Remove accessory drive belts.
  46.  
  47. Remove the air conditioner compressor from the engine and mounting brackets. Keep the A/C compressor hoses connected. Position the assembly aside and secure out of the way.
  48.  
  49. Detach the wiring harness connector to the alternator.
  50.  
  51. Remove the alternator.
  52.  
  53. Raise and safely support the vehicle. Remove the right and left halfshaft assemblies.
  54.  
  55. Disconnect the starter motor wiring and remove the starter motor.
  56.  
  57. Drain the engine oil and remove the oil filter.
  58.  
  59. Remove the right and left fender inner splash shields.
  60.  
  61. Disconnect the exhaust pipe from the exhaust manifold.
  62.  
  63. Remove the front motor mount and mount bracket as an assembly.
  64.  
  65. Remove the rear transaxle motor mount and bracket.
  66.  
  67. Remove the power steering pump and mounting bracket assembly from the engine.
  68.  
  69. Detach, label and remove the wiring harness and connectors from the front of the engine.
  70.  
  71. Remove bending braces.
  72.  
  73. Remove the transaxle case inspection cover.
  74.  
  75. Mark the flexplate-to-torque converter location.
  76.  
  77. Remove the bolts that mount the converter to the flexplate. Attach a small C-clamp to the front bottom of the converter housing to prevent the converter from falling out of the transaxle, if necessary.
  78.  
  79. Lower the vehicle to the ground.
  80.  
  81. Disconnect the engine ground straps.
  82.  
  83. Attach an engine lifting hoist to the engine.
  84.  
  85. Remove the right engine mount assembly and left transaxle mount throughbolt.
  86.  
  87. Using the engine hoist, raise the engine and transaxle assembly slowly out of the vehicle. Separate the engine and transaxle. Secure the engine on an engine stand.
  88.  

To install:
  1. Attach the transaxle to the engine assembly.
  2.  
  3. With the hoist attached to the engine/transaxle assembly, lower the engine/transaxle into the engine compartment.
  4.  
  5. Align the engine and transaxle motor mounts to their attaching points. Install the right engine and left transaxle mount bolts.
  6.  
  7. Remove the engine hoist.
  8.  
  9. Install bending braces.
  10.  
  11. Install the alternator.
  12.  
  13. Install and reattach the wiring harness connectors on the front of the engine.
  14.  
  15. Install the air conditioning compressor to the engine.
  16.  
  17. Install the power steering pump and mounting bracket to the engine.
  18.  
  19. Install accessory drive belts and adjust to the proper tension, if necessary.
  20.  
  21. Raise and safely support the vehicle.
  22.  
  23. Remove the C-clamp from the torque converter housing, if utilized.
  24.  
  25. Align the flexplate and torque converter with the marks made previously.
  26.  
  27. Install the converter-to-flexplate mounting bolts. Tighten them to 55 ft. lbs. (75 Nm).
  28.  
  29. Install the transaxle case lower inspection cover.
  30.  
  31. Install right and left halfshaft assemblies.
  32.  
  33. Install the engine and transaxle mount and bracket assemblies.
  34.  
  35. Install the exhaust system to the exhaust manifolds.
  36.  
  37. Install the left and right fender inner splash shields.
  38.  
  39. Install the starter assembly and reconnect the starter motor wiring.
  40.  
  41. Reconnect the automatic transaxle shift linkage.
  42.  
  43. Lower the vehicle.
  44.  
  45. Reattach the fuel line quick-disconnect fitting to the fuel rail.
  46.  
  47. Reconnect the cooling system heater hoses to the engine.
  48.  
  49. Unblock the heater hoses to the rear heater unit, if equipped.
  50.  
  51. Secure the engine ground straps.
  52.  
  53. Reattach the engine and throttle body vacuum connections and wiring harness connectors.
  54.  
  55. Reconnect the throttle body linkage.
  56.  
  57. Install the radiator, cooling fan and shroud assembly.
  58.  
  59. Reconnect the upper and lower radiator hoses.
  60.  
  61. Install the battery tray, battery and battery cover into the vehicle.
  62.  
  63. Install the air cleaner assembly and hoses.
  64.  
  65. Install a new engine oil filter. Fill the crankcase to the proper oil level with the correct type of clean engine oil.
  66.  
  67. Refill the cooling system to the proper level with a 50 / 50 mixture of clean ethylene glycol antifreeze and water.
  68.  
  69. Install the wiper unit into the vehicle engine compartment, making sure the wiper unit is installed properly over the weld-studs on the lower windshield fence. Install and tighten the attaching nuts to the weld-studs.
  70.  
  71. Install and tighten the attaching bolts securing the wiper unit to the dash panel.
  72.  
  73. Install the sound absorbers to each end of the wiper unit.
  74.  
  75. Install the drain tubes to the bottom of the wiper unit and reconnect the windshield washer hose to the hose coupling inside the wiper unit.
  76.  
  77. Reattach the wiper unit wiring connector to the engine wiring harness.
  78.  
  79. Place the cowl cover onto the vehicle. Reconnect the right side windshield washer hose to the right washer nozzle located on the underside of the cowl cover.
  80.  
  81. Engage the retainers that secure the cowl cover to the front fender edge.
  82.  
  83. Install and tighten the wing nuts that secure the front of the cowl cover to the wiper module.
  84.  
  85. Engage the quarter turn fasteners that secure the outer ends of the cowl cover to the wiper module.
  86.  
  87. Install and tighten the bolts that hold the lower area of the cowl cover to the wiper module.
  88.  
  89. Reconnect the positive battery cable, then the negative battery cable and verify that the wiper motor and wiper linkage are in the PARK position.
  90.  
  91. Install the wiper arm in the correct position over the wiper arm pivot. Align the wiper arm positions as follows:
    1. Left arm should be no closer than 2.5 in. (65mm) from the lower edge of the windshield.
    2.  
    3. Right arm should be no closer than 1.5 in. (40mm) from the lower edge of the windshield.
    4.  

  92.  
  93. Install the wiper arm-to-wiper arm pivot retaining nut and tighten to 26 ft. lbs. (35 Nm).
  94.  
  95. Push down the wiper arm cap cover and engage the clip that secures the outside end of the cover to the wiper arm.
  96.  
  97. Operate the windshield wipers and ensure they work and park properly.
  98.  
  99. Adjust linkages.
  100.  
  101. Install the hood.
  102.  
  103. Ensure all electrical connections, cables, hoses, vacuum and fuel lines have been attached.
  104.  
  105. Start the engine and run until normal operating temperature is indicated. Check for leaks. Road test the vehicle.
  106.  

 
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