GrandCaravan 2008

Cylinder Head

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Removal & Installation



3.3L & 3.8L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Disconnect the negative cable from the battery.
  6.  
  7. Remove the upper and lower intake manifolds. Refer to Intake Manifold, removal & installation.
    CAUTION
    The intake manifold gasket is made of very thin metal and may cause personal injury; handle with care.

  8.  
  9. Remove the cylinder head covers. Refer to Valve Covers, removal & installation.
  10.  
  11. Remove the spark plugs from the cylinder head.
  12.  
  13. Remove the oil dipstick and tube.
  14.  
  15. Remove the exhaust manifold(s). Refer to Exhaust Manifold, removal & installation.
  16.  
  17. Remove the rocker arm and shaft assemblies. Refer to Rocker Arms/Shafts, removal & installation.
  18.  
  19. Remove the push rods and mark the positions to ensure reinstallation in the original locations.
  20.  
  21. Remove the 8 head bolts from each cylinder head and remove the cylinder heads.
  22.  

To install:

  1. Clean all the sealing surfaces of the engine block and the cylinder heads.
  2.  
  3. Position a new gasket on the engine block. The left bank gasket is identified with an L stamped in the exposed area of the gasket located at the front of the engine. The right bank gasket is identified with an R stamped in the exposed area of the gasket also, but it is located at the rear of the engine.
  4.  
  5. The cylinder head bolts should be examined BEFORE reuse. If the threads are necked down, the bolts must be replaced.
  6.  
  7. Necking can be checked by holding a scale or straight edge against the threads. If all the threads do not contact the scale, the bolt should be replaced.

    Click image to see an enlarged view

    Fig. The cylinder head bolts should be examined BEFORE reuse. If the threads are necked down, the bolts must be replaced

  8.  
  9. Tighten the cylinder head bolts 1-8 in the following sequence. Using the 4 step torque turn method, tighten according to the following values:
    1. Step 1: Bolts 1-8 to 45 ft. lbs. (61 Nm).
    2.  
    3. Step 2: Bolts 1-8 to 65 ft. lbs. (88 Nm).
    4.  
    5. Step 3: Bolts 1-8 (again) to 65 ft. lbs. (88 Nm).
    6.  
    7. Step 4: Bolts 1-8 turn an additional 1 / 4 turn (90°).
      NOTE
      The bolt torque after the 1 / 4 turn should be over 90 ft. lbs. (122 Nm). If not, replace the bolt.



      Click image to see an enlarged view

      Fig. Cylinder head bolt tightening sequence-3.3L and 3.8L engines

    8.  

  10.  
  11. Inspect the push rods and replace worn or bent rods.
  12.  
  13. Install the push rods.
  14.  
  15. Install the rocker arm and shaft assemblies. Refer to Rocker Arms/Shafts, removal & installation.
  16.  
  17. Install the cylinder head covers. Refer to Valve Covers, removal & installation.
  18.  
  19. Install the exhaust manifolds. Refer to Exhaust Manifold, removal & installation.
  20.  
  21. Install a new O-ring on the dipstick tube. Install the dipstick tube assembly.
  22.  
  23. Install the spark plugs.
  24.  
  25. Install the upper and lower intake manifolds. Refer to Intake Manifold, removal & installation.
  26.  
  27. Fill the cooling system with the proper type and amount of fluid.
  28.  
  29. Connect the negative cable to the battery.
  30.  

4.0L Engine
Left Side

Specific to:

Chrysler Town & Country 2008-2009

Dodge Grand Caravan 2008-2009

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Perform the fuel system pressure relief procedure.
  4.  
  5. Disconnect and isolate the negative battery cable.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove the engine cover.
  10.  
  11. Remove the air cleaner element housing.
  12.  
  13. Remove the upper intake manifold. Refer to Intake Manifold, removal & installation.
  14.  
  15. Remove fuel rail and lower intake manifold. Refer to Intake Manifold, removal & installation.
  16.  
  17. Remove the radiator crossmember.
  18.  
  19. Remove the coolant recovery container and the radiator fan assembly.
  20.  
  21. Raise and safely support the vehicle.
  22.  
  23. Remove the right front tire.
  24.  
  25. Remove the right inner splash shield.
  26.  
  27. Remove accessory drive belt.
  28.  
  29. Remove the accessory drive belt tensioner (1).

