water pump CHRYSLER CARAVAN 2005 Owner's Manual

8W-30 FUEL/IGNITION SYSTEM
Component Page
A/C Compressor Clutch.............. 8W-30-20
A/C Compressor Clutch Relay........ 8W-30-4, 20
A/C Pressure Sensor........... 8W-30-13, 18, 27
Accelerator Pedal Position Sensor.... 8W-30-32, 34
Ambient Temperature Sensor........... 8W-30-8
Auto Shut Down Relay.... 8W-30-4, 11, 14, 16, 19
Battery.............. 8W-30-2, 6, 10, 15, 20, 28
Battery Temperature Sensor......... 8W-30-8, 27
Body Control Module.............. 8W-30-5, 21
Boost Pressure Sensor............... 8W-30-27
Brake Lamp Switch............ 8W-30-7, 23, 33
Cabin Heater Assist................. 8W-30-24
Camshaft Position Sensor........... 8W-30-8, 26
Clockspring................... 8W-30-5, 25, 32
Clutch Pedal Interlock Switch.......... 8W-30-7
Clutch Pedal Upstop Switch........... 8W-30-32
Crank Case Ventilation Heater......... 8W-30-21
Crankshaft Position Sensor...... 8W-30-12, 17, 26
Data Link Connector.............. 8W-30-3, 24
Dosing Pump...................... 8W-30-24
ECM/PCM Relay........ 8W-30-20, 22, 26, 28, 30
EGR Solenoid................... 8W-30-15, 30
Engine Control Module . . . 8W-30-20, 21, 22, 23, 24,
25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35
Engine Coolant Temp Sensor.... 8W-30-13, 18, 27
Engine Oil Pressure Sensor........... 8W-30-23
Engine Oil Pressure Switch............ 8W-30-7
EVAP/Purge Solenoid................. 8W-30-4
Front Control Module......... 8W-30-2, 5, 24, 32
Fuel Heater....................... 8W-30-31
Fuel Heater Relay................ 8W-30-21, 31
Fuel Injector No. 1............ 8W-30-14, 19, 29
Fuel Injector No. 2............ 8W-30-14, 19, 29
Fuel Injector No. 3............ 8W-30-14, 19, 29
Fuel Injector No. 4............ 8W-30-14, 19, 29
Fuel Injector No. 5.................. 8W-30-19
Fuel Injector No. 6.................. 8W-30-19
Fuel Pressure Sensor................ 8W-30-33
Fuel Pressure Solenoid............... 8W-30-22
Fuel Pump Module................ 8W-30-5, 21
Fuel Pump Relay.................... 8W-30-5
Fuse 15........................ 8W-30-24, 31
Fuse 16 . . 8W-30-4, 11, 14, 16, 19, 20, 22, 26, 28, 30
Fuse 17.................... 8W-30-2, 5, 21, 31
Fuse 18........................... 8W-30-20
Fuse 26........................... 8W-30-33
Fuselink.......................... 8W-30-28Component Page
G100...................... 8W-30-2, 6, 15, 21
G101................. 8W-30-2, 6, 7, 10, 15, 20
G103....................... 8W-30-20, 21, 24
G300........................ 8W-30-7, 23, 32
G302........................ 8W-30-5, 21, 31
Generator....................... 8W-30-4, 21
Glow Plug No. 1.................... 8W-30-28
Glow Plug No. 2.................... 8W-30-28
Glow Plug No. 3.................... 8W-30-28
Glow Plug No. 4.................... 8W-30-28
Glow Plug Relay.................... 8W-30-28
Idle Air Control Motor................ 8W-30-9
Ignition Coil.................... 8W-30-11, 16
Ignition Switch..................... 8W-30-10
Inlet Air Temperature Sensor....... 8W-30-12, 17
Integrated Power Module . . 8W-30-2, 3, 4, 5, 10, 11,
