Chrysler Caravan/Voyager/Town and Country 1996-1999

Timing Chain Cover

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REMOVAL & INSTALLATION



3.3L and 3.8L Engines

See Figures 1, 2, 3 and 4



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Fig. Fig. 1: Install the new oil seal with the installation tool C-4992-3.3L and 3.8L engines



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Fig. Fig. 2: Remove these four engine bracket fasteners-3.3L and 3.8L engines

  1. If removing the timing chain, turn the crankshaft and position the engine so the No. 1 piston is at TDC on the compression stroke (firing position).
  2.  
  3. Disconnect the negative battery cable. Drain the engine coolant.
  4.  
  5. Support the engine with a floor jack and remove the right engine mount.
  6.  
  7. Raise and safely support the vehicle. Drain the engine oil.
  8.  
  9. Remove the oil pan and oil pump pick-up tube. If necessary, remove the transaxle inspection cover.
  10.  
  11. Remove the right front wheel and inner fender splash shield.
  12.  
  13. Remove the accessory drive belt.
  14.  
  15. Remove the air conditioning compressor and set aside. Remove A/C compressor mounting bracket.
  16.  
  17. Remove the crankshaft pulley bolt and remove the pulley using a suitable puller.
  18.  
  19. Remove the idler pulley from the engine bracket and remove the bracket.
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  21. Remove the cam sensor from the timing chain cover.
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  23. Unbolt and remove the timing chain cover from the engine. Make sure the oil pump inner rotor does not fall out.
  24.  



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Fig. Fig. 3: To remove the timing chain cover loosen the seven fasteners-3.3L and 3.8L engines



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Fig. Fig. 4: Timing chain case cover gaskets and O-rings-3.3L and 3.8L engines

  1. Remove the crankshaft oil seal from the cover. The seal must be removed from the cover when installing to ensure proper oil pump engagement. The seal is installed from the front AFTER the timing chain front cover is completely installed as outlined below.
  2.  

To install:
  1. Using a new gasket, install the timing chain cover to the engine. DO NOT adhere the new gasket to the cover. Make sure the lower edge of the gasket is flush to 0.020 in. (0.50mm) past the lower edge of the cover.
  2.  
  3. If necessary, rotate the crankshaft so the oil pump drive flats are vertical and position the oil pump rotor so its mating flats are in the same position. Make certain that the oil pump is engaged onto the crankshaft before proceeding, or severe engine damage will result. Install the attaching bolts and torque to 20 ft. lbs. (27 Nm).
  4.  
  5. Use tool C-4992 or equivalent seal driver to install the crankshaft oil seal.
  6.  
  7. Install the crankshaft pulley.
  8.  
  9. Install the engine bracket and torque the bolts to 40 ft. lbs. (54 Nm). Install the idler pulley to the engine bracket.
  10.  
  11. Install the cam sensor, first clean off the old spacer from the sensor face completely. Inspect the O-ring for damage and replace if necessary. A new spacer must be attached to the cam sensor, prior to installation. If a new spacer is not used, engine performance will be affected. Oil the O-ring lightly and push the sensor into its bore in the timing case cover until contact is made with the cam timing sprocket. Hold in this position and tighten it to 108 inch lbs. (12 Nm).
  12.  
  13. Reconnect the sensor connector to the wiring harness connector. Position the wiring harness away from the accessory drive belt.
  14.  
  15. Install the air conditioning compressor and mounting bracket.
  16.  
  17. Install the drive belt.
  18.  
  19. Install the inner splash shield and the wheel. Torque the wheel lug nuts, in a star pattern, to 95 ft. lbs. (129 Nm).
  20.  
  21. Install the oil pan with a new gasket. Torque the oil pan bolts to 105 inch lbs. (12 Nm).
  22.  
  23. Install the motor mount.
  24.  
  25. Refill the cooling system to the correct level with a 50 / 50 mixture of clean, fresh ethylene glycol antifreeze and water.
  26.  
  27. Fill the engine with the proper amount and type of clean engine oil.
  28.  
  29. Reconnect the negative battery cable. Road test the vehicle and check for leaks.
  30.  

 
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