    Click image to see an enlarged view

    Fig. Remove the accessory drive belt tensioner

  30.  
  31. Remove the crankshaft damper. Refer to Crankshaft Damper, removal & installation.
  32.  
  33. Remove the lower outer timing belt cover bolts.
  34.  
  35. Remove the left exhaust manifold/converter (maniverter). Refer to Exhaust Manifold, removal & installation.
  36.  
  37. Lower the vehicle.
  38.  
  39. Remove the accessory drive belt idler pulley.
  40.  
  41. Remove the power steering mounting bolts and set the pump aside.
  42.  
  43. Support the engine with a block of wood and a floor jack.
  44.  
  45. Remove the upper engine mount.
  46.  
  47. Remove the power steering reservoir bolts and set the reservoir aside.
  48.  
  49. Remove the remaining outer timing belt cover bolts and the cover.
  50.  
  51. Rotate the engine to TDC and align timing belt marks (1, 8, 9).

    Click image to see an enlarged view

    Fig. Timing Belt alignment-4.0L engine

  52.  
  53. Remove the timing belt tensioner (12) and reset the tensioner.
  54.  
  55. Remove the timing belt (4).
  56.  
  57. Remove the left cylinder head cover-to-cylinder head ground strap.
  58.  
  59. Remove the left cylinder head cover. Refer to Valve Covers, removal & installation.
  60.  
  61. Remove 10 bolts and the left rocker arm assembly.
  62.  
  63. Remove the 3 bolts (2) and the left camshaft thrust plate (1) with the gasket (3).

    Click image to see an enlarged view

    Fig. Camshaft thrust plate removal-4.0L engine

  64.  
  65. Counter-hold the left cam gear and remove the cam gear retaining bolt.
  66.  
  67. Push the camshaft out of the back of the cylinder head approximately 3.5 inches and remove the cam gear.

    Click image to see an enlarged view

    Fig. Camshaft Gear removal LH-4.0L engine

  68.  
  69. Remove the 4 inner timing cover-to-left cylinder head retaining bolts (1) and (2).

    Click image to see an enlarged view

    Fig. Timing cover removal-4.0L engine

  70.  
  71. Remove the cylinder head bolts in REVERSE of tightening sequence shown.

    Click image to see an enlarged view

    Fig. Cylinder head tightening sequence-4.0L engine

  72.  
  73. Push the camshaft (5) out of the back of the cylinder head approximately 3.5 inches and remove the cylinder head.
  74.  
  75. Clean and inspect all mating surfaces.
  76.  

To install:

  1. The cylinder head bolts should be examined BEFORE reuse. If the threads are necked down, the bolts must be replaced.
  2.  
  3. Necking can be checked by holding a scale or straight edge against the threads. If all the threads do not contact the scale, the bolt should be replaced.

    Click image to see an enlarged view

    Fig. The cylinder head bolts should be examined BEFORE reuse. If the threads are necked down, the bolts must be replaced

  4.  
  5. Install the camshaft in the cylinder head. Push the camshaft out of the back of the cylinder head approximately 3.5 inches. Install the head gasket and the cylinder head over the locating dowels.
    WARNING
    The cylinder head gaskets are not interchangeable between cylinder heads and are clearly marked right or left.

  6.  
  7. Ensure that the correct head gaskets are used and are oriented correctly on cylinder block.
  8.  
  9. Install and finger tighten the 8 head bolts.
  10.  
  11. Tighten the cylinder head bolts in the following sequence, using the 4 step torque-turn method. Tighten according to the following torque values:
    1. Step 1: All to 45 ft. lbs. (61 Nm).
    2.  
    3. Step 2: All to 65 ft. lbs. (88 Nm).
    4.  
    5. Step 3: All (again) to 65 ft. lbs. (88 Nm).
    6.  
    7. Step 4: Plus 90° turn. Do not use a torque wrench for this step.
      NOTE
      The bolt torque after the 90° turn should be over 90 ft. lbs. (122 Nm) in the tightening direction. If not, replace the bolt.