14, 16, 19, 20, 21, 22, 24,
26, 28, 30, 31, 32, 33
Knock Sensor....................... 8W-30-9
Left Speed Control Switch.......... 8W-30-5, 25
Lift Pump Motor.................... 8W-30-31
Lift Pump Relay.................... 8W-30-31
Manifold Absolute Pressure Sensor . . . 8W-30-13, 18
Mass Air Flow Sensor................ 8W-30-22
Natural Vacuum Leak Detection
Assembly....................... 8W-30-10
Oxygen Sensor 1/1 Upstream........... 8W-30-6
Oxygen Sensor 1/2 Downstream......... 8W-30-6
Powertrain Control Module . . 8W-30-2, 3, 4, 5, 6, 7,
8, 9, 10, 11, 12, 13, 14,
15, 16, 17, 18, 19
Radiator Fan Relay............... 8W-30-11, 16
Radiator Fan Relay No. 1............. 8W-30-33
Radiator Fan Relay No. 2............. 8W-30-33
Radiator Fan Relay No. 3............. 8W-30-33
Right Speed Control Switch......... 8W-30-5, 25
Speed Control Servo.................. 8W-30-7
Starter Motor Relay............... 8W-30-5, 21
Throttle Position Sensor........... 8W-30-12, 17
Transmission Control
Module................ 8W-30-28, 32, 34, 35
Transmission Control Relay........... 8W-30-28
Transmission Range Sensor........... 8W-30-32
Vehicle Speed Sensor.............. 8W-30-9, 30
Water In Fuel Sensor................ 8W-30-32
RS8W-30 FUEL/IGNITION SYSTEM8W-30-1

Component Page
Rear Blower Front Control Switch (3 Zone
MTC)......................... 8W-80-124
Rear Blower Motor Power Module C1 (3 Zone
ATC) .......................... 8W-80-125
Rear Blower Motor Power Module C2 (3 Zone
ATC) .......................... 8W-80-125
Rear Blower Rear Control Switch C1 (3 Zone
MTC)......................... 8W-80-125
Rear Blower Rear Control Switch C2 (3 Zone
MTC)......................... 8W-80-125
Rear Dome Lamp (Except Luxury)..... 8W-80-126
Rear Intrusion Sensor (United
Kingdom)...................... 8W-80-126
Rear Mode Motor (3 Zone ATC)....... 8W-80-126
Rear Power Outlet................. 8W-80-126
Rear Temperature Motor (3 Zone ATC) . . 8W-80-127
Rear View Mirror C1 (Luxury)........ 8W-80-127
Rear View Mirror C2 (Hands Free)..... 8W-80-127
Rear Wiper Motor.................. 8W-80-128
Recirculation Door Actuator.......... 8W-80-128
Right B-Pillar Switch (Power Sliding
Door).......................... 8W-80-128
Right Cinch/Release Motor (Power Sliding
Door).......................... 8W-80-128
Right Curtain Airbag Squib.......... 8W-80-129
Right Cylinder Lock Switch (Export) . . . 8W-80-129
Right Door Speaker................ 8W-80-129
Right Fog Lamp................... 8W-80-129
Right Front Door Ajar Switch (Base) . . . 8W-80-130
Right Front Door Lock Motor/Ajar Switch (Except
Base).......................... 8W-80-130
Right Front Impact Sensor........... 8W-80-130
Right Front Park/Turn Signal Lamp.... 8W-80-130
Right Front Wheel Speed Sensor...... 8W-80-131
Right Full Open Switch (Power Sliding
Door).......................... 8W-80-131
Right Headlamp (Caravan/Voyager Except
Export)........................ 8W-80-131
Right Headlamp (Town And Country) . . . 8W-80-131
Right Headlamp Leveling Motor
(Export)....................... 8W-80-132
Right High Beam Lamp (Export)...... 8W-80-132
