Chrysler Caravan/Voyager/Town and Country 1996-1999

Oil Pump

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REMOVAL & INSTALLATION



2.4L Engine

See Figures 1 and 2



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Fig. Fig. 1: Exploded view of the oil pump-2.4L engine

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Drain the engine oil and the engine coolant into suitable containers.
  6.  
  7. Lower the vehicle.
  8.  
  9. Remove the accessory drive belts, as required.
  10.  
  11. Take up the weight of the engine with an engine support tool and remove the right engine mount and bracket. Be sure the engine is safely supported.
  12.  
  13. Remove the timing belt cover.
  14.  
  15. Loosen the timing belt tensioner bolts and remove the tensioner and the timing belt.
  16.  
  17. Raise and safely support the vehicle.
  18.  



Click image to see an enlarged view

Fig. Fig. 2: Oil pump and pick-up tube assembly-2.4L engine

  1. Remove the oil pan assembly. Remove the oil pump pick-up tube and O-ring.
  2.  
  3. Using a suitable puller, remove the crankshaft damper from the front of the crankshaft.
  4.  
  5. Using a suitable puller, draw the crankshaft sprocket from the front of the crankshaft.
  6.  
  7. Loosen the oil pump bolts and remove. Take note of the location of each bolt for reassembly. Remove the oil pump from the face of the engine block. If necessary, tap lightly with a soft face mallet. Use care working with light alloy parts.
  8.  
  9. To remove the relief valve from the pump body, unscrew threaded plug, then pull out the spring and valve. Note the order of the parts' removal.
  10.  

To install:
  1. Clean all parts well for inspection. Remove the bolts holding the back cover to the pump body. Remove the pump rotors. The mating surface of the oil pump should be smooth. Replace the pump cover if scratched or grooved.
  2.  
  3. The pump should be checked for wear by carefully measuring the components.
  4.  

If oil pressure is low and the pump is within specifications, inspect for worn engine bearings or other reasons for oil pressure loss.

  1. Clean all oil pump parts in suitable solvent before assembly. Assemble the pump with new parts as required. Install the inner rotor with the chamfer facing the cast iron oil pump cover (back of the pump) . Tighten the cover bolts to 105 inch lbs. (12 Nm).
  2.  
  3. Install the relief valve first, then the spring, gasket and cover cap into the pump body. Note that installing the spring first will seriously damage the engine. The relief valve goes in first. Tighten the cover cap to 40 ft. lbs. (55 Nm).
  4.  
  5. Prime the oil pump before installation by filling the rotor cavity with clean engine oil.
  6.  
  7. Insert a new oil ring seal in the oil pump counterbore on the pump body discharge passage. Apply Mopar Gasket Maker or equivalent anaerobic type gasket sealer, to the oil pump body flange. This material cures in the absence of air when squeezed between two flat machined metal surfaces. For this reason, the mating surfaces of both the pump body and the engine block must be spotlessly clean so all air will be expelled when the parts are bolted together and tightened. Install the pump slowly onto the crankshaft aligning the oil pump rotor flats with the flats on the crankshaft until seated to the engine block. Tighten the fasteners to 20 ft. lbs. (28 Nm).
  8.  
  9. Install a new front oil seal. Install the seal with the spring side towards the inside of the engine. Tap the seal into place until flush with the cover.
  10.  
  11. Install the crankshaft sprocket. A special tool is used to draw the sprocket onto the end of the crankshaft. Use care if using a substitute tool.
  12.  
  13. Raise and safely support the vehicle.
  14.  
  15. Install the oil pump pick-up tube and O-ring. Tighten the oil pump pick-up tube mounting bolt to 20 ft. lbs. (28 Nm).
  16.  
  17. Thoroughly clean the oil pan and be sure the gasket rails are in good condition. Use Mopar Silicone Rubber Adhesive Sealant or equivalent sealer at the oil pump-to-engine block parting line. Use a new oil pan gasket, install the oil pan and tighten the 13 oil pan bolts to 105 inch lbs. (12 Nm).
  18.  
  19. Install a new oil filter.
  20.  
  21. Lower the vehicle.
  22.  
  23. Install the timing belt and covers using the recommended procedures. Use care to be sure all valve timing marks are aligned. This is most important. Failure to properly align the timing marks will result in severe engine damage.
  24.  
  25. Install the crankshaft damper. A special tool making use of a 12mm x 1.75 x 150mm bolt is used to draw the crankshaft damper onto the end of the crankshaft. Use care if using substitute tools. Tighten the center bolt to 105 ft. lbs. (142 Nm).
  26.  
  27. Install the accessory drive belts, as required. Adjust the accessory drive belts to the proper tension.
  28.  
  29. Install the engine mount and bracket, as required. Remove the engine support fixture from the vehicle.
  30.  
  31. Refill the engine with the correct type and amount of fresh, clean engine oil. Refill the cooling system with a 50 / 50 mixture of clean, ethylene glycol antifreeze and water.
  32.  
  33. Test run the vehicle to check for leaks. An oil pressure gauge should be installed to verify proper engine oil pressure.
  34.  