    8.  

  12.  
  13. Install the 4 inner timing cover-to-cylinder head bolts. Tighten the bolts to 40 ft. lbs. (54 Nm).
    NOTE
    The camshaft sprockets are keyed and not interchangeable from side to side because of the camshaft position sensor pick-up.

  14.  
  15. Push the camshaft back into the cylinder head and install the camshaft sprocket.
  16.  
  17. Install a NEW sprocket attaching bolt into place. The 10 inch (255mm) bolt is to be installed in the left camshaft and the 8 3 / 8 inch (213mm) bolt is to be installed into the right camshaft. Counter-hold the camshaft sprocket and tighten the camshaft sprocket bolt to 75 ft. lbs. (102 Nm) plus a 90° turn.
  18.  
  19. Install the camshaft thrust plate (1) and gasket (3). Tighten the 3 bolts to 250 inch lbs. (28 Nm).
  20.  
  21. Rotate the left camshaft gear (7) to align its timing mark (8). Verify that the right camshaft gear (2) timing mark (1) and crankshaft gear (10) timing mark (9) are still aligned.

    Click image to see an enlarged view

    Fig. Timing Belt alignment-4.0L engine

  22.  
  23. Install the timing belt (4) starting at the crankshaft sprocket (10) going in a counterclockwise direction. Install the belt around the last sprocket. Maintain tension on the belt as it is positioned around the tensioner pulley (11).
  24.  
  25. Holding the tensioner pulley (11) against the belt, install the tensioner (12) into the housing and tighten the 2 bolts to 250 inch lbs. (28 Nm). Each camshaft sprocket mark should remain aligned with the cover marks.
  26.  
  27. When the tensioner is in place, pull the retaining pin to allow the tensioner to extend to the tensioner pulley bracket.
  28.  
  29. Rotate crankshaft the sprocket 2 revolutions and check the timing marks on the camshafts and crankshaft. The marks should line up within their respective locations. If the marks do not line up, repeat the procedure.
    NOTE
    With the camshaft gears in these positions, the lobes are in a neutral position (no load to the valve). This will allow the rocker arm shaft assembly to be tightened into position with little or no valve spring load on it.

  30.  
  31. Install the rocker arm and shaft assembly and the 10 bolts making sure that the identification marks face toward the front of the engine for the left head and toward the rear of the engine for the right head.
  32.  
  33. Tighten the 10 rocker arm/shaft assembly bolts in sequence to 275 inch lbs. (31 Nm).

    Click image to see an enlarged view

    Fig. Rocker arm tightening sequence-4.0L engine

  34.  
  35. Clean the cylinder head and cover mating surfaces. Inspect and replace the gasket and seals, as necessary.
  36.  
  37. Install the left cylinder head cover and tighten bolts to 105 inch lbs. (12 Nm).
  38.  
  39. Install the spark plugs. Tighten to 20 ft. lbs. (28 Nm).
  40.  
  41. Install ignition coils into the cylinder head.
  42.  
  43. Install and tighten the coil mounting bolts to 60 inch lbs. (7 Nm).
  44.  
  45. Reposition the engine wire harness and install the retainers to the cylinder head cover. Connect and lock the electrical connectors to the ignition coils and the knock sensor.
  46.  
  47. Install the front timing belt outer covers.
  48.  
  49. Tighten the timing cover bolts as follows:

    M6 bolts: 105 inch lbs. (12 Nm)
     
    M8 bolts: 250 inch lbs. (28 Nm)
     
    M10 bolts: 40 ft. lbs. (54 Nm)
     