Right Instrument Panel Speaker...... 8W-80-132
Right Liftgate Flood Lamp........... 8W-80-132
Right Low Beam Lamp (Export)....... 8W-80-133
Right Mid Reading Lamp (Premium/
Luxury)........................ 8W-80-133
Right Park Lamp (Export)........... 8W-80-133
Right Power Mirror................ 8W-80-133
Right Rear Lamp Assembly.......... 8W-80-134
Right Rear Pillar Speaker (Highline
Audio)......................... 8W-80-134Component Page
Right Rear Reading Lamp (Luxury).... 8W-80-134
Right Rear Speaker................ 8W-80-134
Right Rear Vent Motor.............. 8W-80-135
Right Rear Wheel Speed Sensor....... 8W-80-135
Right Remote Radio Switch.......... 8W-80-135
Right Repeater Lamp (Export)........ 8W-80-135
Right Side Impact Sensor 1 (Export) . . . 8W-80-135
Right Side Impact Sensor 1 (Except
Export)........................ 8W-80-136
Right Side Impact Sensor 2.......... 8W-80-136
Right Side Impact Sensor 3.......... 8W-80-136
Right Sliding Door Control Module C1 (Power
Sliding Door)................... 8W-80-136
Right Sliding Door Control Module C2 (Power
Sliding Door)................... 8W-80-137
Right Sliding Door Latch Sensing Switch (Power
Sliding Door)................... 8W-80-137
Right Sliding Door Lock Motor (Power Sliding
Door).......................... 8W-80-137
Right Sliding Door Lock Motor/Ajar Switch (Manual
Sliding Door)................... 8W-80-138
Right Sliding Door Motor (Power Sliding
Door).......................... 8W-80-138
Right Speed Control Switch.......... 8W-80-138
Right Turn Signal Lamp (Export)...... 8W-80-138
Right Visor/Vanity Lamp (Except Base/
Export)........................ 8W-80-139
Sentry Key Remote Entry Module
(SKREEM)..................... 8W-80-139
Siren (United Kingdom)............. 8W-80-139
Speed Control Servo (Gas)........... 8W-80-139
Sunroof Module (Except Export)....... 8W-80-140
Sunroof Switch (Except Export)....... 8W-80-140
Thatcham Alarm Module (United
Kingdom)...................... 8W-80-140
Throttle Position Sensor (Gas)........ 8W-80-141
Traction Control Switch............. 8W-80-141
Trailer Tow Connector (Except Export) . . 8W-80-141
Transmission Control Module (Diesel) . . 8W-80-141
Transmission Control Relay (Diesel).... 8W-80-143
Transmission Range Sensor.......... 8W-80-143
Transmission Solenoid/Pressure Switch
Assembly...................... 8W-80-143
Vehicle Speed Sensor (MTX).......... 8W-80-144
Washer Fluid Level Switch........... 8W-80-144
Washer Pump Motor................ 8W-80-144
Water In Fuel Sensor (Diesel)......... 8W-80-144
Wiper Module..................... 8W-80-144
RS8W-80 CONNECTOR PIN-OUTS8W-80-5

VEHICLE SPEED SENSOR (MTX) - BLACK 3 WAY
CAV CIRCUIT FUNCTION
1 F855 20PK/YL (2.4L) 5 VOLT SUPPLY
1 F202 18PK/GY (DIESEL) FUSED IGNITION SWITCH OUTPUT (RUN-START)
2 K900 18DB/DG (2.4L) SENSOR GROUND
2 K900 20DB/DG (DIESEL) SENSOR GROUND
3 N7 18DB/OR (2.4L) VEHICLE SPEED SIGNAL
3 N7 20DB/OR (DIESEL) VEHICLE SPEED SENSOR SIGNAL
WASHER FLUID LEVEL SWITCH - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 Z401 18BK/LB (EXCEPT EXPORT) GROUND
