2002 CHRYSLER CARAVAN service

REMOVAL - ENGINE ASSEMBLY
(1) Perform fuel pressure release procedure (Refer
to 14 - FUEL SYSTEM/FUEL DELIVERY - STAN-
DARD PROCEDURE).
(2) Disconnect negative battery cable.
(3) Remove air cleaner and hoses.
(4) Disconnect the fuel line from fuel rail (Refer to
14 - FUEL SYSTEM/FUEL DELIVERY/QUICK
CONNECT FITTING - STANDARD PROCEDURE).
(5) Remove the wiper module (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
REMOVAL).
(6) Block off heater hoses to the rear heater sys-
tem using pinch-off pliers (if equipped).
(7) Drain the cooling system (Refer to 7 - COOL-
ING - STANDARD PROCEDURE).
(8) Disconnect the heater hoses.
(9) Remove the radiator upper support crossmem-
ber (Refer to 23 - BODY/EXTERIOR/GRILLE OPEN-
ING REINFORCEMENT - REMOVAL).
(10) Remove the radiator fans (Refer to 7 - COOL-
ING/ENGINE/RADIATOR FAN - REMOVAL).
(11) Disconnect the throttle cables from the throt-
tle body.
(12) Disconnect the MAP, IAC, and TPS electrical
connectors.
(13) Disconnect the EGR transducer electrical con-
nector (if equipped).
(14) Disconnect the vacuum hoses from throttle
body.
(15) Disconnect the brake booster and speed con-
trol vacuum hoses.
(16) Disengage wire harness clip from the right
side engine mount.
(17) Remove the power steering reservoir from
mounting position and set aside.Do notdisconnect
hose.
(18) Disconnect ground strap from rear of cylinder
head.
(19) Disconnect engine coolant temperature (ECT)
sensor and ignition coil electrical connectors.
(20) Disconnect the fuel injector electrical harness
connector and disengage clip from support bracket.
(21) Disconnect camshaft and crankshaft position
sensor electrical connectors.
(22) Evacuate air conditioning system. Refer to 24
- HEATING & AIR CONDITIONING.
(23) Disconnect A/C compressor electrical connec-
tor.(24) Disconnect the A/C lines from compressor.
Cover and seal all openings of hoses and compressor.
(25) Remove the radiator upper hose.
(26) Disengage electrical harness clip at transaxle
dipstick tube.
(27) Remove transaxle dipstick tube. Seal opening
using a suitable plug.
NOTE: When the transaxle cooler lines are removed
from the rolled-groove type fittings at the transaxle,
damage to the inner wall of the hose will occur. To
prevent prevent potential leakage, the cooler hoses
must be cut off flush at the transaxle fitting, and a
service cooler hose splice kit must be installed
upon reassembly.
(28) Using a blade or suitable hose cutter, cut
transaxle oil cooler lines off flush with fittings. Plug
cooler lines and fittings to prevent debris from enter-
ing transaxle or cooler circuit. A service splice kit will
be installed upon reassembly.
(29) Disconnect transaxle shift linkage and electri-
cal connectors.
(30) Raise vehicle on hoist and drain the engine
oil.
(31) Remove the axle shafts. (Refer to 3 - DIFFER-
ENTIAL & DRIVELINE/HALF SHAFT - REMOVAL)
(32) Remove crossmember cradle plate (Fig. 6).
Fig. 6 Crossmember Cradle Plate
1 - CRADLE PLATE
RSENGINE 3.3/3.8L9-87
ENGINE 3.3/3.8L (Continued)
ProCarManuals.com

(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 connector.
(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).
(49) Install the radiator upper support crossmem-
ber (Refer to 23 - BODY/EXTERIOR/GRILLE OPEN-
ING REINFORCEMENT - INSTALLATION).
(50) Install the wiper module (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
INSTALLATION).
(51) Connect the fuel line to fuel rail (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY/FUEL LINES -
STANDARD PROCEDURE).
(52) Install the air cleaner and hoses.
(53) Install new oil filter. Fill engine crankcase
with proper oil to correct level.
(54) Connect negative cable to battery.
(55) Fill the cooling system (Refer to 7 - COOLING
- STANDARD PROCEDURE).
(56) Start engine and run until operating temper-
ature is reached.
(57) Adjust transmission linkage, if necessary.
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
RSENGINE 3.3/3.8L9-91
ENGINE 3.3/3.8L (Continued)
ProCarManuals.com

