TownAndCountry 2008

Engine

Print

Removal & Installation



3.3L & 3.8L Engines

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 pressure release procedure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the air cleaner and hoses.
  8.  
  9. Disconnect the fuel line from the fuel rail.
  10.  
  11. Remove the wiper module.
  12.  
  13. Block off the heater hoses to the rear heater system, if equipped, using a pinch-off pliers.
  14.  
  15. Drain the cooling system.
  16.  
  17. Disconnect the heater hoses.
  18.  
  19. Remove the radiator upper support crossmember.
  20.  
  21. Remove the radiator fans. Refer to Engine Fan, removal & installation.
  22.  
  23. Disconnect the ETC connector from the throttle body.
  24.  
  25. Disconnect the MAP, IAC, and TPS electrical connectors.
  26.  
  27. Disconnect the EGR transducer electrical connector, if equipped.
  28.  
  29. Disconnect the vacuum hoses from the throttle body.
  30.  
  31. Disconnect the brake booster and the speed control vacuum hoses.
  32.  
  33. Disengage the wire harness clip from the right side engine mount.
  34.  
  35. Remove the power steering reservoir from the mounting position and set it aside.
  36.  
  37. Disconnect the ground strap from the rear of the cylinder head.
  38.  
  39. Disconnect the Engine Coolant Temperature (ECT) sensor and the ignition coil electrical connectors.
  40.  
  41. Disconnect the fuel injector electrical harness connector and disengage the clip from the support bracket.
  42.  
  43. Disconnect the camshaft and the crankshaft position sensor electrical connectors.
  44.  
  45. Evacuate the air conditioning system. Refer to Heating & Air Conditioning, Evacuating The System.
  46.  
  47. Disconnect the A/C compressor electrical connector.
  48.  
  49. Disconnect the A/C lines from the compressor. Cover and seal all the openings of the hoses and the compressor.
  50.  
  51. Remove the radiator upper hose.
  52.  
  53. Disengage the electrical harness clip at the transaxle dipstick tube.
  54.  
  55. Remove the transaxle dipstick tube. Seal the opening using a suitable plug.
  56.  
  57. Remove the transaxle cooler lines.
  58.  
  59. Disconnect the transaxle shift linkage and the electrical connectors.
  60.  
  61. Raise the vehicle on a hoist and drain the engine oil.
  62.  
  63. Remove the axle halfshafts. Refer to Halfshafts, removal & installation.
  64.  
  65. Remove the fore/aft crossmember (1).

    Click image to see an enlarged view

    Fig. Remove the fore/aft crossmember-3.3L and 3.8L engines

  66.  
  67. Disconnect the exhaust pipe from the exhaust manifold.
  68.  
  69. Remove the front engine mount bracket.
  70.  
  71. Remove the engine rear mount bracket.
  72.  
  73. Remove the transaxle case cover.
  74.  
  75. Remove the flexplate-to-torque converter bolts. Mark the torque converter-to-flexplate orientation for reassembly.
  76.  
  77. Remove the power steering pressure hose support clip attaching bolt.
  78.  
  79. Disconnect the knock sensor electrical connector (3.8L only).
  80.  
  81. Disconnect the engine block heater electrical connector, if equipped.
  82.  
  83. Remove the accessory drive belt splash shield.
  84.  
  85. Remove the accessory drive belt. Refer to Accessory Drive Belts, removal & installation.
  86.  
  87. Disconnect the radiator lower hose.
  88.  
  89. Remove the air conditioning compressor from the engine.
  90.  
  91. Remove the alternator. Refer to Alternator, removal & installation.
  92.  
  93. Remove the water pump pulley attaching bolts and position the pulley between the pump hub and the housing.
  94.  
  95. Disconnect the oil pressure switch electrical connector.
  96.  
  97. Disconnect the wiring harness support clip from the engine oil dipstick tube.
  98.  
  99. Install Special Tools 6912 and 8444 Adapters on the right side (rear) of the engine block.
  100.  
  101. Lower the vehicle.
  102.  
  103. Remove the power steering pump and set it aside.
  104.  
  105. Raise the vehicle enough to allow the engine dolly Special Tool 6135 and cradle Special Tool 6710 with the post Special Tool 6848 and the adaptor Special Tool 6909 to be installed under the vehicle.
  106.  
  107. Loosen the cradle/post mounts to allow movement for positioning the posts into the locating holes on the engine.
  108.  
  109. Slowly lower the vehicle and position the cradle/post mounts until the engine is resting on the posts.
  110.  
  111. Tighten all the cradle/post mounts to the cradle frame. This will keep the mounts from moving when removing or installing the engine and transaxle.