1 Z401 20BK/LB (EXPORT) GROUND
2 W1 18BR/TN WASHER FLUID LEVEL SWITCH SENSE
WASHER PUMP MOTOR - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 W20 18BR/YL REAR WASHER PUMP MOTOR CONTROL
2 W10 18BR FRONT WASHER PUMP MOTOR CONTROL
WATER IN FUEL SENSOR (DIESEL) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 F853 20LG/RD WATER IN FUEL SENSOR SIGNAL
2 K900 18RD SENSOR GROUND
WIPER MODULE - DK. GRAY 4 WAY
CAV CIRCUIT FUNCTION
1 W3 14BR/WT FRONT WIPER HIGH/LOW RELAY LOW SPEED OUT-
PUT
2 W7 20BR/GY WIPER PARK SWITCH SENSE
3 W4 14BR/OR FRONT WIPER HIGH/LOW RELAY HIGH SPEED OUT-
PUT
4 Z103 14BK/WT GROUND
8W - 80 - 144 8W-80 CONNECTOR PIN-OUTSRS

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Right Sliding Door Motor BK At Sliding Door 45
Right Speed Control Switch WT At Steering Wheel N/S
Right Turn Signal Lamp (Export) OR At Lamp N/S
Right Visor/Vanity Lamp BK At Lamp N/S
Sentry Key Remote Entry Module
(SKREEM)BK At Steering Column 20, 21, 22, 23, 31
Siren (United Kingdom) BK Left Front Body N/S
Speed Control Servo (Gas) BK Near Controller Antilock Brake 11, 17, 18
Sunroof Module (Except Export) BK At Sunroof N/S
Sunroof Switch (Except Export) NAT Near Overhead Console N/S
Thatcham Alarm Module (United
Kingdom)BK Top Right Side of Instrument Panel
Near SpeakerN/S
Throttle Position Sensor (Gas) GY On Throttle Body 10, 11, 17
Traction Control Switch BK Rear of Swtich 21, 22, 31
Trailer Tow Connector (Except
Export)Left Quarter Panel N/S
Transmission Control Relay
(Diesel)Near Transmission 16
Transmission Range Sensor DKGY Top of Transmission 14, 19
Transmission Solenoid/Pressure
Switch AssemblyBK Side of Transmission 14, 19
Vehicle Speed Sensor (MTX) BK Rear of Transmission 16
Washer Fluid Level Switch BK Bottom of Reservoir 3
Washer Pump Motor BK Right Fender Well 3
Water in Fuel Sensor (Diesel) BK Left Rear Engine Compartment N/S
Wiper Module DKGY Left Side Cowl 6
GROUNDS
GROUND NUMBER LOCATION FIG.
G100 Body Ground Near Powertrain Control Module N/S
G101 Above Starter 13, 15, 18
G102 Left Headlamp Area 1
G103 Above Starter 15
G200 Left Side of Instrument Panel 20, 21 29
G201 Right Side of Instrument Panel 20, 24, 29
G202 Near Radio N/S
G300 Left B Pillar 32
G301 Right B Pillar 33, 39
G302 Left Rear Quarter 47
G303 Liftgate Ground 49
8W - 91 - 12 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

CYLINDER-TO-CYLINDER LEAKAGE TEST
To determine if an engine cylinder head gasket is
leaking between adjacent cylinders, follow the proce-
dures in Cylinder Compression Pressure Test (Refer
to 9 - ENGINE - DIAGNOSIS AND TESTING). An
engine cylinder head gasket leaking between adja-
cent cylinders will result in approximately a 50±70%
reduction in compression pressure.
CYLINDER-TO-WATER JACKET LEAKAGE TEST
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING WITH COOLANT PRES-
SURE CAP REMOVED.
VISUAL TEST METHOD
With the engine cool, remove the coolant pressure
cap. Start the engine and allow it to warm up until
thermostat opens.
If a large combustion/compression pressure leak
exists, bubbles will be visible in the coolant.
