11/26/22, 7:13 AM Print Article
2005 Dodge Caravan
Powertrain Diagnostics & Repair / Engine / Mechanical / 3.3L & 3.8L ENGINE (SERVICE
INFORMATION)
VALVE TIMING
STANDARD PROCEDURE
STANDARD PROCEDURE - VALVE TIMING VERIFICATION
1. Remove front cylinder head cover and all 6 spark plugs.
2. Rotate engine until the #2 piston is at TDC of the compression stroke.
3. Install a degree wheel on the crankshaft pulley.
4. With proper adaptor, install a dial indicator into #2 spark plug hole. Using the indicator find TDC on the compression stroke.
5. Position the degree wheel to zero.
6. Remove dial indicator from spark plug hole.
7. Place a 5.08 mm (0.200 in.) spacer between the valve stem tip of #2 intake valve and rocker arm pad. Allow tappet to bleed down to
give a solid tappet effect.
8. Install a dial indicator so plunger contacts the #2 intake valve spring retainer as nearly perpendicular as possible. Zero the indicator.
9. Rotate the engine clockwise until the intake valve has lifted.254 mm (0.010 in.).
CAUTION: Do not turn crankshaft any further clockwise as intake valve might bottom and result in serious damage.
10. Degree wheel should read 6 degrees BTDC to 6 degrees ATDC.
STANDARD PROCEDURE - MEASURING TIMING CHAIN WEAR
NOTE: This procedure must be performed with the timing chain cover removed (Refer to ENGINE/VALVE TIMING/TIMING
CHAIN COVER - REMOVAL)
.
1. Position a scale next to timing chain so that any movement of chain may be measured. See Fig. 161.
2. Position a torque wrench and socket on the camshaft sprocket attaching bolt. Apply force in the direction of crankshaft rotation to
take up slack to the following torque:
41 N.m (30 ft. lb.) with cylinder heads installed
20 N.m (15 ft. lb.) with cylinder heads removed
NOTE: With torque applied to the camshaft sprocket bolt, crankshaft should not be permitted to move. It may be
necessary to block crankshaft to prevent rotation.
3. Holding a measuring scale along edge of chain links. See Fig. 161.
4. Apply force in the reverse direction to the following torque:
41 N.m (30 ft. lb.) with cylinder heads installed
20 N.m (15 ft. lb.) with cylinder heads removed
5. Measure amount of sprocket/chain movement.
6. Install a new timing chain and sprockets if movement exceeds 3.175 mm (1/8 in.).
https://crs.mymitchell.com/PrintArticle.aspx?secIDs=1262,1263,1264,1265,1266,1267,1268,1269,1270,1271,1272,1273,1274,1275&Id=0.6923514622… 1/9
11/26/22, 7:13 AM Print Article
Fig. 161: Measuring Timing Chain Wear
1 - TORQUE WRENCH
TIMING CHAIN COVER
REMOVAL
1. Disconnect negative cable from battery.
2. Drain cooling system. (Refer to COOLING - STANDARD PROCEDURE)
3. Raise vehicle on hoist.
4. Drain engine oil.
5. Remove right wheel and inner splash shield.
6. Remove oil pan. (Refer to ENGINE/LUBRICATION/OIL PAN - REMOVAL)
7. Remove oil pick-up tube. See Fig. 162.
Fig. 162: OIL PICKUP TUBE
1 - BOLT
2 - OIL PICK-UP TUBE
https://crs.mymitchell.com/PrintArticle.aspx?secIDs=1262,1263,1264,1265,1266,1267,1268,1269,1270,1271,1272,1273,1274,1275&Id=0.6923514622… 2/9
11/26/22, 7:13 AM Print Article
3 - O-RING
8. Remove accessory drive belt. (Refer to COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL)
9. Remove A/C compressor and set aside.
10. Remove crankshaft vibration damper. (Refer to ENGINE/ENGINE BLOCK/VIBRATION DAMPER - REMOVAL)
11. Remove radiator lower hose.
12. Remove heater hose from timing chain cover housing or water pump inlet tube (if engine oil cooler equipped). See Fig. 163 and Fig.
164.