  50.  
  51. Install the power steering reservoir. Tighten the mounting nut to 108 inch lbs. (12 Nm).
  52.  
  53. Install the power steering pump.
  54.  
  55. Install the accessory drive belt idler pulley. Tighten the bolt to 250 inch lbs. (28 Nm).
  56.  
  57. Install the upper engine mount.
  58.  
  59. Install the left exhaust manifold/converter (maniverter). Refer to Exhaust Manifold, removal & installation.
  60.  
  61. Install the crankshaft damper. Refer to Crankshaft Damper, removal & installation.
  62.  
  63. Install the accessory drive belt tensioner (1). Tighten the bolt to 45 ft. lbs. (61 Nm).
  64.  
  65. Install the accessory drive belt. Refer to Accessory Drive Belts, removal & installation.
  66.  
  67. Install the right inner splash shield (1) (Refer to 23 - Body/Exterior/SHIELD, Splash - Installation)
  68.  
  69. Install the right front tire (Refer to 22 - Tires and Wheels - Installation)
  70.  
  71. Lower the vehicle.
  72.  
  73. Install the coolant recovery container and radiator fan assembly.
  74.  
  75. Install the radiator crossmember.
  76.  
  77. Install the lower intake manifold and the fuel rail.
  78.  
  79. Install the upper intake manifold including the EGR tube.
  80.  
  81. Install and connect the air cleaner element housing.
  82.  
  83. Install the engine cover.
  84.  
  85. Fill the coolant system with the proper type and amount of fluid.
  86.  
  87. Connect the negative battery cable. Tighten the nut to 40 inch lbs. (5 Nm).
  88.  

Right Side

Specific to:

Chrysler Town & Country 2008-2009

Dodge Grand Caravan 2008-2009

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Perform the fuel system pressure relief procedure.
  4.  
  5. Disconnect and isolate the negative battery cable.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove the engine cover.
  10.  
  11. Remove the air cleaner element housing.
  12.  
  13. Remove the upper intake manifold. Refer to Intake Manifold, removal & installation.
  14.  
  15. Remove the EGR tube.
  16.  
  17. Remove fuel rail and the lower intake manifold. Refer to Intake Manifold, removal & instillation.
  18.  
  19. Raise and safely support the vehicle.
  20.  
  21. Remove right front tire.
  22.  
  23. Remove right inner splash shield.
  24.  
  25. Remove accessory drive belt. Refer to Accessory Drive Belts, removal & installation.
  26.  
  27. Remove the accessory drive belt tensioner (1).

    Click image to see an enlarged view

    Fig. Remove the accessory drive belt tensioner

  28.  
  29. Remove crankshaft damper bolt.
  30.  
  31. Using Puller 1023 and Crankshaft Insert 9020, remove crankshaft damper.
  32.  
  33. Remove the lower outer timing belt cover bolts.
  34.  
  35. Remove right exhaust manifold/catalytic converter (maniverter) (2)

    Click image to see an enlarged view

    Fig. Remove right exhaust manifold/catalytic converter

  36.  
  37. Lower the vehicle.
  38.  
  39. Remove the accessory drive belt idler pulley.
  40.  
  41. Remove the power steering mounting bolts and set the pump aside.
  42.  
  43. Support the engine with a block of wood and a floor jack.
  44.  
  45. Remove the upper engine mount.
  46.  
  47. Remove the power steering reservoir bolts and set the reservoir aside.
  48.  
  49. Remove the remaining outer timing belt cover bolts and cover.
  50.  
  51. Rotate the engine to TDC and align the timing belt marks (1, 8, 9).

    Click image to see an enlarged view

    Fig. Timing Belt alignment-4.0L engine

  52.  
  53. Remove the timing belt tensioner (12) and reset the tensioner.
  54.  
  55. Remove the timing belt (4).
  56.  
  57. Remove the right valve cover to cylinder head ground strap.
  58.  
  59. Remove the EGR valve with 2 bolts and the gasket.
  60.  
  61. Remove the right cylinder head cover. Refer to Valve Covers, removal & installation.
  62.  
  63. Remove the 10 bolts and the right rocker arm assembly.
  64.  
  65. Remove the 3 bolts (2) and the left camshaft thrust plate (1) with the gasket (3).

    Click image to see an enlarged view

    Fig. Camshaft thrust plate removal-4.0L engine

  66.  
  67. Counter-hold the left cam gear and remove the cam gear retaining bolt.
  68.  
  69. Push the camshaft out of the back of the cylinder head approximately 3.5 inches and remove the cam gear.

    Click image to see an enlarged view

    Fig. Camshaft gear removal RH-4.0L engine

  70.  
  71. Remove the 3 inner timing cover to right cylinder head retaining bolts (1).