COOLING SYSTEM TESTER METHOD
WARNING: WITH COOLING SYSTEM TESTER IN
PLACE, PRESSURE WILL BUILD UP FAST. EXCES-
SIVE PRESSURE BUILT UP, BY CONTINUOUS
ENGINE OPERATION, MUST BE RELEASED TO A
SAFE PRESSURE POINT. NEVER PERMIT PRES-
SURE TO EXCEED 138 kPa (20 psi).
Install Cooling System Tester 7700 or equivalent to
pressure cap neck. Start the engine and observe the
tester's pressure gauge. If gauge pulsates with every
power stroke of a cylinder a combustion pressure
leak is evident.
CHEMICAL TEST METHOD
Combustion leaks into the cooling system can also
be checked by using Bloc-Chek Kit C-3685-A or
equivalent. Perform test following the procedures
supplied with the tool kit.
REMOVAL - CYLINDER HEAD
(1) Perform fuel system pressure release procedure
before attempting any repairs.(Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY - SPECIFICA-
TIONS)
(2) Disconnect battery negative cable.
(3) Drain cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(4) Remove air filter housing and inlet tube.
(5) Remove upper intake manifold. (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
REMOVAL)(6) Remove heater tube support bracket from cyl-
inder head.
(7) Disconnect radiator upper and heater supply
hoses from intake manifold water outlet connections.
(8) Remove accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)
(9) Raise vehicle and remove exhaust pipe from
manifold.
(10) Remove power steering pump reservoir and
line support bracket from lower intake manifold and
set aside. Do not disconnect lines.
(11) Remove ignition coil and wires from engine.
(12) Disconnect cam sensor and fuel injector wir-
ing connectors.
(13) Remove timing belt and camshaft sprockets.
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT/CHAIN AND SPROCKETS - REMOVAL)
(14) Remove timing belt idler pulley and rear tim-
ing belt cover. (Refer to 9 - ENGINE/VALVE TIM-
ING/TIMING BELT / CHAIN COVER(S) -
REMOVAL)
(15) Remove cylinder head cover. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL)
(16) Remove camshafts (Refer to 9 - ENGINE/
CYLINDER HEAD/CAMSHAFT(S) - REMOVAL).
NOTE: Identify rocker arm position to ensure cor-
rect re-installation in original position, if reused.
(17) Remove rocker arms. (Refer to 9 - ENGINE/
CYLINDER HEAD/ROCKER ARMS - REMOVAL)
(18) Remove cylinder head bolts in REVERSE
sequence of tightening (Fig. 19).
(19) Remove cylinder head from engine block.
(20) Inspect and clean cylinder head. (Refer to 9 -
ENGINE/CYLINDER HEAD - INSPECTION) (Refer
to 9 - ENGINE/CYLINDER HEAD - CLEANING)
CLEANING
To ensure engine gasket sealing, proper surface
preparation must be performed, especially with the
use of aluminum engine components and multi-layer
steel cylinder head gaskets.
NOTE: Multi-Layer Steel (MLS) head gaskets require
a scratch free sealing surface.
Remove all gasket material from cylinder head and
block (Refer to 9 - ENGINE - STANDARD PROCE-
DURE). Be careful not to gouge or scratch the alumi-
num head sealing surface.
Clean all engine oil passages.
9 - 26 ENGINE 2.4LRS
CYLINDER HEAD (Continued)

(5) Install rocker arms. (Refer to 9 - ENGINE/
CYLINDER HEAD/ROCKER ARMS - INSTALLA-
TION)
(6) Install camshafts. (Refer to 9 - ENGINE/CYL-
INDER HEAD/CAMSHAFT(S) - INSTALLATION).
(7) Install cylinder head cover. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION)
(8) Install timing belt rear cover and timing belt
idler pulley. (Refer to 9 - ENGINE/VALVE TIMING/
TIMING BELT / CHAIN COVER(S) - INSTALLA-
TION)
(9) Install timing belt and camshaft sprockets.
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT/CHAIN AND SPROCKETS - INSTALLATION)
(10) Connect cam sensor and fuel injectors wiring
connectors.
