Chrysler Caravan/Voyager/Town n Country 1984-1995

Oil Pump

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REMOVAL & INSTALLATION



2.2L and 2.5L Engines

See Figures 1, 2, 3 and 4



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Fig. Fig. 1: Oil pump application-2.2L and 2.5L engines



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Fig. Fig. 2: Oil pump shaft alignment-2.2L engines



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Fig. Fig. 3: Oil pump pick-up tube and screen



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Fig. Fig. 4: Oil pump pick-up tube and screen-2.2L engines

  1. Raise and safely support the vehicle.
  2.  
  3. Drain the oil and remove engine oil pan. For more details, refer to the oil pan removal procedure earlier in this section.
  4.  


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 pump mounting bolts.
  2.  
  3. Pull the pump down and out of the engine.
  4.  

To install:
  1. Prime the new oil pump, by filling it with fresh oil. Check crankshaft/intermediate shaft timing and oil pump drive alignment. Adjust if necessary.
  2.  
  3. Install pump and rotate back and forth slightly to ensure full surface contact of pump and block.
  4.  
  5. While holding pump in fully seated position, install pump mounting bolts. Tighten the mounting bolts to 15 ft. lbs. (20 Nm).
  6.  
  7. Install engine oil pan. For more details, refer to the oil pan installation procedures.
  8.  
  9. Refill crankcase, then start the engine.
  10.  
  11. Check engine oil pressure and check the engine for any oil leaks.
  12.  

2.6L Engines

See Figure 5



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Fig. Fig. 5: Oil pump assembly-2.6L engines

  1. Remove the accessory drive belts.
  2.  
  3. Remove the timing chain case cover. Refer to the Front Timing Cover and Seal procedure later in this section.
  4.  
  5. Remove the silent shaft chain assembly and timing chain assembly. For more details, refer to the timing chain removal procedures.
  6.  
  7. Remove the silent shaft bolt (it's the bolt directly above the silent chain sprocket).
  8.  
  9. Remove the oil pump bolts and pull the pump housing straight forward. Remove the gaskets and the oil pump backing plate.
  10.  

To install:
  1. Clean gasket from mounting surfaces.
  2.  
  3. Install new gaskets/seals, align mating marks of the oil pump gears, refill the pump with oil, and install the pump assembly.
  4.  
  5. Install oil pump silent shaft sprocket and sprocket bolt. Tighten sprocket bolt to 25 ft. lbs. (34 Nm).
  6.  
  7. Install timing chain and silent shaft chain assembly. Refer to the timing chain installation procedure earlier in this section.
  8.  
  9. Install the timing chain case cover. Refer to the Front Timing Cover and Seal procedure later in this section.
  10.  
  11. Install the accessory drive belts.
  12.  
  13. Reconnect the battery negative cable.
  14.  
  15. Start the engine, then check for correct engine oil pressure and for any oil leakage.
  16.  

3.0L Engines

See Figure 6



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Fig. Fig. 6: Oil pump components-3.0L engines

The oil pump assembly used on this engine is mounted at the front of the crankshaft. The oil pump also retains the crankshaft front oil seal.

  1. Remove the accessory drive belts.
  2.  
  3. Remove the timing belt cover and timing belt. Refer to the timing belt removal and installation procedures in this section.
  4.  
  5. Remove the crankshaft sprocket.
  6.  
  7. Remove the oil pump mounting bolts (5), and remove oil pump assembly. Mark mounting bolts for proper installation during reassembly.
  8.  

To install:
  1. Clean the oil pump and engine block gasket surfaces thoroughly.
  2.  
  3. Position a new gasket on pump assembly and install on cylinder block. Make sure correct length bolts are in proper locations and tighten all bolts to 10 ft. lbs. (14 Nm).
  4.  
  5. Install the crankshaft sprocket and timing belt. Recheck engine timing marks.
  6.  
  7. Install the timing belt covers. For more details, refer to the timing belt cover installation procedures.
  8.  
  9. Install the accessory drive belts.
  10.  
  11. Refill the crankcase and start the engine.
  12.  
  13. Check for correct engine oil pressure and for any oil leakage.
  14.  

3.3L and 3.8L Engines

See Figures 7 and 8



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Fig. Fig. 7: Oil pump assembly-3.3L and 3.8L engines



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Fig. Fig. 8: Oil pressure relief valve-3.3L and 3.8L engines

  1. Disconnect the negative battery cable. Remove the dipstick.
  2.  
  3. Raise the vehicle and support safely. Drain the oil and remove the oil pan.
  4.  
  5. Remove the oil pickup.
  6.  
  7. Remove the chain case cover.
  8.  
  9. Disassemble the oil pump as required.
  10.  