    Click image to see an enlarged view

    Fig. Timing cover removal-4.0L engine

  72.  
  73. Remove the cylinder head bolts in REVERSE of the tightening sequence shown.
    NOTE
    Because of clearance restrictions when removing the right cylinder head, the front 4 cylinder head bolts (2) must be loosened, raised, and supported with a rubber band (3) before the cylinder head can be removed.



    Click image to see an enlarged view

    Fig. Cylinder head tightening sequence-4.0L engine

  74.  
  75. Push the camshaft (5) out of the back of the cylinder head approximately 3.5 inches and remove the cylinder head.
  76.  
  77. Clean and inspect all mating surfaces.

    Click image to see an enlarged view

    Fig. When removing/installing the right cylinder head, the front 4 cylinder head bolts (2) must be loosened, raised, and supported with a rubber band (3) before the cylinder head can be removed/installed

  78.  

To install:

  1. The cylinder head bolts should be examined BEFORE reuse. If the threads are necked down, the bolts must be replaced.
  2.  
  3. Necking can be checked by holding a scale or straight edge against the threads. If all the threads do not contact the scale, the bolt should be replaced.

    Click image to see an enlarged view

    Fig. The cylinder head bolts should be examined BEFORE reuse. If the threads are necked down, the bolts must be replaced

  4.  
  5. Install the camshaft in the cylinder head. Push the camshaft out of the back of the cylinder head approximately 3.5 inches. Install the head gasket and the cylinder head over the locating dowels.
    WARNING
    The cylinder head gaskets are not interchangeable between cylinder heads and are clearly marked right or left.

  6.  
  7. Ensure that the correct head gaskets are used and are oriented correctly on the cylinder block.
    NOTE
    Before installing the cylinder head bolts, lubricate the threads with engine oil.

  8.  
  9. Insert the front 4 cylinder head bolts (2) into the cylinder head. Pull the bolts up to the top of their travel and retain with rubber bands (3).
  10.  
  11. Push camshaft (5) out of the back of the cylinder head approximately 3.5 inches. Install head gasket and cylinder head over locating dowels.
  12.  
  13. Install and finger tighten 8 head bolts (2).

    Click image to see an enlarged view

    Fig. When removing/installing the right cylinder head, the front 4 cylinder head bolts (2) must be loosened, raised, and supported with a rubber band (3) before the cylinder head can be removed/installed

  14.  
  15. Tighten the cylinder head bolts in the following sequence, using the 4 step torque-turn method. Tighten according to the following torque values:
    1. Step 1: All to 45 ft. lbs. (61 Nm).
    2.  
    3. Step 2: All to 65 ft. lbs. (88 Nm).
    4.  
    5. Step 3: All (again) to 65 ft. lbs. (88 Nm).
    6.  
    7. Step 4: Plus 90° turn. Do not use a torque wrench for this step.
      NOTE
      The bolt torque after the 90° turn should be over 90 ft. lbs. (122 Nm) in the tightening direction. If not, replace the bolt.

    8.  

  16.  
  17. Install inner timing cover-to-cylinder head bolts. Tighten the bolts to 40 ft. lbs. (54 Nm).
    NOTE
    The camshaft sprockets are keyed and not interchangeable from side to side because of the camshaft position sensor pick-up.

  18.  
  19. Push the camshaft back into the cylinder head and install the camshaft sprocket.
  20.  
  21. Install a NEW sprocket attaching bolt into place. The 10 inch (255mm) bolt is to be installed in the left camshaft and the 8 3 / 8 inch (213mm) bolt is to be installed into the right camshaft. Counter-hold the camshaft sprocket and tighten the camshaft sprocket bolt to 75 ft. lbs. (102 Nm), plus a 90° turn.
  22.  
  23. Install the camshaft thrust plate (1) and gasket (3). Tighten the 3 bolts to 250 inch lbs. (28 Nm).
  24.  
  25. Install a new gasket between the EGR solenoid/valve and the rear of the cylinder head.
  26.  
  27. Position the EGR solenoid/valve assembly to the rear of the cylinder head. Install and tighten the 2 mounting bolts to 80 inch lbs. (8 Nm).
  28.  
  29. Rotate the right camshaft gear (2) to align its timing mark (1). Verify that the left camshaft gear (7) timing mark (8) and crankshaft gear (10) timing mark (9) are still aligned.