Fig. 163: HEATER RETURN HOSE (Without Engine Oil Cooler)
1 - CAP AND CLAMP (OIL COOLER EQUIPPED ONLY)
2 - HOSE ASSEMBLY - HEATER RETURN
3 - BOLT - HEATER TUBE ATTACHING
4 - BOLT - HEATER TUBE ATTACHING
https://crs.mymitchell.com/PrintArticle.aspx?secIDs=1262,1263,1264,1265,1266,1267,1268,1269,1270,1271,1272,1273,1274,1275&Id=0.6923514622… 3/9
11/26/22, 7:13 AM Print Article
Fig. 164: HEATER HOSES 3.3/3.8L (With Engine Oil Cooler)
1 - HOSE - HEATER SUPPLY
2 - HOSE - HEATER RETURN
3 - TUBE ASSEMBLY - HEATER RETURN
4 - BOLT - TUBE ASSEMBLY
5 - BOLT - TUBE ASSEMBLY
6 - HOSE - HEATER RETURN/OIL COOLER OUTLET
13. Remove the right side engine mount. (Refer to ENGINE/ENGINE MOUNTING/RIGHT MOUNT - REMOVAL)
14. Remove idler pulley from engine bracket. See Fig. 165.
15. Remove the engine mount bracket. See Fig. 165.
16. Remove camshaft position sensor from timing chain cover. See Fig. 165.
https://crs.mymitchell.com/PrintArticle.aspx?secIDs=1262,1263,1264,1265,1266,1267,1268,1269,1270,1271,1272,1273,1274,1275&Id=0.6923514622… 4/9
11/26/22, 7:13 AM Print Article
Fig. 165: Engine Mount Bracket
1 - CAMSHAFT SENSOR
2 - BOLT - CAMSHAFT SENSOR
3 - BOLT - MOUNT BRACKET (VERTICAL)
4 - BRACKET - ENGINE MOUNT
5 - BOLT - MOUNT BRACKET (HORIZONTAL)
6 - PULLEY - IDLER
7 - BOLT - IDLER PULLEY
8 - SPACER - IDLER PULLEY BOLT
9 - BOLT - MOUNT BRACKET (HORIZONTAL)
17. Remove the water pump for cover removal clearance. (Refer to COOLING/ENGINE/WATER PUMP - REMOVAL)
18. Remove the bolt attaching the power steering pump support strut to the front cover. See Fig. 166.
19. Remove the timing chain cover fasteners. Remove timing chain cover. See Fig. 167.
Fig. 166: Power Steering Pump Strut
1 - BOLT - LOWER
https://crs.mymitchell.com/PrintArticle.aspx?secIDs=1262,1263,1264,1265,1266,1267,1268,1269,1270,1271,1272,1273,1274,1275&Id=0.6923514622… 5/9
11/26/22, 7:13 AM Print Article
2 - STRUT - P/S PUMP
3 - BOLT - UPPER
INSTALLATION
1. Be sure mating surfaces of chain case cover and cylinder block are clean and free from burrs. Crankshaft oil seal must be removed
to insure correct oil pump engagement.
NOTE: DO NOT USE SEALER ON COVER GASKET
2. Position new gasket on timing cover. See Fig. 167. Adhere new gasket to chain case cover, making sure that the lower edge of the
gasket is flush to 0.5 mm (0.020 in.) passed the lower edge of the cover.
Fig. 167: Timing Chain Cover and Gasket
1 - GASKET
2 - TIMING CHAIN COVER
3. Rotate crankshaft so that the oil pump drive flats are in the vertical position.
4. Position oil pump inner rotor so the mating flats are in the same position as the crankshaft drive flats. See Fig. 167.
CAUTION: Make sure the oil pump is engaged on the crankshaft correctly or severe damage may result.
5. Install timing cover. See Fig. 167.
6. Install timing chain cover bolts. Tighten M8 bolts to 27 N.m (20 ft. lbs.) and M10 bolts to 54 N.m (40 ft. lbs.). See Fig. 168.
https://crs.mymitchell.com/PrintArticle.aspx?secIDs=1262,1263,1264,1265,1266,1267,1268,1269,1270,1271,1272,1273,1274,1275&Id=0.6923514622… 6/9
11/26/22, 7:13 AM Print Article
Fig. 168: TIMING CHAIN COVER BOLT LOCATIONS
1 - BOLT - M8 x 1.25 x 95 4 - BOLT - M8 x 1.25 x 80
2 - BOLT - M10 x 1.5 x 100 5 - BOLT - M8 x 1.25 x 45
3 - BOLT - M10 x 1.5 x 85
7. Install crankshaft front oil seal. (Refer to ENGINE/ENGINE BLOCK/CRANKSHAFT OIL SEAL - FRONT - INSTALLATION)
8. Install water pump and pulley. (Refer to COOLING/ENGINE/WATER PUMP - INSTALLATION)
9. Install crankshaft vibration damper. (Refer to ENGINE/ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION)
10. Install engine mount bracket and tighten M10 to 54 N.m (40 ft. lbs.), M8 bolt to 28 N.m (21 ft. lb. lbs.). See Fig. 165.
11. Install idler pulley on engine mount bracket. See Fig. 165.
12. Install right side engine mount. (Refer to ENGINE/ENGINE MOUNTING/RIGHT MOUNT - INSTALLATION)
13. Install camshaft position sensor (Refer to ELECTRICAL/IGNITION CONTROL/CAMSHAFT POSITION SENSOR - INSTALLATION)
.