    Click image to see an enlarged view

    Fig. Adapter tools 6912 and 8444 mounted on the block-3.3L and 3.8L engines



    Click image to see an enlarged view

    Fig. View of Special Tool 6848

  112.  
  113. Lower the vehicle so the weight of ONLY THE ENGINE AND TRANSAXLE is on the cradle.
  114.  
  115. Install and secure the safety straps to the cradle fixture and around the engine.
  116.  
  117. Remove the engine right side mount to the engine attaching bolts.
  118.  
  119. Remove the left mount through bolt.
  120.  
  121. Raise the vehicle slowly. It is necessary to move the engine/transaxle assembly with the dolly to allow for removal around the body flanges.

    Click image to see an enlarged view

    Fig. Removed engine/transaxle assembly shown attached to a dolly through special adaptor tools-3.3L and 3.8L engines

  122.  

To install:

  1. Position the engine and transaxle assembly under the vehicle. Slowly lower the vehicle down over the engine and transaxle. It is necessary to move the engine/transaxle assembly with the dolly for clearance around the body flanges.
  2.  
  3. Align the engine and transaxle mounts to the attaching points. Install the mounting bolts at the right engine mount (3).

    Click image to see an enlarged view

    Fig. Install the mounting bolts at the right engine mount-3.3L and 3.8L engines

  4.  
  5. Align the engine and transaxle mounts to the attaching points. Install the left transaxle mount (4).

    Click image to see an enlarged view

    Fig. Install the left transaxle mount-3.3L and 3.8L engines

  6.  
  7. Remove the safety straps from around the engine.
  8.  
  9. Slowly raise the vehicle enough to remove the engine dolly and cradle Special Tools 6135, 6710, 6848, and 6909.
  10.  
  11. Remove Special Tools 6912 and 8444.
  12.  
  13. Lower the vehicle.
  14.  
  15. Install the power steering pump and the pressure line support.
  16.  
  17. Install the alternator and the wiring harness.
  18.  
  19. Raise the vehicle.
  20.  
  21. Attach the wiring harness support clip to the engine oil dipstick tube.
  22.  
  23. Connect the oil pressure switch electrical connector.
  24.  
  25. Install the A/C compressor.
  26.  
  27. Install the water pump pulley.
  28.  
  29. Connect the radiator lower hose.
  30.  
  31. Install the accessory drive belt. Refer to Accessory Drive Belts, removal & installation.
  32.  
  33. Install the accessory drive belt splash shield.
  34.  
  35. Connect the engine block heater electrical connector, if equipped.
  36.  
  37. Connect the knock sensor electrical connector (3.8L only).
  38.  
  39. Install the torque converter to the flexplate bolts.
  40.  
  41. Install the transaxle case cover.
  42.  
  43. Install the powertrain struts. On the 3.3L engine, tighten the bolts in the sequence shown.

    Click image to see an enlarged view

    Fig. Install the powertrain struts and tighten the bolts in the sequence shown-3.3L engine

