Chrysler Town, Dodge Caravan. Manual — part 1093
CAMSHAFT(S)
DESCRIPTION
The camshafts are made of gray cast iron with
eight machined lobes and four bearing journals (Fig.
20).
OPERATION
When the camshaft rotates the lobes actuate the
hydraulic lifters and rocker arms, forcing downward
on the rocker arms which opens the valves.
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove front wiper unit (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER
MODULE
-
REMOVAL).
(3) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(4) Drain cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(5) Remove air cleaner housing.
(6) Remove power steering belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
REMOVAL).
(7) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
REMOVAL).
(8) Remove generator (Refer to 8 - ELECTRICAL/
CHARGING/GENERATOR - REMOVAL).
(9) Support engine and remove right engine mount
(Refer to 9 - ENGINE/ENGINE MOUNTING/RIGHT
MOUNT - REMOVAL).
CAUTION: Before removing the cylinder head cover/
intake manifold or timing belt the engine must put
at 90° after TDC. Failure to do so could result in
valve and/or piston damage during reassembly.
(Refer to 9 - ENGINE/VALVE TIMING - STANDARD
PROCEDURE)
(10) Remove timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(11) Remove timing belt (Refer to 9 - ENGINE/
VALVE
TIMING/TIMING
BELT/CHAIN
AND
SPROCKETS - REMOVAL).
(12) Remove timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(13) Remove cylinder head cover/intake manifold
(Refer to 9 - ENGINE/CYLINDER HEAD/CYLIN-
DER HEAD COVER(S) - REMOVAL).
(14) With cylinder head cover/intake manifold on
work bench, remove plugs at rear of cylinder head
cover/intake manifold.
(15) Remove camshaft oil seals (Fig. 21).
(16) Remove snapring and thrust washer from
camshaft (Fig. 21).
(17) Slide camshaft through access hole at rear of
cylinder head cover/intake manifold.
INSTALLATION
(1) Lubricate the camshafts with Mopar
t Engine
Oil Supplement, or equivalent.
(2) Carefully install camshafts into access holes in
rear of cylinder head cover/intake manifold.
Fig. 20 CAMSHAFTS
1 - INTAKE CAMSHAFT
2 - EXHAUST CAMSHAFT
Fig. 21 CAMSHAFT ASSEMBLY
1 - INTAKE CAMSHAFT
2 - SNAPRING
3 - CAMSHAFT OIL SEAL
4 - THRUST WASHER
5 - CYLINDER HEAD COVER/INTAKE MANIFOLD
6 - EXHAUST CAMSHAFT
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ENGINE
9 - 25
(3) Install thrust washer, snapring, and camshaft
oil seal (Fig. 21).
CHECKING CAMSHAFT ENDPLAY
(1) After camshafts are properly installed in cylin-
der head cover check end play of camshafts with a
dial indicator. The end play should be between .10
mm – .30 mm.
NOTE: If the camshaft endplay is not within speci-
fication, measure thickness of the camshaft spacer.
Camshaft spacer thickness should be 2.8 ± .02mm.
(4) Install access hole plugs and gaskets at rear of
cylinder head cover/intake manifold. Torque plugs to
80N·m.
(5) Install cylinder head cover/intake manifold on
engine block (Refer to 9 - ENGINE/CYLINDER
HEAD/CYLINDER HEAD COVER(S) - INSTALLA-
TION).
(6) Install timing belt inner cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(7) Install timing belt (Refer to 9 - ENGINE/
VALVE
TIMING/TIMING
BELT/CHAIN
AND
SPROCKETS - INSTALLATION).
(8) Install timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(9) Install right engine mount (Refer to 9 -
ENGINE/ENGINE MOUNTING/RIGHT MOUNT -
INSTALLATION).
(10) Install generator (Refer to 8 - ELECTRICAL/
CHARGING/GENERATOR - INSTALLATION).
(11) Install accessory drive belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
INSTALLATION).
(12) Install power steering belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
INSTALLATION).
(13) Install air cleaner housing.
(14) Refill cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(15) Install front wiper unit (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER
MODULE
-
INSTALLATION).
(16) Connect negative battery cable.
CYLINDER HEAD COVER(S)
DESCRIPTION
The cylinder head cover is made of cast aluminum
and is also the intake manifold on this engine (Fig.
22).
REMOVAL
CAUTION: Before removing the cylinder head cover/
intake manifold the engine must put at 90° after
TDC. Failure to do so could result in valve and/or
piston damage during reassembly. (Refer to 9 -
ENGINE/VALVE TIMING - STANDARD PROCEDURE)
(1) Disconnect negative battery cable.
(2) Remove front wiper unit (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER
MODULE
-
REMOVAL).
(3) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(4) Drain cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(5) Rotate engine until 90° after TDC is reached.
Install both camshaft locking pins and the crankshaft
locking pin. (Refer to 9 - ENGINE/VALVE TIMING -
STANDARD PROCEDURE)
(6) Remove air cleaner housing assembly.
(7) Remove power steering belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
REMOVAL).
(8) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
REMOVAL).
(9) Remove generator (Refer to 8 - ELECTRICAL/
CHARGING/GENERATOR - REMOVAL).
(10) Support engine and remove right engine
mount (Refer to 9 - ENGINE/ENGINE MOUNTING/
RIGHT MOUNT - REMOVAL).
Fig. 22 CYLINDER HEAD COVER/INTAKE
MANIFOLD
9 - 26
ENGINE
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CAMSHAFT(S) (Continued)
(11) Remove outer timing belt cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(12) Remove timing belt (Refer to 9 - ENGINE/
VALVE
TIMING/TIMING
BELT/CHAIN
AND
SPROCKETS - REMOVAL).