3.0L Engine

See Figure 3



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Fig. Fig. 3: Exploded view of the oil pump assembly-3.0L engine

The oil pump assembly is mounted at the front of the crankshaft. The oil pump housing also retains the front crankshaft oil seal. Since the timing belt must be removed to access the front cover, care must be taken. It is good practice to set the engine up to TDC No. 1 cylinder firing position. Verify that all timing marks on the crankshaft and camshaft sprockets are properly aligned before removing the timing belt. This serves as a point of reference for all work that follows. Valve timing is most important and engine damage will result if the work is incorrect.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the accessory drive belts.
  4.  
  5. Remove the air conditioning compressor from the mounting bracket and lay it aside, if equipped. Remove the compressor mounting bracket and adjustable drive belt tensioner from the engine.
  6.  
  7. Remove the power steering pump/alternator belt tensioner mounting bolt and remove the tensioner.
  8.  
  9. Remove the power steering pump mounting bracket bolts, rear support locknut and set the power steering pump aside.
  10.  
  11. Raise and safely support the vehicle.
  12.  
  13. Drain the engine oil into a suitable container.
  14.  
  15. Remove the right inner fender inner shield.
  16.  
  17. Remove the crankshaft drive pulley bolt, drive pulley and torsional damper. Lower the vehicle.
  18.  
  19. Place a floor jack under the engine. Separate the engine mount insulator from the engine mount bracket.
  20.  
  21. Raise the engine slightly and remove the engine mount bracket.
  22.  
  23. Remove the timing belt cover and timing belt.
  24.  
  25. Remove the crankshaft sprocket.
  26.  
  27. Remove the five oil pump mounting bolts, then remove the oil pump assembly. Mark the mounting bolts for proper installation during reassembly.
  28.  
  29. Remove the front crankshaft oil seal from the oil pump cover.
  30.  

To install:
  1. Clean all parts well for inspection. Remove the bolts holding the rear cover to the oil pump body. Remove the pump rotors. The mating surface of the oil pump should be smooth. Replace the pump cover if scratched or grooved.
  2.  
  3. The pump should be checked for wear by carefully measuring the components.
  4.  

If oil pressure is low and the pump is within specifications, inspect for worn engine bearings or other reasons for oil pressure loss.

