Category Archives: Cars

Timing chain cover to engine block water coolant leak

Chrysler Voyager 3.3 V6 (2000)

Timing chain cover to engine block water coolant leak.

As well as the usual coolant water leaks associated with my Chrysler Voyager 3.3 V6 (2000)

e.g. Radiator, water pump, hoses etc. I encountered a slight and intermittent coolant leak between the timing chain cover and the left side of the engine block .

The vehicle which I’ve had from new, has now over 102000 miles on the clock. So I guess this mileage and age was a contributory factor.

Below is a step by step guide of how I replaced the timing chain cover gasket and the failed “O” rings on the water galleries between the timing chain cover and engine block.

You might find this photo guide useful if you decide to tackle the job yourself.

I’m sure you can do the job without removing the bonnet and wiper box, but for the time it takes it makes the rest of the job a lot more accessible plus it gives a bit more light on the subject.

1. Disconnect battery and remove bonnet and wiper box.

See this link for wiper box removal

2. The vehicle runs on LPG, so turn of the gas supply at the tank.

3. Drain radiator and remove LPG control valve.

4. With the hoses removed you can just see the residue of the coolant leak between the timing cover and engine block.

5. Raise the vehicle with suitable jack and support with axle stands.

Remove right front wheel, the plastic wing protector and the plastic crankshaft pulley protector.

6. Remove the serpentine belt using a combination spanner on the bolt head of the belt tensioner pulley. Do this by reaching up from the underside of the vehicle. You might need to use a ring spanner on the open ended jaw of the combination spanner for extra leverage against the spring tension. Pull the belt from the crankshaft pulley.

7. Remove water pump and hoses.

8. Slacken the crankshaft pulley bolt (easier with an air wrench)

Use a puller to remove the pulley. It will be tight all the way off.

9. Remove the idler pulley, unbolt the aircon pump and cable tie to one side. Do not remove any pipes from the aircon pump!

10. Drain the engine oil and remove the sump and pick up pipe. Removal of a stabiliser bracket on the side of the engine block may be required to remove the starter ring gear cover.

11. Suitably support the engine for the removal of the right side engine mounting.

12. Remove the engine mounting. First remove the vertical and horizontal bolt to the engine mounting bracket then remove the 3 bolts fixing the rubber mounting bracket to the chassis.

13. Remove the 3 bolts holding engine mounting plate to the timing chain cover (left in photo)

14. Unplug the camshaft sprocket positioning sensor multi plug.

15. Remove the 8 timing chain cover bolts and ease the cover over end of crankshaft to remove.

16. Check timing chain cover for faults. Note on this photo the two water gallery “O” rings are damaged and are the cause of the coolant leak. The lower left hand port on the casing has an “O” ring for the oil gallery.

17. Clean the timing chain cover mating surface with a scraper and Emery cloth, paying particular attention to the “O” ring seats which are very close to the edge of the casing.

18. Clean the engine block mating surface and check timing chain and sprockets for serviceability.

19. Fit 3 new “O” rings and gasket to the timing chain cover using a suitable gasket sealant.

20. Refit timing chain cover ensuring “O” rings do not drop out of position.

Rotate if necessary the two flats on the oil pump drive so they align with the two flats on the crankshaft.

21. Refit sump with new gasket and and oil pick up pipe “O” ring.

22. Refit crankshaft pulley using a long 10mm bolt and nut to jack the pulley back on the crankshaft. It will be a tight fit all the way.

23. Rebuild the remainder of the components.

It might be worth replacing the serpentine drive belt at this stage.

24. Parts used:

Timing chain cover gasket and “O” rings, not expensive

Sump gasket set, quite expensive.

Part Codes:

B0000K04621958 – Sealing Gasket (timing chain cover)

B00K04483444AB – Ring (timing chain cover)

B0000K04483443 – Sealing Gasket (timing chain cover)

B00k05241062AB – Seal Kit (sump)

Changing the spark plugs on a Chrysler Voyager V6

The rear spark plugs on a Chrysler Voyager V6 (2000) at first seem very difficult to change. I have heard of various methods, from gaining access from underneath the car, to lifting the inlet manifold an inch or two.

I decided to take the easiest approach, which might not be the quickest if you have access to a vehicle lift, but is relatively straight forward.

As well as a new set of spark plugs and ignition leads you may need a new inlet manifold gasket as it could break when you remove the manifold

Below is a step by step photo guide on how to replace the spark plugs, which you might find helpful if tackling the job yourself.

Note position of wiper arms
Remove wiper arm spindle cap
Remove wiper arm spindle nut
Remove wiper arm and wiper top panel screws
Panel clips
Remove flat nuts from wiper top panel studs
Disconnect screen washer tubing
Disconnect screen washer tubing on jets
Remove wiper box top bracket nuts
Remove main wiper box bolts
Remove main wiper box bolts
Remove wiper motor multiplug
Disconnect wiper box drain pipes
Lift out wiper box assembly for easy access to inlet manifold
Remove 3 alternator bracket bolts and rotate plate upwards
Remove distributor bolts
Remove air box and vacuum pipes, breather pipes, multiplugs, throttle cables on throttle body
Remove exhaust recirculation pipe bolts (a bit tricky)
Remove inlet manifold support bracket bolt from engine block
Remove cable mounting bracket bolt on back of manifold(left side) (a bit tricky)
Remove cable mounting bracket bolt (right side) (also a bit tricky)
View of cable bracket/bolts on back of manifold(may assist in removal)
Remove earth wires on bulkhead stud
Remove inlet manifold nuts and bolts
Remove inlet manifold and cover engine inlet ports
Remove ignition leads and Remove and replace rear spark plugs
Remove ignition leads and Remove and replace front spark plugs
Check wiring and multiplug cable mounting bracket
Fit new inlet manifold gasket
Fit new air filter at this stage if necessary and rebuild

Refit rear ignition leads; rebuild inlet manifold assembly, electrics and wiper box.

Parts used