Chrysler Caravan/Voyager/Town and Country 1996-1999

Timing Chain and Gears

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REMOVAL & INSTALLATION



3.3L and 3.8L Engines

See Figures 1 and 2



Click image to see an enlarged view

Fig. Fig. 1: Timing mark alignment for 3.3 and 3.8L engines

  1. 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 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.
  18.  
  19. Remove the idler pulley from the engine bracket and remove the bracket.
  20.  
  21. Remove the camshaft position sensor.
  22.  
  23. Remove the timing chain cover from the engine. Make sure the oil pump inner rotor does not fall out. Remove the 3 O-rings from the coolant passages and the oil pump outlet.
  24.  
  25. Remove the camshaft sprocket attaching cup washer and remove the timing chain with both sprockets attached. Remove the timing chain snubber.
  26.  
  27. Remove the crankshaft sprocket using a suitable puller tool.
  28.  



Click image to see an enlarged view

Fig. Fig. 2: Measuring timing chain stretch and wear-3.3 and 3.8L engines

To install:
  1. Assemble the timing chain and sprockets.
  2.  
  3. Turn the crankshaft and camshaft to line up with the key way locations of the sprockets.
  4.  
  5. Slide both sprockets over their respective shafts and use a straightedge to confirm alignment.
  6.  
  7. Install the cup washer and camshaft bolt. Torque the bolt to 40 ft. lbs. (54 Nm).
  8.  
  9. Check camshaft end-play. The specification with a new plate is 0.005-0.012 in. (0.0127-0.304mm) and 0.012 in. (0.310mm) maximum with a used plate. Replace the thrust plate if not within specifications.
  10.  
  11. Install the timing chain snubber.
  12.  
  13. Clean all parts well. Thoroughly clean and dry the gasket mating surfaces. Install new O-rings to the block.
  14.  
  15. 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.
  16.  
  17. Using a new gasket, install the chain case 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.
  18.  
  19. 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).
  20.  
  21. Use tool C-4992 or equivalent seal driver to install the crankshaft oil seal.
  22.  
  23. Install the crankshaft pulley using a bolt approximately 6 in. (150mm) long and thrust bearing and washer plate. Make sure the pulley bottoms out on the crankshaft seal diameter. Install the bolt and torque to 40 ft. lbs. (54 Nm).
  24.  
  25. Install the engine bracket and torque the bolts to 40 ft. lbs. (54 Nm). Install the idler pulley to the engine bracket.
  26.  
  27. Install the camshaft position sensor.
  28.  
  29. Install the air conditioning compressor and mounting bracket.
  30.  
  31. Install the drive belt.
  32.  
  33. Install the inner splash shield and the wheel. Torque the wheel lug nuts, in a star pattern, to 95 ft. lbs. (129 Nm).
  34.  
  35. Install the oil pan.
  36.  
  37. Install the motor mount.
  38.  
  39. Refill the cooling system to the correct level with a 50 / 50 mixture of clean, fresh ethylene glycol antifreeze and water.
  40.  
  41. Fill the engine with the proper amount and type of clean engine oil.
  42.  
  43. Reconnect the negative battery cable. Road test the vehicle and check for leaks.
  44.  

 
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