    Click image to see an enlarged view

    Fig. Timing Belt alignment-4.0L engine

  30.  
  31. Install the timing belt (4) starting at the crankshaft sprocket (10) going in a counterclockwise direction. Install the belt around the last sprocket. Maintain tension on the belt as it is positioned around the tensioner pulley (11).
  32.  
  33. Holding the tensioner pulley (11) against the belt, install the tensioner (12) into the housing and tighten the 2 bolts to 250 inch lbs. (28 Nm). Each camshaft sprocket mark should remain aligned with the cover marks.
  34.  
  35. When the tensioner is in place, pull the retaining pin to allow the tensioner to extend to the tensioner pulley bracket.
  36.  
  37. Rotate the crankshaft sprocket 2 revolutions and check the timing marks on the camshafts and crankshaft. The marks should line up within their respective locations. If the marks do not line up, repeat the procedure.
    NOTE
    With the camshaft gears in these positions, the lobes are in a neutral position (no load to the valve). This will allow the rocker arm shaft assembly to be tightened into position with little or no valve spring load on it.

  38.  
  39. Install the rocker arm and shaft assembly and the 10 bolts making sure that the identification marks face toward the front of engine for the left head and toward the rear of the engine for the right head.
  40.  
  41. Tighten the 10 rocker arm/shaft assembly bolts in sequence to 275 inch lbs. (31 Nm).

    Click image to see an enlarged view

    Fig. Rocker arm tightening sequence-4.0L engine

  42.  
  43. Clean the cylinder head and the cover mating surfaces. Inspect and replace the gasket and seals, as necessary.
  44.  
  45. Install the right cylinder head cover and 8 bolts. Tighten the bolts to 105 inch lbs. (12 Nm).
  46.  
  47. Install the spark plugs. Tighten to 20 ft. lbs. (28 Nm).
  48.  
  49. Install the ignition coils into the cylinder head.
  50.  
  51. Install and tighten the coil mounting bolts to 60 inch lbs. (6.7 Nm).
  52.  
  53. Reposition the engine wire harness and install the retainers to the cylinder head cover. Connect and lock the electrical connectors to the ignition coils, capacitor, and EGR valve.
  54.  
  55. Install the front timing belt outer covers.
  56.  
  57. Tighten the timing cover bolts as follows:

    M6 bolts: 105 inch lbs. (12 Nm)
     
    M8 bolts: 250 inch lbs. (28 Nm)
     
    M10 bolts: 40 ft. lbs. (54 Nm)
     

  58.  
  59. Install the power steering reservoir. Tighten the mounting nut to 108 inch lbs. (12 Nm).
  60.  
  61. Install the power steering pump.
  62.  
  63. Install the accessory drive belt idler pulley. Tighten the bolt to 250 inch lbs. (28 Nm).
  64.  
  65. Install the upper engine mount.
  66.  
  67. Install the right exhaust manifold/converter (maniverter). Refer to Exhaust Manifold, removal & installation.
  68.  
  69. Install the crankshaft damper. Refer to Crankshaft Damper, removal & installation.
  70.  
  71. Install the accessory drive belt tensioner (1). Tighten the bolt to 45 ft. lbs. (61 Nm).
  72.  
  73. Install the accessory drive belt. Refer to Accessory Drive Belts, removal & installation.
  74.  
  75. Install the right inner splash shield.
  76.  
  77. Install the right front tire.
  78.  
  79. Lower the vehicle.
  80.  
  81. Install the lower intake manifold and fuel rail.
  82.  
  83. Install the upper intake manifold. Refer to Intake Manifold, removal & installation.
  84.  
  85. Install the EGR tube.
  86.  
  87. Install and connect the air cleaner element housing.
  88.  
  89. Install the engine cover.
  90.  
  91. Fill the coolant system with the proper type and amount of fluid.
  92.  
  93. Connect the negative battery cable. Tighten the nut to 40 inch lbs. (4.5 Nm).
  94.  

 
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