Chrysler Caravan/Voyager/Town n Country 1984-1995

Front Timing Cover and Seal

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REMOVAL & INSTALLATION



2.2L and 2.5L Engines

See Figures 1, 2, 3, 4, 5, 6, 7 and 8



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Fig. Fig. 1: Timing system and seals-2.2L and 2.5L engines



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Fig. Fig. 2: Right inner splash shield-2.2L and 2.5L engines



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Fig. Fig. 3: Crankshaft and water pump pulley-2.2L and 2.5L engines



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Fig. Fig. 4: Timing belt cover-2.2L and 2.5L engines



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Fig. Fig. 5: Remove the 3 water pump pulley retaining screws and remove the pulley



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Fig. Fig. 6: Remove the 4 crankshaft pulley retaining screws and remove the pulley



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Fig. Fig. 7: After removing the upper cover remove the lower cover retaining screws



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Fig. Fig. 8: Removing the lower cover

  1. Remove the accessory drive belts.
  2.  
  3. Support the vehicle on jackstands and remove the right inner splash shield.
  4.  
  5. Loosen and remove the 3 water pump pulley mounting screws and remove the pulley.
  6.  
  7. Remove the 4 crankshaft pulley retaining screws.
  8.  
  9. Remove the nuts at upper portion of timing cover and screws from lower portion and remove both halves of cover.
  10.  

To install:
  1. Install the cover. Secure the upper section to cylinder head with nuts and lower section to cylinder block with screws.
  2.  
  3. Install the crankshaft pulley and tighten the bolt to 20 ft. lbs. (27 Nm).
  4.  
  5. Lower the vehicle.
  6.  
  7. Install the water pump pulley, then tighten the mounting bolts to 105 inch lbs. (12 Nm).
  8.  
  9. Install the accessory drive belts.
  10.  

2.6L Engines

See Figure 9



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Fig. Fig. 9: Timing case cover assembly-2.6L engines

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Remove the accessory drive belts.
  6.  
  7. Remove the alternator mounting bolts and remove alternator.
  8.  
  9. Remove the power steering mounting bolts and set power steering pump aside.
  10.  
  11. Remove the air conditioner compressor mounting bolts and set compressor aside.
  12.  
  13. Support the vehicle on jackstands and remove right inner splash shield.
  14.  
  15. Drain the engine oil.
  16.  


CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

  1. Remove the crankshaft pulley.
  2.  
  3. Lower the vehicle and place a jack under the engine with a piece of wood between jack and lifting point.
  4.  
  5. Raise the jack until contact is made with the engine. Relieve pressure by jacking slightly and remove the center bolt from the right engine mount. Remove right engine mount.
  6.  
  7. Remove the engine oil dipstick.
  8.  
  9. Remove the engine valve cover. Refer to Rocker Cover removal procedures earlier in this section.
  10.  
  11. Remove the front (2) cylinder head to timing chain cover bolts.
  12.  

Do not loosen any other cylinder head bolts.

  1. Remove the oil pan retaining bolts and lower the oil pan.
  2.  
  3. Remove the screws holding the timing indicator and engine mounting plate.
  4.  
  5. Remove the bolts holding the timing chain case cover and remove the cover.
  6.  

To install:
  1. Clean and inspect the chain case cover for cracks or other damage.
  2.  
  3. Position a new timing chain case cover gasket on the case cover. Trim as required to assure a proper fit at the top and bottom.
  4.  
  5. Coat the cover gasket with sealant (P/N 3419115) or equivalent. Install chain case cover and tighten mounting bolts to 13 ft. lbs. (18 Nm).
  6.  
  7. Install the (2) front cylinder head-to-timing chain case cover mounting bolts and tighten to 13 ft. lbs. (18 Nm).
  8.  
  9. Install the engine oil pan, then tighten the mounting bolts to 53 inch lbs. (6 Nm).
  10.  
  11. Install the engine mounting plate and timing indicator.
  12.  
  13. Install the crankshaft pulley.
  14.  
  15. Install the right engine mount, lower engine and install right engine mount center bolt.
  16.  
  17. Install the engine valve cover.
  18.  
  19. Install the engine oil dipstick.
  20.  
  21. Install the air conditioner compressor.
  22.  
  23. Install the power steering pump.
  24.  
  25. Install the alternator.
  26.  
  27. Install the accessory drive belts.
  28.  
  29. Fill the engine crankcase with recommended engine oil.
  30.  
  31. Install the air cleaner assembly.
  32.  
  33. Connect the negative battery cable.
  34.  