(11) Install ignition coil and wires. Connect igni-
tion coil wiring connector.
(12) Install power steering pump reservoir and
line support bracket to cylinder head.
(13) Raise vehicle and install the exhaust pipe to
the manifold.(14) Install accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION)
(15) Install heater tube support bracket to cylinder
head.
(16) Connect radiator upper and heater hoses to
intake manifold water outlet connections.
(17) Install upper intake manifold. (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSTALLATION)
(18) Using new gaskets, install EGR tube and
tighten fasteners to 11 N´m (95 in. lbs.).
(19) Install air inlet tube and housing.
(20) Connect all vacuum lines, electrical wiring,
ground straps and fuel line.
(21) Fill cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(22) Connect battery negative cable.
CAMSHAFT OIL SEAL(S)
REMOVAL
(1) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
REMOVAL).
(2) Hold each camshaft sprocket with Special Tool
6847 while removing center bolt (Fig. 20).
(3) Remove camshaft sprockets.
(4) Remove rear timing belt cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT COVER(S)
- REMOVAL).
(5) Remove camshaft seal using Special Tool
C-4679A (Fig. 21).
Fig. 18 Cylinder Head Gasket Positioning
1 - PART NUMBER FACES UP
2 - NO. 1 CYLINDER
Fig. 19 Cylinder Head Tightening Sequence
Fig. 20 Camshaft Sprocket - Removal/Installation
1 - SPECIAL TOOL 6847
9 - 28 ENGINE 2.4LRS
CYLINDER HEAD (Continued)

(3) Remove crankshaft sprocket using Special
Tools 6793 and insert C-4685-C2 (Fig. 123).
CLEANING
Do Not attempt to clean a timing belt. If contami-
nation from oil, grease, or coolants have occurred, the
timing belt should be replaced.
Clean all sprockets using a suitable solvent. Clean
all sprocket grooves of any debris.
INSTALLATION
INSTALLATION - CRANKSHAFT SPROCKET
CAUTION: The crankshaft sprocket is set to a pre-
determined depth from the factory for correct tim-
ing belt tracking. If removed, use of Special Tool6792 is required to set the sprocket to original
installation depth. An incorrectly installed sprocket
will result in timing belt and engine damage.
(1) Install crankshaft sprocket using Special Tool
6792 (Fig. 124).
(2) Install timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION)
INSTALLATION - CAMSHAFT SPROCKETS
(1) Install camshaft sprockets. Hold camshaft
sprockets with Special Tool 6847 while tightening
center bolts to 115 N´m (85 ft. lbs.) (Fig. 122).
(2) Install timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
INSTALLATION).
(3) Connect negative battery cable.
INSTALLATION - TIMING BELT
(1) Set crankshaft sprocket to TDC by aligning the
sprocket with the arrow on the oil pump housing.
(2) Set camshafts timing marks so that the
exhaust camshaft sprocket is a 1/2 notch below the
intake camshaft sprocket (Fig. 125).
CAUTION: Ensure that the arrows on both camshaft
sprockets are facing up.
(3) Install timing belt. Starting at the crankshaft,
go around the water pump sprocket, idler pulley,
camshaft sprockets and then around the tensioner
(Fig. 126).
(4) Move the exhaust camshaft sprocket counter-
clockwise (Fig. 126) to align marks and take up belt
slack.
Fig. 122 Camshaft Sprocket - Removal/Installation
1 - SPECIAL TOOL 6847
Fig. 123 Crankshaft Sprocket - Removal
1 - SPECIAL TOOL 6793
2 - SPECIAL TOOL C-4685±C2
3 - CRANKSHAFT SPROCKET
Fig. 124 Crankshaft Sprocket - Installation
1 - SPECIAL TOOL 6792
2 - TIGHTEN NUT TO INSTALL
RSENGINE 2.4L9-67
TIMING BELT AND SPROCKET(S) (Continued)

(41) Disconnect the knock sensor electrical connec-
tor (3.8L only).
