GrandCaravan 2008

Valve Covers

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Removal & Installation



3.3L & 3.8L Engines
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. Disconnect the spark plug wires from the spark plugs.
  4.  
  5. Disconnect the crankcase vent hose from the valve cover (also called the cylinder head cover).
  6.  
  7. Remove the valve cover bolts (2).
  8.  
  9. Remove the valve cover and gasket.

    Click image to see an enlarged view

    Fig. Remove the valve cover bolts-3.3L and 3.8L engines

  10.  

To install:

  1. Clean the cylinder head and valve cover the mating surfaces. Inspect the valve cover surface for flatness. Replace the gasket as necessary.
  2.  
  3. Assemble the gasket to the valve cover by inserting the fasteners through each bolt hole on the cover and the gasket.
  4.  
  5. Install the valve cover and the bolts. Tighten valve cover bolts (2) to 105 inch lbs. (12 Nm).
  6.  
  7. Connect the crankcase vent hose.
  8.  
  9. Connect the spark plug wires to the spark plugs.
  10.  

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. Disconnect the negative cable from the battery.
  4.  
  5. Remove the wiper module.
  6.  
  7. Disconnect the spark plug wires from the plugs.
  8.  
  9. Disconnect the PCV hose from the valve cover (1) (also called the cylinder head cover).
  10.  
  11. Remove the valve cover bolts.
  12.  
  13. Remove the valve cover and the gasket.

    Click image to see an enlarged view

    Fig. Disconnect the PCV hose (1) from the valve cover (1)-3.3L and 3.8L engines



    Click image to see an enlarged view

    Fig. Remove the valve cover bolts-3.3L and 3.8L engines

  14.  

To install:

  1. Clean the cylinder head and valve cover mating surfaces. Inspect the valve cover surface for flatness. Replace the gasket as necessary.
  2.  
  3. Inspect the PCV valve hose for damage. Replace as necessary.
  4.  
  5. Inspect the seal (3) on the cover bolt for wear or damage. Replace the bolt assembly as necessary.
    NOTE
    The valve cover bolts contain a torque limiter sleeve and a seal (3). The seal and torque sleeve is replaced with the bolt.

  6.  
  7. Assemble the gasket to the cylinder cover by inserting the bolt assemblies (2) through each bolt hole on the cover and the gasket.
  8.  
  9. Install the valve cover and bolts.
  10.  
  11. Tighten the valve cover bolts (2) to 105 inch lbs. (12 Nm).
    NOTE
    Be sure that the PVC valve is properly seated inside the valve cover protrusion and that the PCV valve hose completely covers the protrusion of the PCV valve housing.

  12.  
  13. Connect the PCV hose (1) to the valve cover.
  14.  
  15. Connect the spark plug wires to the spark plugs.
  16.  
  17. Install the wiper module.
  18.  
  19. Connect the negative battery cable. Tighten the nut to 40 inch lbs. (5 Nm).
  20.  

4.0L Engine
Left Bank

Specific to:

Chrysler Town & Country 2008-2009

Dodge Grand Caravan 2008-2009


WARNING
DO NOT START OR RUN THE ENGINE WITH THE VALVE COVER REMOVED FROM THE ENGINE. DAMAGE OR PERSONAL INJURY MAY OCCUR.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect and isolate the negative battery cable.
  4.  
  5. Remove the upper intake manifold from the engine. Refer to Intake Manifold, removal & installation.
  6.  
  7. Cover the lower intake manifold with a suitable cover during service.
  8.  
  9. Disconnect and remove the 3 ignition coils (3).

    Click image to see an enlarged view

    Fig. Disconnect and remove the 3 ignition coils (3)-4.0L engine

  10.  
  11. Remove the upper intake manifold support brackets from the engine.
  12.  
  13. Position the engine wiring harness aside.
  14.  
  15. Completely loosen the valve cover retaining bolts and remove the valve cover.
  16.  
  17. Disconnect the MVA hose from the valve cover assembly, if required.
  18.  

To install:

  1. Clean the cylinder head and valve cover mating surfaces. Inspect and replace the gasket and the seals, as necessary.
  2.  
  3. To replace the spark plug tube seals:
    1. Using a suitable pry tool, carefully remove the tube seals.
    2.  
    3. Position a new seal with the part number on the seal facing the valve cover.
    4.  
    5. Install the seals using Special Tool MD-998306.

      Click image to see an enlarged view

      Fig. To replace the spark plug tube seals (2), use Special Tool MD-998306 (1)-4.0L engine

    6.  

  4.  
  5. Install the valve cover and the bolts. Tighten to 90 inch lbs. (10 Nm).
  6.  
  7. Connect the MVA hose, if required.
  8.  
  9. Position the wiring harness on the valve cover.
  10.  
  11. Clip the wire harness to the attachment holes around the perimeter of the valve cover.
  12.  
  13. Install the upper intake manifold support brackets onto the front and rear of the engine.
  14.  
  15. Install the ignition coils. Tighten the mounting screws to 60 inch lbs. (7 Nm).
  16.  
  17. Connect the ignition coil electrical connectors.
  18.  
  19. Install the upper intake manifold. Refer to Intake Manifold, removal & installation.
  20.  
  21. Connect the negative battery cable. Tighten the nut to 40 inch lbs. (5 Nm).
  22.  

Right Bank

Specific to:

Chrysler Town & Country 2008-2009

Dodge Grand Caravan 2008-2009


WARNING
DO NOT START OR RUN THE ENGINE WITH THE VALVE COVER REMOVED FROM THE ENGINE. DAMAGE OR PERSONAL INJURY MAY OCCUR.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the upper intake manifold from the engine. Refer to Intake Manifold, removal & installation.
  6.  
  7. Cover the lower intake manifold with a suitable cover during service.
  8.  
  9. Disconnect and remove the 3 ignition coils.
  10.  
  11. Unclip the wire harness from the attachment holes around the perimeter of the valve cover.
  12.  
  13. Completely loosen the valve cover retaining bolts and remove the valve cover.

    Click image to see an enlarged view

    Fig. Disconnect and remove the 3 ignition coils (3)-4.0L engine

  14.  

To install:

  1. Clean the cylinder head and valve cover mating surfaces. Inspect and replace the gasket and the seals, as necessary.
  2.  
  3. To replace the spark plug tube seals:
    1. Using a suitable pry tool, carefully remove the tube seals.
    2.  
    3. Position a new seal with the part number on the seal facing the valve cover.
    4.  
    5. Install the seals using Special Tool MD-998306.

      Click image to see an enlarged view

      Fig. To replace the spark plug tube seals (2), use Special Tool MD-998306 (1)-4.0L engine

    6.  

  4.  
  5. Install the valve cover bolts and tighten to 90 inch lbs. (10 Nm).
  6.  
  7. Clip the wire harness to the attachment holes around the perimeter of the valve cover.
  8.  
  9. Install the ignition coils. Tighten the mounting screws to 60 inch lbs. (7 Nm).
  10.  
  11. Connect the ignition coil electrical connectors.
  12.  
  13. Install the upper intake manifold. Refer to Intake Manifold, removal & installation.
  14.  
  15. Connect the negative battery cable. Tighten the nut to 40 inch lbs. (5 Nm).
  16.  

 
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