  1. Clean all oil pump parts in suitable solvent before assembly. Assemble the pump with new parts as required.
  2.  
  3. Clean the oil pump and engine block gasket surfaces thoroughly.
  4.  
  5. Position a new gasket on the pump assembly and install on the cylinder block. Be sure the correct length bolts are in their proper locations and tighten all bolts to 11 ft. lbs. (15 Nm).
  6.  
  7. Install a new front crankshaft oil seal into the oil pump using seal installer tool MD-998717 or an equivalent seal driver tool.
  8.  
  9. Install the crankshaft sprocket and timing belt. Recheck the engine timing marks.
  10.  
  11. Install the timing belt covers. Tighten the timing belt cover fasteners to 10 ft. lbs. (14 Nm).
  12.  
  13. Raise the engine slightly and install the engine mount bracket. Install the engine mount insulator into the engine mount bracket.
  14.  
  15. Install the torsional damper, crankshaft drive pulley and drive pulley bolt. Tighten to 112 ft. lbs. (151 Nm).
  16.  
  17. Install the right fender inner splash shield. Lower the vehicle.
  18.  
  19. Install the power steering mount bracket and power steering pump.
  20.  
  21. Install the power steering/alternator belt tensioner.
  22.  
  23. Install the air conditioning adjustable drive belt tensioner and mounting bracket. Tighten the mounting bolts to 40 ft. lbs. (54 Nm).
  24.  
  25. Install the air conditioning compressor. Tighten the compressor mounting bolts to 40 ft. lbs. (54 Nm).
  26.  
  27. Install the accessory drive belts and adjust to the proper tension.
  28.  
  29. Reconnect the negative battery cable.
  30.  
  31. Refill the crankcase with the correct amount of clean engine oil and start the engine. Check for leaks.
  32.  
  33. Check engine oil pressure.
  34.  

3.3L and 3.8L Engines

See Figures 4, 5, 6 and 7



Click image to see an enlarged view

Fig. Fig. 4: Oil pump system operation

  1. Disconnect the negative battery cable. Remove the dipstick. Drain the cooling system.
  2.  
  3. Raise the vehicle and support safely. Support the engine and remove the right side engine mount.
  4.  
  5. Drain the oil and remove the oil pan.
  6.  
  7. Remove the oil pick-up tube. Remove the transaxle inspection cover, if necessary.
  8.  
  9. Remove the timing chain case cover.
  10.  
  11. Disassemble the oil pump as required.
  12.  

To install:
  1. Clean all parts well for inspection. Remove the bolts holding the back cover to the pump body. Remove the pump rotors. The mating surface of the oil pump should be smooth. Replace the pump cover if scratched or grooved.
  2.  
  3. The pump should be checked for wear by carefully measuring the components.
  4.  

If oil pressure is low and the pump is within specifications, inspect for worn engine bearings or other reasons for oil pressure loss.

  1. Clean all oil pump parts in suitable solvent before assembly. Assemble the pump with new parts as required. Install the inner rotor with the chamfer facing the cast iron oil pump cover (back of the pump) . Tighten the cover bolts to 105 inch lbs. (12 Nm).
  2.  



Click image to see an enlarged view

Fig. Fig. 5: Oil pump assembly and mounting bolt lengths



Click image to see an enlarged view

Fig. Fig. 6: Oil pump assembly components



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Fig. Fig. 7: Checking the oil pump pressure after installation is complete

  1. Install the relief valve first, then the spring, then the cover cap into the pump body. Note that installing the spring first will seriously damage the engine. The relief valve goes in first.
  2.  
  3. Prime the oil pump by filling the rotor cavity with fresh oil and turning the rotors until oil comes out the pressure port. Repeat a few times until no air bubbles are present.
  4.  
  5. Install the chain case cover. Tighten the timing chain case cover bolts as follows:
    1. M8 x 1.25-20 ft. lbs. (27 Nm)
    2.  
    3. M10 x 1.5-40 ft. lbs. (54 Nm)
    4.  

  6.  
  7. Clean out the oil pick-up or replace as required. Replace the oil pick-up O-ring and install the pick-up to the pump. Tighten the pick-up tube retaining bolt to 250 inch lbs. (28 Nm).
  8.  
  9. Install the oil pan. Install the right side engine mount.
  10.  
  11. Lower the vehicle. Install the dipstick. Refill the engine with the proper amount of oil.
  12.  
  13. Refill the cooling system to the proper level.
  14.  
  15. Reconnect the negative battery cable and start the engine.
  16.  
  17. Check the area for leaks and check the oil pressure.
  18.  

 
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