(42) Disconnect the engine block heater electrical
connector (if equipped).
(43) Remove the accessory belt splash shield.
(44) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(45) Disconnect the radiator lower hose.
(46) Remove air conditioning compressor from
engine.
(47) Remove the generator (Refer to 8 - ELECTRI-
CAL/CHARGING/GENERATOR - REMOVAL).
(48) Remove the water pump pulley attaching
bolts and position pulley between pump hub and
housing.
(49) Disconnect the oil pressure switch electrical
connector.
(50) Disconnect wiring harness support clip from
engine oil dipstick tube.
(51) Install Special Tools 6912 and 8444 Adapters
on the right side (rear) of engine block (Fig. 9).
(52) Lower the vehicle.
(53) Remove the power steering pump and set
aside.(54) Raise vehicle enough to allow engine dolly
Special Tool 6135 and cradle Special Tool 6710 with
post Special Tool 6848 and adaptor Special Tool 6909
to be installed under vehicle (Fig. 12).
(55) Loosen cradle/post mounts to allow movement
for positioning posts into locating holes on the engine
(Fig. 10) and (Fig. 11). Slowly lower vehicle and posi-
tion cradle/post mounts until the engine is resting on
posts. Tighten all cradle/post mounts to cradle frame.
This will keep mounts from moving when removing
or installing engine and transmission.
(56) Lower vehicle so the weight ofONLY THE
ENGINE AND TRANSMISSIONis on the cradle.
(57) Install and secure the safety straps to the cra-
dle fixture and around the engine (Fig. 12).
(58) Remove the engine right side mount to engine
attaching bolts (Fig. 13).
(59) Remove the left mount through bolt (Fig. 14).
Fig. 8 POWERTRAIN SUPPORTS AND DUST COVER
1 - BRACKET - ENGINE REAR MOUNT
2 - BOLT - TRANSAXLE CASE COVER
3 - STRUT - TRANSAXLE TO ENGINE HORIZONTAL
4 - BOLT - HORIZONTAL STRUT
5 - BOLT - STRUT TO TRANSAXLE
6 - COVER - TRANSAXLE CASE LOWER
7 - STRUT - TRANSAXLE TO ENGINE
8 - BOLT - STRUT TO ENGINE
9 - BOLT - ENGINE REAR MOUNT BRACKET
Fig. 9 ADAPTER TOOLS MOUNTED ON BLOCK
1 - SPECIAL TOOL 6912
2 - SPECIAL TOOL 8444
Fig. 10 Positioning Special Tool 6848 for use with
Adapters 8444 & 6912
1 - SLOTS
2 - SPECIAL TOOLS 6848
9 - 90 ENGINE 3.3/3.8LRS
ENGINE 3.3/3.8L (Continued)

(9) Raise vehicle.
(10) Attach wiring harness support clip to the
engine oil dipstick tube.
(11) Connect oil pressure switch electrical connec-
tor.
(12) Install the A/C compressor.
(13) Install the water pump pulley.
(14) Connect the radiator lower hose.
(15) Install the accessory drive belt and splash
shield (Refer to 7 - COOLING/ACCESSORY DRIVE/
DRIVE BELTS - INSTALLATION).(16) Connect the engine block heater electrical con-
nector (if equipped).
(17) Connect the knock sensor electrical connector
(3.8L only).
(18) Install the torque converter to flex plate bolts.
(19) Install the transaxle case cover (Fig. 8).
(20) Install the powertrain struts (Fig. 8).
(21) Install the engine rear mount bracket.
(22) Install the engine front mount and bracket
assembly.
(23)AWD equipped;Install the power transfer
unit (PTU) (Refer to 21 - TRANSMISSION/TRANS-
AXLE/POWER TRANSFER UNIT - INSTALLA-
TION).
(24) Install the axle shafts (Refer to 3 - DIFFER-
ENTIAL & DRIVELINE/HALF SHAFT - INSTALLA-
TION).