SPECIFICATIONS
3.3/3.8L ENGINE
DESCRIPTION SPECIFICATION
General Specification
Type 60É V-6 Engine
Number of Cylinders 6
Displacement
Ð3.3L 3.3 Liters
(201 cu. in.)
Ð3.8L 3.8 Liters
(231 cu. in.)
Bore
Ð3.3L 93.0 mm
(3.66 in.)
Ð3.8L 96.0 mm
(3.779 in.)
Stroke
Ð3.3L 81.0 mm
(3.188 in.)
Ð3.8L 87.0 mm
(3.425 in.)
Compression Ratio
Ð3.3L 9.35:1
Ð3.8L 9.6:1
Firing Order 1-2-3-4-5-6
Cylinder Number (Front
to Rear)
ÐFront Bank 2,4,6
ÐRear Bank 1,3,5
Compression PressureÐ
Minimum689.5 kPa
(100 psi)
Max. Variation Between
Cylinders25%
Cylinder Block
Cylinder Bore Diameter
(Standard)
Ð3.3L 92.993±93.007 mm
(3.661±3.6617 in.)
Ð3.8L 95.993±96.007 mm
(3.7792±3.780 in.)
DESCRIPTION SPECIFICATION
Out-of-Round (Service
Limits)0.076 mm
(0.003 in.)
Taper (Service Limits) 0.051 mm
(0.002 in.)
Lifter Bore Diameter 22.980±23.010 mm
(0.905±0.906 in.)
Deck Surface Flatness
(Max.)0.1 mm
(0.004 in.)
Pistons
Piston Diameter
Ð3.3L ÐMeasured 39.8
mm (1.567 in.) from
piston top92.968±92.998 mm
(3.660±3.661 in.)
Ð3.8L ÐMeasured 33.01
mm (1.30 in.) from piston
top95.968±95.998 mm
(3.778±3.779 in.)
Clearance in Bore @
Size Location (New)-0.005±0.039 mm
(-0.0002±0.0015 in.)
Weight
Ð3.3L 362  5 grams
(12.77  0.1764 oz.)
Ð3.8L 426  5 grams
(15.03  0.1764 oz.)
Piston Pins
Type Press Fit in Rod
(Serviced as an
Assembly)
Clearance in Piston @
21É C (70É F)0.006±0.019 mm
(0.0002±0.0007 in.)
Clearance in Connecting
Rod(Interference Fit)
Diameter 22.87±22.88 mm
(0.9007±0.9009 in.)
Length
Ð3.3L 67.25±67.75 mm
(2.648±2.667 in.)
Ð3.8L 71.25±71.75
(2.805±2.824 in.)
Piston Rings
Ring End GapÐTop
Compression Ring0.18±0.38 mm
(0.007±0.015 in.)
Wear Limit 1.0 mm
(0.039 in.)
9 - 92 ENGINE 3.3/3.8LRS
ENGINE 3.3/3.8L (Continued)
ProCarManuals.com

DESCRIPTION SPECIFICATION
Bearing Clearance (Max.
allowable)0.127 mm
(0.005 in.)
End Play 0.254±0.508 mm
(0.010±0.020 in.)
(Max. allowable) 0.304 mm
(0.012 in.)
Camshaft Bearing
Diameter
No. 1 50.800±50.825 mm
(1.9999±2.0009 in.)
No. 2 50.393±50.419 mm
(1.9839±1.9849 in.)
No. 3 50.013±50.038 mm
(1.9690±1.9699 in.)
No. 4 49.606±49.632 mm
(1.9529±1.954 in.)
Exhaust Valve Timing
ClosesÐ3.3L (ATDC) 13É
ClosesÐ3.8L (ATDC) 18É
OpensÐ3.3L (BBDC) 43É
OpensÐ3.8L (BBDC) 46É
DurationÐ3.3L 236É
DurationÐ3.8L 244É
Intake Valve Timing
ClosesÐ3.3L (ABDC 52É
ClosesÐ3.8L (ABDC 63É
OpensÐ3.3L (ATDC) 6É
OpensÐ3.8L (ATDC) 1É
DurationÐ3.3L 226É
DurationÐ3.8L 242É
Valve OverlapÐ3.3L 7É
Valve OverlapÐ3.8L 17É
Lifters
Type Hydraulic Roller
Diameter O.D. 22.949±22.962 mm
(0.903±0.904 in.)
Clearance In Block 0.020±0.061 mm
0.0007±0.0024 in.)
Cylinder Head
Gasket Thickness
(Compressed)0.65±0.75 mm
(0.025±0.029 in.)DESCRIPTION SPECIFICATION
Valve Seat
Angle 44.5±45É
Valve Seat Runout
(Service Limits)0.0762 mm
(0.003 in.)
Valve Seat WidthÐIntake
& Exhaust1.50±2.00 mm
(0.057±0.078 in.)
Valve Guide
Guide Bore Diameter
(Std.)6.975±7.00 mm
(0.274±0.275 in.)
Valves
Valve Lift (Zero
Lash)ÐIntake & Exhaust
Ð3.3L 9.80 mm
(0.385 in.)
Ð3.8L 11.0 mm
(0.433 in.)
Face AngleÐIntake 45±45.5É
Face AngleÐExhaust 45±45.5É
Head DiameterÐIntake 47.87±48.13 mm
(1.88±1.89 in.)
Head DiameterÐExhaust 35.37±35.63 mm
(1.39±1.40 in.)
Valve Margin
Intake 0.825±0.973 mm
(0.032±0.038 in.)
Exhaust 1.565±1.713 mm
(0.061±0.067 in.)
Valve Length (Overall)
Intake 125.84±126.6 mm
(4.95±4.98 in.)
Exhaust 127.2±127.96 mm
(5.00±5.04 in.)
Valve Stem Tip Height
Intake (valve tip to spring
seat washer)48.1±49.7 mm
(1.89±1.95 in.)
Exhaust (valve tip to
spring seat washer)48.53±50.09 mm
(1.91±1.97 in.)
Valve Stem Diameter
Intake (Standard) 6.935±6.953 mm
(0.2730±0.2737 in.)
9 - 94 ENGINE 3.3/3.8LRS
ENGINE 3.3/3.8L (Continued)
ProCarManuals.com