14. Connect the heater return hose at rear of timing chain cover or at water pump inlet tube (if engine oil cooler equipped). See Fig. 163
and Fig. 164.
15. Connect the radiator lower hose.
16. Install A/C compressor.
17. Install accessory drive belt. (Refer to COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION)
18. Install oil pump pick-up tube with new O-ring. Tighten attaching bolt to 28 N.m (250 in. lbs.).
19. Install oil pan. (Refer to ENGINE/LUBRICATION/OIL PAN - INSTALLATION)
20. Install inner splash shield and right front wheel.
21. Fill crankcase with engine oil to proper level.
22. Fill cooling system. (Refer to COOLING - STANDARD PROCEDURE)
23. Connect negative cable to battery.
TIMING CHAIN AND SPROCKETS
REMOVAL
REMOVAL - TIMING CHAIN AND CAMSHAFT SPROCKET
1. Disconnect negative cable from battery.
2. Remove the timing chain cover. (Refer to ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S)
- REMOVAL)
3. Rotate engine by turning crankshaft until the timing marks are aligned as shown in Fig. 169.
4. Remove camshaft sprocket attaching bolt.
5. Remove the timing chain with camshaft sprocket.
6. Remove the crankshaft sprocket. (Refer to ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL)
https://crs.mymitchell.com/PrintArticle.aspx?secIDs=1262,1263,1264,1265,1266,1267,1268,1269,1270,1271,1272,1273,1274,1275&Id=0.6923514622… 7/9
11/26/22, 7:13 AM Print Article
Fig. 169: Timing Mark Alignment
1 - CAMSHAFT SPROCKET TIMING MARK (DOT)
2 - PLATED LINK
3 - CRANKSHAFT SPROCKET TIMING MARK (DOT)
4 - ARROWS
REMOVAL - CRANKSHAFT SPROCKET
1. Remove the timing chain. (Refer to ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL)
2. Using Special Tools 8539, 5048-6, and 5048-1, remove the crankshaft sprocket while holding the crankshaft from turning. See Fig.
170. Be careful not to damage the crankshaft surfaces.
Fig. 170: CRANKSHAFT SPROCKET - REMOVAL
1 - SPECIAL TOOL 5048-6
2 - SPECIAL TOOL 5048-1
https://crs.mymitchell.com/PrintArticle.aspx?secIDs=1262,1263,1264,1265,1266,1267,1268,1269,1270,1271,1272,1273,1274,1275&Id=0.6923514622… 8/9
11/26/22, 7:13 AM Print Article
3 - SPECIAL TOOL 8450
4 - CRANKSHAFT SPROCKET
5 - SPECIAL TOOL 8539
INSTALLATION
INSTALLATION - CRANKSHAFT SPROCKET
1. Position the sprocket on the crankshaft (timing mark out) with the timing slot aligned with the timing pin.
2. Install sprocket using Special Tool 8452. See Fig. 171. Install sprocket until it is fully seats on the crankshaft.
Fig. 171: CRANKSHAFT SPROCKET - INSTALLATION
1 - SPECIAL TOOL 8452-3
2 - SPECIAL TOOL 8452-1
3 - CRANKSHAFT SPROCKET
4 - THRUST BEARING / WASHER
3. Install the timing chain and camshaft sprocket. (Refer to ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS -
INSTALLATION)
INSTALLATION - TIMING CHAIN AND CAMSHAFT SPROCKET
1. Rotate crankshaft so the timing arrow is to the 12 o'clock position. See Fig. 169.
NOTE: Lubricate timing chain and sprockets with clean engine oil before installation.
2. While holding camshaft sprocket and chain in hand, place timing chain around the sprocket, aligning the plated link with the dot on
the sprocket. Position the timing arrow to the 6 o'clock position. See Fig. 169.
3. Place timing chain around crankshaft sprocket with the plated link lined up with the dot on the sprocket. Install camshaft sprocket
into position.
4. Use a straight edge to check alignment of timing marks.
5. Install camshaft sprocket bolt and washer. Tighten bolt to 54 N.m (40 ft. lbs.).
6. Rotate crankshaft 2 revolutions and check timing mark alignment. See Fig. 169. If timing marks do not line up, remove camshaft
sprocket and realign.
7. Install the timing chain cover. (Refer to ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S)
- INSTALLATION)
8. Connect negative cable to battery.
Created/Modified Date: 2/2/2012 2:52:37 AM
https://crs.mymitchell.com/PrintArticle.aspx?secIDs=1262,1263,1264,1265,1266,1267,1268,1269,1270,1271,1272,1273,1274,1275&Id=0.6923514622… 9/9