(13) Remove inner timing belt cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(14) Disconnect camshaft position sensor, boost
pressure/intake air temperature sensor, EGR sole-
noid, and fuel pressure sensor electrical connectors
(Fig. 23).
(15) Disconnect vacuum lines at EGR solenoid.
(16) Position electrical harness out of way.
(17) Remove fuel injectors (Refer to 14 - FUEL
SYSTEM/FUEL
INJECTION/FUEL
INJECTOR
-
REMOVAL).
(18) Remove fuel rail (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/FUEL RAIL - REMOVAL).
(19) Remove power steering pump reservoir from
bracket.
(20) Remove oil dipstick tube retaining bolt at
intake manifold inlet.
(21) Disconnect oil separator outlet hose at separa-
tor.
(22) Remove turbo inlet tube retaining bolt at
intake manifold.
(23) Disconnect EGR tube at intake manifold inlet
tube.
(24) Remove cylinder head cover/intake manifold
retaining bolts (Fig. 24).
(25) Lift cylinder head cover/intake manifold from
cylinder head (Fig. 24).
NOTE: When removing rocker arm and lifter assem-
blies, be sure to keep them in order as they were
removed from the cylinder head. Always keep lifters
in an upright position when removed from cylinder
head.
Fig. 23 ENGINE COMPONENT LOCATIONS
1 - FUEL INJECTOR RETURN LINE
2 - FUEL INJECTOR SUPPLY LINE
3 - OIL SEPARATOR
4 - FUEL INJECTOR
5 - CAMSHAFT POSITION SENSOR
6 - BOOST PRESSURE/INTAKE AIR TEMPERATURE SENSOR
7 - EGR SOLENOID
8 - FUEL PRESSURE SENSOR
9 - CYLINDER HEAD COVER/INTAKE MANIFOL
10 - FUEL RAIL
11 - WIRING HARNESS RETAINING CLIPS
Fig. 24 CYLINDER HEAD COVER/INTAKE
MANIFOLD ASSEMBLY
1 - CYLINDER HEAD COVER/INTAKE MANIFOLD BOLTS(LONG)
2 - CYLINDER HEAD COVER/INTAKE MANIFOLD
3 - CYLINDER HEAD
4 - CYLINDER HEAD COVER/INTAKE MANIFOLD GASKET
5 - CYLINDER HEAD COVER/INTAKE MANIFOLD BOLTS(SHORT)
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ENGINE
9 - 27
CYLINDER HEAD COVER(S) (Continued)
(26) Remove rocker arm and lifter assemblies from
cylinder head (Fig. 25).
(27) Remove cylinder head cover/intake manifold
gasket from cylinder head.
INSTALLATION
(1) Clean and inspect sealing surfaces.
(2) Install new gasket on cylinder head.
NOTE: Apply a small amount of grease on each
valve stem. This will help hold the rocker arm in
position during the cylinder head cover installation.
(3) Install rocker arm and lifter assemblies in cyl-
inder head (Fig. 25).Be sure to put rocker arm
and
lifter
assemblies
in
same
location
as
removed.
(4) Install cylinder head cover/intake manifold
alignment studs in cylinder head (Fig. 26).
(5) Install cylinder head cover/intake manifold
over alignment stud.
NOTE: Be sure to lubricate cylinder head cover/in-
take manifold retaining bolts with engine oil before
assembly. If new bolts are being installed, DO NOT
lubricate before assembly.
(6) Install two cylinder head cover/intake manifold
retaining bolts and tighten finger tight.
(7) Remove alignment studs and install remaining
retaining bolts (Fig. 24). Tighten retaining bolts fin-
ger tight.
(8) Torque cylinder head cover/intake manifold
retaining bolts following procedure below.
CYLINDER HEAD COVER/INTAKE MANIFOLD
TIGHTENING PROCEDURE
(1) Coat all bolts being reused with clean engine
oil.
(2) Install the M8x35 bolts into holes 1,2,3,4,5, and
12.
Install
the
M8x85
bolts
into
holes
6,7,8,9,10,11,13,14,15, and 16. Tighten all bolt hand
tight.
(3) Alternate between bolts #11 and #16 to seat
cylinder head cover/intake manifold on cylinder head
(Fig. 27). Torque bolts to 7 N·m.
(4) Torque all cylinder head cover/intake manifold
retaining bolts to 25 N·m in numerical order starting
with #1 and ending with #16 (Fig. 27).
(9) Connect EGR tube at intake manifold inlet
tube. Torque clamp to 10.8 N·m.
(10) Install turbo inlet tube retaining bolt at
intake manifold. Torque bolt to 27.5 N·m.
(11) Connect oil separator outlet hose at separator.
(12) Install oil dipstick tube retaining bolt at
intake manifold inlet. Torque bolt to 10 N·m.
Fig. 25 CYLINDER HEAD COVER/INTAKE
MANIFOLD GASKET LOCATION
1 - THERMOSTAT HOUSING
2 - ROCKER ARM AND LIFTER ASSEMBLY
3 - CYLINDER HEAD COVER/INTAKE MANIFOLD
4 - CYLINDER HEAD
Fig. 26 CYLINDER HEAD COVER/INTAKE
MANIFOLD ALIGNMENT STUDS VM.1066
1 - CYLINDER HEAD COVER/INTAKE MANIFOLD ALIGNMENT
STUDS VM.1066
2 - CYLINDER HEAD
9 - 28
ENGINE
RG
CYLINDER HEAD COVER(S) (Continued)
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