(4) Remove the cylinder head covers. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL)
(5) Remove the spark plugs from cylinder head.
(6) Remove the dipstick and tube (Fig. 18).
(7) Remove exhaust manifold(s). (Refer to 9 -
ENGINE/MANIFOLDS/EXHAUST MANIFOLD -
REMOVAL)
(8) Remove rocker arm and shaft assemblies.(Refer
to 9 - ENGINE/CYLINDER HEAD/ROCKER ARMS -
REMOVAL) Remove push rods andmark positions
to ensure installation in original locations.
(9) Remove the eight head bolts from each cylinder
head and remove cylinder heads (Fig. 22).
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.
INSPECTION
(1) Before cleaning, check for leaks, damage and
cracks.
(2) Clean cylinder head and oil passages.
(3) Check cylinder head for flatness (Fig. 19).
(4) Cylinder head must be flat within:
²Standard dimension = less than 0.05 mm (0.002
inch.)
²Service Limit = 0.2 mm (0.008 inch.)
²Grinding Limit = Maximum of 0.2 mm (0.008
inch.) is permitted.
Fig. 17 Cylinder Head and Components
1 - VALVE LOCKS 5 - SPRING SEATS
2 - RETAINERS 6 - CYLINDER HEAD
3 - VALVE SPRINGS 7 - VALVE - EXHAUST
4 - VALVE STEM SEALS 8 - VALVE - INTAKE
RSENGINE 3.3/3.8L9 - 101
CYLINDER HEAD (Continued)
ProCarManuals.com

(3) Assemble gasket to cylinder cover by inserting
the bolt assemblies through each bolt hole on the
cover and gasket (Fig. 26).
(4) Install cylinder head cover and bolts (Fig. 27).(5) Tighten cylinder head cover bolts to 12 N´m
(105 in. lbs.) (Fig. 27).
(6) Connect PCV hose to cylinder head cover.
(7) Connect power steering pump supply hose sup-
port clip to cylinder head cover (Fig. 24).
(8) Connect spark plug wires to spark plugs.
(9) Install wiper module. (Refer to 8 - ELECTRI-
CAL/WIPERS/WASHERS/WIPER MODULE -
INSTALLATION)
(10) Connect negative cable to battery.
Fig. 24 P/S Supply Hose
1 - POWER STEERING RESERVOIR
2 - CLAMP
3 - SUPPLY HOSE
4 - CLIP
5 - POWER STEERING PUMP
Fig. 25 PCV Hose
1 - HOSE - PCV
2 - P C V VA LV E
Fig. 26 CYLINDER HEAD COVER GASKET
1 - CYLINDER HEAD COVER
2 - BOLT
3 - SEAL (SERVICED WITH BOLT)
4 - GASKET
Fig. 27 Cylinder Head Cover
1 - CYLINDER HEAD COVER
2 - BOLT
9 - 104 ENGINE 3.3/3.8LRS
CYLINDER HEAD COVER - RIGHT (Continued)
ProCarManuals.com