  44.  
  45. Install the engine rear mount bracket.
  46.  
  47. Install the engine front mount and bracket assembly.
  48.  
  49. Install the axle halfshafts. Refer to Halfshafts, removal & installation.
  50.  
  51. Connect the exhaust pipe to the exhaust manifold.
  52.  
  53. Install the crossmember cradle plate.
  54.  
  55. Lower the vehicle.
  56.  
  57. Connect the transaxle shift linkage.
  58.  
  59. Connect the transaxle electrical connectors.
  60.  
  61. Remove the plugs from the transaxle cooler hoses and install the transaxle oil cooler line service splice kit. Refer to the instructions included with the kit.
  62.  
  63. Install the transaxle dipstick tube and attach the electrical harness clip.
  64.  
  65. Connect the A/C lines to the compressor.
  66.  
  67. Connect the A/C compressor electrical connector.
  68.  
  69. Evacuate and recharge the A/C system.
  70.  
  71. Connect the crankshaft and the camshaft position sensors.
  72.  
  73. Connect the fuel injector electrical harness connector and engage the clip to the support bracket.
  74.  
  75. Connect the ECT sensor and the ignition coil electrical connectors.
  76.  
  77. Connect the ground strap to the rear of the cylinder head.
  78.  
  79. Install the power steering reservoir.
  80.  
  81. Engage the wire harness clip to the engine right side mount.
  82.  
  83. Connect the brake booster and the speed control vacuum hoses.
  84.  
  85. Connect the vacuum hoses to the throttle body.
  86.  
  87. Connect the EGR transducer electrical connector, if equipped.
  88.  
  89. Connect the TPS, IAC, and MAP sensor electrical connectors.
  90.  
  91. Connect the throttle cables to the throttle body.
  92.  
  93. Install the radiator fans. Refer to Engine Fan, removal & installation.
  94.  
  95. Connect the radiator upper hose.
  96.  
  97. Connect the heater hoses. Remove the pinch-off pliers from the rear heater hoses, if equipped.
  98.  
  99. Install the radiator upper support crossmember.
  100.  
  101. Install the wiper module.
  102.  
  103. Connect the fuel line to the fuel rail.
  104.  
  105. Install the air cleaner and the hoses.
  106.  
  107. Install a new oil filter. Fill the engine crankcase with the proper oil to the correct level.
  108.  
  109. Connect the negative cable to the battery.
  110.  
  111. Fill the cooling system with the proper type and amount of fluid.
  112.  
  113. Start the engine and run it until the operating temperature is reached.
  114.  
  115. Check for leaks and verify that the engine is operating normally.
  116.  
  117. Adjust the transaxle linkage, as needed.
  118.  

4.0L Engine

Specific to:

Chrysler Town & Country 2008-2009

Dodge Grand Caravan 2008-2009

  1. Before servicing the vehicle, refer to the Precautions Section.
    NOTE
    Capture and store any residual fluid drainage, or leakage from ancillary components, in the appropriately marked containers.

  2.  
  3. Remove the engine cover.
  4.  
  5. Perform the fuel pressure release procedure.
  6.  
  7. Disconnect the positive and negative battery cables.
  8.  
  9. Disconnect the harness retainer, remove the 3 battery tray fasteners, and remove the battery tray.
  10.  
  11. Disconnect the coolant overflow line at the radiator fill cap, and remove the coolant overflow bottle.
  12.  
  13. Drain the coolant.
  14.  
  15. Remove the air filter housing.
  16.  
  17. Disconnect the cooling fan harness connectors and.
  18.  
  19. Release the left and right cooling fan clips, and remove the cooling fan assembly.
  20.  
  21. Release the tension from the accessory drive belt tensioner, and remove the accessory drive belt. Refer to Accessory Drive Belts, removal & installation.
  22.  
  23. Remove the alternator. Refer to Alternator, removal & installation.
  24.  
  25. Remove the power steering line bracket retainers and.
  26.  
  27. Disconnect the EVAP purge solenoid harness connector and the A/C pressure transducer harness connector.
  28.  
  29. Disconnect the harness retainer from the power steering pump.
  30.  
  31. Remove the bolts and reposition the power steering pump.
  32.  
  33. Disconnect the lower radiator hose from the engine.
  34.  
  35. Disconnect the fuel supply line at the fuel rail.
  36.  
  37. Disconnect the EVAP purge line and brake booster vacuum hose from the upper intake manifold.
  38.  
  39. Remove the upper radiator hose.
  40.  
  41. Disconnect the input shaft speed sensor harness connector (1), the crankshaft position sensor harness connector (2), the downstream O2 sensor harness connector (3), and the upstream O2 sensor harness connector (4) from the rear maniverter.