To install:
  1. Assemble the pump. Tighten the cover screws to 10 ft. lbs. (14 Nm).
  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.
  6.  
  7. Clean out the oil pickup or replace as required. Replace the oil pickup O-ring and install the pickup to the pump.
  8.  
  9. Install the oil pan.
  10.  
  11. Install the dipstick. Fill the engine with the proper amount of oil.
  12.  
  13. Connect the negative battery cable and check the oil pressure. Check for any oil leaks.
  14.  

INSPECTION



2.2L and 2.5L Engines

  1. Remove the cover from the oil pump.
  2.  
  3. Check end-play of the inner rotor using a feeler gauge and a straight edge placed across the pump body. The specification is 0.001-0.004 in. (0.03-0.09mm).
  4.  
  5. Measure the clearance between the inner and outer rotors. The maximum clearance is 0.008 in. (0.20mm).
  6.  
  7. Measure the clearance between the outer rotor and the pump body. The maximum clearance is 0.014 in. (0.35mm).
  8.  
  9. The minimum thickness of the outer rotor is 0.944 in. (23.96mm). The minimum diameter of the outer rotor is 2.77 in. (62.70mm). The minimum thickness of the inner rotor is 0.943 in. (23.95mm).
  10.  
  11. Check the cover for warpage. The maximum allowable is 0.003 in. (0.076mm).
  12.  
  13. Check the pressure relief valve for damage. The spring's free length specification is 1.95 in. (49.50mm).
  14.  
  15. Assemble the outer rotor with the larger chamfered edge in the pump body. Tighten the cover screws to 10 ft. lbs. (14 Nm).
  16.  

2.6L Engines
  1. Remove the cover from the oil pump.
  2.  
  3. Measure the clearance between the gears and their bearings. The specification for both is 0.0008-0.0020 in. (0.02-0.05mm).
  4.  
  5. Check the clearance between the gears and the housing. The specification for both gears is 0.004-0.006 in. (0.11-0.15mm).
  6.  
  7. Check end-play of the gears using a feeler gauge and a straight edge placed across the pump body. The specification for both is 0.002-0.004 in. (0.04-0.11mm).
  8.  
  9. Check the pressure relief valve for damage. The spring's free length specification is 1.85 in. (47.00mm).
  10.  
  11. If the gears were removed from the body, install them with the mating aligned. If they are not aligned properly, the silent shaft will be out of time.
  12.  
  13. Tighten the cover screws to 13 ft. lbs. (18 Nm).
  14.  

3.0L Engines
  1. Remove the rear cover.
  2.  
  3. Remove the pump rotors and inspect the case for excessive wear.
  4.  
  5. Measure the diameter of the inner rotor hub that sits in the case. Measure the inside diameter of the inner rotor hub bore. Subtract the first measurement from the second; if the result is over 0.006 in. (0.15mm), replace the oil pump assembly.
  6.  
  7. Measure the clearance between the outer rotor and the case. The specification is 0.004-0.007 in. (0.10-0.18mm).
  8.  
  9. Check the side clearance of the rotors using a feeler gauge and a straight edge placed across the case. The specification is 0.0015-0.0035 in. (0.04-0.09mm).
  10.  
  11. Check the relief plunger and spring for damage and breakage.
  12.  
  13. Install the rear cover to the case.
  14.  

3.3L and 3.8L Engines
  1. Thoroughly clean and dry all parts. The mating surface of the chain case cover should be smooth. Replace the pump cover if it is scratched or grooved.
  2.  
  3. Lay a straight edge across the pump cover surface. If a 0.076mm feeler gauge can be inserted between the cover and the straight edge, the cover should be replaced.
  4.  
  5. The maximum thickness of the outer rotor is 0.301 in. (7.63mm). The minimum diameter of the outer rotor is 3.14 in. (79.78mm). The minimum thickness of the inner rotor is 0.301 in. (7.64m).
  6.  
  7. Install the outer rotor onto the chain case cover, press to one side and measure the clearance between the rotor and case. If the measurement exceeds 0.022 in. (56mm) and the rotor is good, replace the chain case cover.
  8.  
  9. Install the inner rotor to the chain case cover and measure the clearance between the rotors. If the clearance exceeds 0.008 in. (0.203mm), replace both rotors.
  10.  
  11. Place a straight edge over the chain case cover between bolt holes. If a 0.004 in. (0.102mm) thick feeler gauge can be inserted under the straight edge, replace the pump assembly.
  12.  
  13. Inspect the relief valve plunger for scoring and freedom of movement. Small marks may be removed with 400-grit wet or dry sandpaper.
  14.  
  15. The relief valve spring should have a free length of 1.95 in. (49.5mm).
  16.  
  17. Assemble the pump using new parts where necessary.
  18.  

 
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