3.0L Engines

See Figure 10



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Fig. Fig. 10: Timing belt covers-3.0L engines

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the accessory drive belts.
  4.  
  5. Remove the air conditioner compressor mounting bracket bolts and lay compressor aside.
  6.  
  7. Remove the air conditioner mounting bracket and adjustable drive belt tensioner from engine.
  8.  
  9. Remove the steering pump/alternator belt tensioner mounting bolt and remove belt tensioner.
  10.  
  11. Remove the power steering pump mounting bracket bolts, rear support locknut and set power steering pump aside.
  12.  
  13. Raise the vehicle and support on jackstands.
  14.  
  15. Remove the right inner splash shield.
  16.  
  17. Remove the crankshaft drive pulley bolt, drive pulley and torsional damper.
  18.  
  19. Lower the vehicle and place a floor jack under the engine. Separate engine mount insulator from engine mount bracket.
  20.  
  21. Raise the engine slightly and remove engine mount bracket.
  22.  
  23. Remove the timing belt covers.
  24.  

To install:
  1. Install the timing belt covers and tighten all screws to 10 ft. lbs. (14 Nm).
  2.  
  3. Raise the engine slightly and install engine mount bracket.
  4.  
  5. Install the engine mount insulator into engine mount bracket.
  6.  
  7. Install the torsional damper, drive pulley and drive pulley bolt. Tighten bolt to 150 ft. lbs. (205 Nm). Install the right inner splash shield.
  8.  
  9. Install the power steering mounting bracket and install the power steering pump.
  10.  
  11. Install the steering pump/alternator belt tensioner.
  12.  
  13. Install the air conditioner adjustable drive belt tensioner and mounting bracket.
  14.  
  15. Install the air conditioner compressor.
  16.  
  17. Install the accessory drive belts.
  18.  
  19. Connect the negative battery cable.
  20.  

3.3L and 3.8L Engines

See Figures 11 and 12



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Fig. Fig. 11: Timing chain case cover retaining bolts-3.3L and 3.8L engines



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Fig. Fig. 12: Timing chain case cover gaskets and O-rings-3.3L and 3.8L engines

  1. Disconnect the negative battery cable. Drain the cooling system.
  2.  
  3. Support the engine with a suitable engine support device and remove the right side motor mount.
  4.  
  5. Raise the vehicle and support safely. Drain the engine oil and remove the oil pan.
  6.  
  7. Remove the right wheel and tire assembly, then remove the splash shield.
  8.  
  9. Remove the drive belt.
  10.  
  11. Unbolt the air conditioning compressor and position it to the side. Remove the compressor mounting bracket.
  12.  
  13. Remove the crankshaft pulley bolt and remove the pulley using a suitable puller.
  14.  
  15. Remove the idler pulley from the engine bracket and remove the bracket.
  16.  
  17. Remove the cam sensor from the timing chain cover.
  18.  
  19. Unbolt and remove the 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.
  20.  

To install:
  1. Thoroughly clean and dry the gasket mating surfaces. Install new O-rings to the block.
  2.  
  3. Remove the crankshaft oil seal from the cover. The seal must be removed from the cover when installing to ensure proper oil pump engagement.
  4.  
  5. Using a new gasket, install the chain case cover to the engine.
  6.  
  7. Make certain that the oil pump is engaged onto the crankshaft before proceeding, or severe engine damage will result. Install the attaching bolts and tighten to 20 ft. lbs. (27 Nm).
  8.  
  9. Use tool C-4992 (or equivalent) to install the crankshaft oil seal. Install the crankshaft pulley using a 5.9 in. suitable bolt and thrust bearing and washer plate L-4524 (or equivalent). Make sure the pulley bottoms out on the crankshaft seal diameter. Install the bolt and tighten to 40 ft. lbs. (54 Nm).
  10.  
  11. Install the engine bracket and tighten the bolts to 40 ft. lbs. (54 Nm). Install the idler pulley to the engine bracket.
  12.  
  13. To 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 in to its bore in the timing case cover until contact is made with the cam timing gear. Hold in this position and tighten it to 9 ft. lbs. (12 Nm).
  14.  
  15. Install the air conditioning compressor and bracket.
  16.  
  17. Install the drive belt.
  18.  
  19. Install the inner splash shield, then install the wheel and tire assembly.
  20.  
  21. Install the oil pan with a new gasket.
  22.  
  23. Install the motor mount.
  24.  
  25. Remove the engine temperature sensor and fill the cooling system until the level reaches the vacant sensor hole. Install the sensor and continue to fill the radiator. Fill the engine with the proper amount of oil.
  26.  
  27. Connect the negative battery cable and check for leaks.
  28.  

 
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