    Click image to see an enlarged view

    Fig. Disconnect the harness connectors-4.0L engine

  42.  
  43. Disconnect the transaxle solenoid pack harness connector.
  44.  
  45. Disconnect the harness retainer from the transaxle shifter bracket.
  46.  
  47. Disconnect the output speed sensor harness connectors and.
  48.  
  49. Disconnect the downstream O2 sensor harness connector and the upstream O2 sensor harness connector from the front manifold/converter (maniverter).
  50.  
  51. Remove the 3 rear transaxle mount bracket bolts (1).

    Click image to see an enlarged view

    Fig. Remove the 3 rear transaxle mount bracket bolts (1)-4.0L engine

  52.  
  53. Remove the heater hose and power steering hose bracket retainers from the transaxle bellhousing and the left engine mount.
  54.  
  55. Remove the front heater line bracket retainer.
  56.  
  57. Disconnect the heater hoses.
  58.  
  59. Disconnect the oil cooler lines from the transaxle using the Trans Cooler Line Disconnect 8875A.
  60.  
  61. Disconnect the shift cable from the transaxle manual valve lever.
  62.  
  63. Disconnect the shift cable from the bracket.
  64.  
  65. Raise the vehicle and remove both front tire and wheel assemblies.
  66.  
  67. Remove the oil filter/oil cooler splash shield and the left front wheelhouse splash shield.
  68.  
  69. Remove the transaxle ground strap bolt.
  70.  
  71. Disconnect the PCM harness connector and the inline harness connector.
  72.  
  73. Remove the lower radiator hose from the radiator.
  74.  
  75. Disconnect the wire harness connector from the oil pressure sensor.
  76.  
  77. Disconnect the engine oil cooler line from the engine oil cooler.
  78.  
  79. Disconnect the wire harness connector from the A/C compressor clutch coil. Remove 1 bolt, 2 nuts, 2 studs, and reposition the A/C compressor.
  80.  
  81. Remove the oil dipstick tube bolt, and remove the oil dipstick tube.
  82.  
  83. Remove the front manifold/converter (maniverter).
  84.  
  85. Remove the battery cable nut and the battery cable from the starter solenoid stud. Disconnect the electrical connector from the starter solenoid.
  86.  
  87. Remove the front engine mount through bolt.
  88.  
  89. Remove the 4 rear crossmember bolts (1), the front crossmember bolt (2), and remove the crossmember (3).

    Click image to see an enlarged view

    Fig. Remove the crossmember-4.0L engine

  90.  
  91. Remove the cross-under pipe.
  92.  
  93. Remove the cross-under pipe bracket from the bottom of the transaxle bellhousing.
  94.  
  95. Remove the bolt and the torque converter access cover.
  96.  
  97. Remove the torque converter-to-flexplate bolts (1). Upon removing the bolts, some flexplates have a tight-tolerance (slotted) bolt hole. If present, mark this location (flexplate and converter) with paint for re-alignment during installation.
  98.  
  99. Remove the lower transaxle bellhousing bolts (2).

    Click image to see an enlarged view

    Fig. Remove the torque converter-to-flexplate bolts (1) and the lower transaxle bellhousing bolts (2)-4.0L engine

  100.  
  101. Remove the 3 bolts and the front engine mount bracket.
  102.  
  103. Remove the front exhaust pipe.
  104.  
  105. Remove the rear manifold/converter (maniverter).
  106.  
  107. Remove the fasteners, and remove the rear engine mount heat shield.
  108.  
  109. Remove the rear transaxle mount bracket bolt.
  110.  
  111. Remove the right and left axle halfshafts. Refer to Halfshafts, removal & installation.
  112.  
  113. Position the Power Train Dolly 6135 and Engine Support Cradle 6710A under the engine.
  114.  
  115. Align the front right engine cradle post with the lift point hole in the engine block.
  116.  
  117. Align the front left engine cradle post and Engine Support Bracket 8130 with the lift point hole in the engine block.
  118.  
  119. Install the Power Train Dolly Adapter 10107-1 (2) to the engine block, and align the left rear engine cradle post with the hole in the adapter.
  120.  
  121. Install the Power Train Dolly Adapter 10107-2 (1) to the engine block, and align the right rear engine cradle post with the hole in the support bracket.