(25) Connect exhaust pipe to manifold (Fig. 7).
(26) Install crossmember cradle plate (Fig. 6).
(27) Lower vehicle.
(28) Connect transaxle shift linkage.
(29) Connect transaxle electrical connectors.
(30) Remove plugs from transmission cooler hoses
and install transaxle oil cooler line service splice kit.
Refer to instructions included with kit.
(31) Install transaxle dipstick tube and attach
electrical harness clip.
(32) Connect the A/C lines to compressor.
(33) Connect the A/C compressor electrical connec-
tor.
(34) Evacuate and recharge A/C system.
(35) Connect crankshaft and camshaft position
sensors.
(36) Connect the fuel injector electrical harness
connector and engage clip to support bracket.
(37) Connect engine coolant temperature (ECT)
sensor and ignition coil electrical connectors.
(38) Connect the ground strap to rear of cylinder
head.
(39) Install power steering reservoir.
(40) Engage wire harness clip to engine right side
mount.
(41) Connect the brake booster and speed control
vacuum hoses.
(42) Connect the vacuum hoses to the throttle
body.
(43) Connect the EGR transducer electrical connec-
tor (if equipped).
(44) Connect the TPS, IAC, and MAP sensor elec-
trical connectors.
(45) Connect throttle cables to throttle body.
(46) Install the radiator fans (Refer to 7 - COOL-
ING/ENGINE/RADIATOR FAN - INSTALLATION).
(47) Connect the radiator upper hose.
(48) Connect the heater hoses. Remove pinch-off
pliers from the rear heater hoses (if equipped).
Fig. 13 Right Mount to Engine
1 - BOLT
2 - MOUNT BRACKET
3 - ENGINE RIGHT MOUNT ASSEMBLY
Fig. 14 LEFT MOUNT TO FRAME BRACKET
1 - FRAME BRACKET
2 - FRAME RAIL - LEFT
3 - BOLT
4 - TRANSAXLE MOUNT
9 - 92 ENGINE 3.3/3.8LRS
ENGINE 3.3/3.8L (Continued)

DESCRIPTION N´m Ft.
Lbs.In.
Lbs.
Engine Mounting (Refer to 9 - ENGINE/
ENGINE MOUNTING)
Exhaust ManifoldÐBolts 23 Ð 200
Exhaust Crossover
PipeÐBolts54 40 Ð
Intake Manifold -
LowerÐBolts23 Ð 200
Intake Manifold - Lower
Gasket RetainerÐBolts12 Ð 105
Intake Manifold
UpperÐBolts12 Ð 105
Lifter Yoke RetainerÐ
Bolts12 Ð 105
Oil Filter Attaching Fitting 54 40 Ð
Oil Cooler Attaching
Fitting27 20 Ð
Oil Filter 20 15 Ð
Oil Filter AdapterÐBolts 28 Ð 250
Oil Gallery Plug 27 20 Ð
Oil PanÐBolts 12 Ð 105
Oil Pan DrainÐPlug 27 20 Ð
Oil Pressure Switch 23 Ð 200
Oil Pump Cover
PlateÐScrews12 Ð 105
Oil Pump Pick-up
TubeÐBolt28 Ð 250
Oil Dipstick HousingÐ
Bolts48 35 Ð
Rocker Arm ShaftÐBolts 23 Ð 200
Spark Plug 16 12 Ð
Timing Chain Case Cover
ÐM8 Bolt 27 20 Ð
ÐM10 Bolt 54 40 Ð
Water PumpÐBolts 12 Ð 105
Water Pump PulleyÐ
Bolts28 Ð 250SPECIAL TOOLS
3.3/3.8L ENGINE
Dolly 6135
Cradle 6710A
Adapter 6909A
Adapter 8444
9 - 98 ENGINE 3.3/3.8LRS
ENGINE 3.3/3.8L (Continued)