    Click image to see an enlarged view

    Fig. Install the Power Train Dolly Adapters 10107-1 (2) and 10107-2 (1) to the engine block, and align the engine cradle post with the hole in the support bracket-4.0L engine

  122.  
  123. Install safety straps so that they securely hold the powertrain assembly in the engine cradle. Tighten the fasteners at the base of each engine cradle post, and verify that the engine cradle posts are fully engaged in the lifting points.
  124.  
  125. Remove the right engine mount-to-engine fasteners (1).

    Click image to see an enlarged view

    Fig. Remove the right engine mount-to-engine fasteners (1)-4.0L engine

  126.  
  127. Remove the left engine mount-to-engine fasteners (1).
  128.  
  129. Raise the vehicle body off of the powertrain.
  130.  
  131. Support the transaxle with a suitable lifting device.
  132.  
  133. Remove the remaining transaxle bellhousing bolts, and separate the transaxle from the engine assembly.

    Click image to see an enlarged view

    Fig. Remove the left engine mount-to-engine fasteners (1)-4.0L engine

  134.  

To install:

  1. Position the Power Train Dolly 6135 and Engine Support Cradle 6710A under the engine.
  2.  
  3. Align the front right engine cradle post with the lift point hole in the engine block.
  4.  
  5. Align the front left engine cradle post and Engine Support Bracket 8130 with the lift point hole in the engine block.
  6.  
  7. Install the Power Train Dolly Adapter 10107-1 (2) to the engine block, and align the left rear engine cradle post with the hole in the adapter.
  8.  
  9. Install the Power Train Dolly Adapter 10107-2 (1) to the engine block, and align the right rear engine cradle post with the hole in the support bracket.
  10.  
  11. Install safety straps so that they securely hold the engine assembly in the engine cradle. Tighten the fasteners at the base of each engine cradle post, and verify that the engine cradle posts are engaged in the lifting points.
  12.  
  13. Install the transaxle to the engine assembly, and install the upper transaxle bolts. Tighten to 70 ft. lbs. (95 Nm).
  14.  
  15. Position the powertrain assembly below the vehicle body, and carefully lower the vehicle body onto the powertrain assembly.
  16.  
  17. Install the left side transaxle mount bolts (1). Tighten the transaxle mount bolts to 74 ft. lbs. (100 Nm).
  18.  
  19. Install the right engine mount-to-engine fasteners (1). Tighten to 74 ft. lbs. (100 Nm).
  20.  
  21. Remove the safety straps and lift the vehicle and the engine off of the engine support cradle.
  22.  
  23. Remove the Support Bracket 8130, Power Train Dolly Adapters 10107-1 (2), and 10107-2 (1) from the engine.
  24.  
  25. Install the rear transaxle mount through bolt. Tighten to 40 ft. lbs. (54 Nm).
  26.  
  27. Install the rear Engine Mount Heat Shield, and the fasteners. Tighten the fasteners to 100 inch lbs. (11 Nm).
  28.  
  29. Install the right and left axle halfshafts. Refer to Halfshafts, removal & installation.
  30.  
  31. Install the rear maniverter.
  32.  
  33. Install the front exhaust pipe.
  34.  
  35. Install the front engine mount bracket.
  36.  
  37. If the flexplate has a tight-tolerance (slotted) bolt hole that was marked during removal, realign it with the marked hole on the flexplate, then install the torque converter-to-flexplate bolts. Tighten the torque converter-to-flexplate bolts to 65 ft. lbs. (88 Nm).
  38.  
  39. Install the torque converter access cover.
  40.  
  41. Install the remaining lower transaxle bellhousing bolts. Tighten to 250 inch lbs. (28 Nm).
  42.  
  43. Install the cross-under pipe.
  44.  
  45. Install the crossmember (3), the 4 rear crossmember bolts (1), and the front crossmember bolt (2). Tighten the front crossmember bolt (2) to 80 ft. lbs. (108 Nm). Tighten the 4 rear crossmember bolts (1) to 40 ft. lbs. (55 Nm).
  46.  
  47. Install the front engine mount through bolt. Tighten to 40 ft. lbs. (54 Nm).
  48.  
  49. Install the battery cable and the nut to the starter solenoid stud. Tighten the nut to 128 inch lbs. (15 Nm). Connect the electrical connector to the starter solenoid.
  50.  
  51. Install the front maniverter.
  52.  
  53. Install the oil dipstick tube, and install the oil dipstick tube bolt.
  54.  
  55. Position the A/C compressor onto the engine. Install and tighten the bolt (2) and nuts (3) in the following sequence:
    1. Install the bolt and hand tighten.
    2.  
    3. Install the nuts and hand tighten.
    4.  
    5. Tightened the upper nut to 17 ft. lbs. (23 Nm).
    6.  
    7. Tightened the lower nut to 17 ft. lbs. (23 Nm).
    8.  
    9. Tightened the rear bolt to 17 ft. lbs. (23 Nm).

      Click image to see an enlarged view

      Fig. Install sequence for A/C compressor-4.0L engine

    10.  

  56.  
  57. Reconnect the wire harness connector to the A/C compressor clutch coil.
  58.  
  59. Reconnect the wire harness connector to the oil pressure sensor.
  60.  
  61. Reconnect the engine oil cooler line to the engine oil cooler.
  62.  
  63. Install the lower radiator hose to the radiator.
  64.  
  65. Reconnect the PCM harness connector and the inline harness connector.
  66.  
  67. Install the transaxle ground strap and secure with the transaxle ground strap bolt.
  68.  
  69. Install the oil filter/oil cooler splash shield and the left front wheelhouse splash shield.
  70.  
  71. Install the front tire and wheel assemblies.
  72.  
  73. Reconnect the shift cable to the bracket.
  74.  
  75. Reconnect the shift cable to the transaxle manual valve lever.
  76.  
  77. Reconnect the oil cooler lines to the transaxle.
  78.  
  79. Reconnect the heater hoses and.
  80.  
  81. Install the front heater line bracket retainer.
  82.  
  83. Install the heater hose and the power steering hose bracket retainers to the transaxle bellhousing and the left engine mount.
  84.  
  85. Install the 3 rear transaxle mount bracket bolts. Tighten to 75 ft. lbs. (102 Nm).
  86.  
  87. Reconnect the output speed sensor harness connectors and.
  88.  
  89. Reconnect the harness retainer to the transaxle shifter bracket.
  90.  
  91. Reconnect the transaxle solenoid pack harness connector.
  92.  
  93. Reconnect the input shaft speed sensor harness connector (1), the crankshaft position sensor harness connector (2), the downstream O2 sensor harness connector (3), and the upstream O2 sensor harness connector (4) to the rear maniverter.
  94.  
  95. Install the upper radiator hose.
  96.  
  97. Reconnect the EVAP purge line and the brake booster vacuum hose to the upper intake manifold.
  98.  
  99. Reconnect the fuel supply line at the fuel rail.
  100.  
  101. Install the lower radiator hose to the engine.
  102.  
  103. Reinstall the power steering pump and secure with 3 power steering pump mounting bolts through the pulley. Tighten the pump mounting bolts to 17 ft. lbs. (23 Nm).
  104.  
  105. Reinstall the harness retainer to the power steering pump.
  106.  
  107. Reconnect the EVAP purge solenoid harness connector and the A/C pressure transducer harness connector.
  108.  
  109. Install the power steering line bracket retainers and.
  110.  
  111. Reinstall the alternator. Refer to Alternator, removal & installation.
  112.  
  113. Reinstall the accessory drive belt. Refer to Accessory Drive Belts, removal & installation.
  114.  
  115. Reinstall the cooling fan assembly. Refer to Engine Fan, removal & installation.
  116.  
  117. Reconnect the cooling fan harness connectors.
  118.  
  119. Reinstall the air filter housing.
  120.  
  121. Reinstall the coolant overflow bottle, and reconnect the coolant overflow line at the radiator fill cap.
  122.  
  123. Refill the cooling system with the proper type and amount of fluid.
  124.  
  125. Reconnect the harness retainer, install the 3 battery tray fasteners, and install the battery tray.
  126.  
  127. Reconnect the positive and negative battery cables. Tighten the cable clamp nuts to 45 inch lbs. (5 Nm).
  128.  
  129. Start the engine and inspect for leaks. Verify that the engine is operating normally.
  130.  
  131. Install the engine cover.
  132.  

 
label.common.footer.alt.autozoneLogo