REMOVAL
(1) Remove the valve springs. (Refer to 9 -
ENGINE/CYLINDER HEAD/VALVE SPRINGS -
REMOVAL)
(2) Remove the valve stem seal (Fig. 44).
INSTALLATION
(1) Install the valve stem seal squarely over the
valve guide, using the valve stem as a guide (Fig.
44). Do not force the seal against top of the valve
guide.
(2) Install the valve spring. (Refer to 9 - ENGINE/
CYLINDER HEAD/VALVE SPRINGS - INSTALLA-
TION)
ENGINE BLOCK
DESCRIPTION
The cylinder block is made of cast iron and is a
deep skirt design.
STANDARD PROCEDURE - CYLINDER BORE
HONING
(1) Used carefully, the cylinder bore resizing hone,
recommended tool C-823 or equivalent, equipped
with 220 grit stones, is the best tool for this honing
procedure. In addition to deglazing, it will reduce
taper and out-of-round as well as removing light
scuffing, scoring or scratches. Usually a few strokes
will clean up a bore and maintain the required lim-
its.
(2) Deglazing of the cylinder walls may be done
using a cylinder surfacing hone, recommended tool
C-3501 or equivalent, equipped with 280 grit stones,
if the cylinder bore is straight and round. 20±60
strokes depending on the bore condition, will be suf-
ficient to provide a satisfactory surface. Use a light
honing oil.Do not use engine or transmission oil,
mineral spirits or kerosene.Inspect cylinder walls
after each 20 strokes.
(3) Honing should be done by moving the hone up
and down fast enough to get a cross-hatch pattern.
When hone marksintersectat 40-60 degrees, the
cross hatch angle is most satisfactory for proper seat-
ing of rings (Fig. 45).
(4) A controlled hone motor speed between
200±300 RPM is necessary to obtain the proper cross-
hatch angle. The number of up and down strokes per
minute can be regulated to get the desired 40±60
degree angle. Faster up and down strokes increase
the cross-hatch angle.
(5) After honing, it is necessary that the block be
cleaned again to remove all traces of abrasive.CAUTION: Ensure all abrasives are removed from
engine parts after honing. It is recommended that a
solution of soap and hot water be used with a
brush and the parts then thoroughly dried. The bore
can be considered clean when it can be wiped
clean with a white cloth and cloth remains clean.
Oil the bores after cleaning to prevent rusting.
CLEANING
Clean cylinder block thoroughly using a suitable
cleaning solvent.
INSPECTION
ENGINE BLOCK
(1) Clean cylinder block thoroughly and check all
core hole plugs for evidence of leaking.
(2) If new core plugs are to be installed, (Refer to 9
- ENGINE - STANDARD PROCEDURE - ENGINE
CORE AND OIL GALLERY PLUGS).
(3) Examine block and cylinder bores for cracks or
fractures.
(4) Check block deck surfaces for flatness. Deck
surface must be within service limit of 0.1 mm (0.004
in.).
CYLINDER BORE
NOTE: The cylinder bores should be measured at
normal room temperature, 21ÉC (70ÉF).
Fig. 45 Cylinder Bore Cross-Hatch Pattern
1 - CROSS-HATCH PATTERN
2 - 40ɱ60É
RSENGINE 3.3/3.8L9 - 113
VALVE STEM SEALS (Continued)
ProCarManuals.com

The cylinder walls should be checked for out-of-
round and taper with Tool C119 or equivalent (Fig.
46) (Refer to 9 - ENGINE - SPECIFICATIONS). If
the cylinder walls are badly scuffed or scored, the
cylinder block should be replaced, and new pistons
and rings fitted.
Measure the cylinder bore at three levels in direc-
tions A and B (Fig. 46). Top measurement should be
10 mm (3/8 in.) down and bottom measurement
should be 10 mm (3/8 in.) up from bottom of bore.
(Refer to 9 - ENGINE - SPECIFICATIONS).
CAMSHAFT & BEARINGS (IN
BLOCK)
DESCRIPTION
The nodular iron camshaft is mounted in the
engine block and supported with four steel backed
aluminum bearings (Fig. 47). A thrust plate, located
in front of the first bearing, is bolted to the block and
controls the camshaft end play (Fig. 47). To distin-
guish camshafts between the 3.3L and 3.8L engines,
a cast-in ring is located between the rear bearing
journal and rear lobe (Fig. 48). The 3.3L engine
application is as-cast only. The 3.8L engine applica-
tion the cast ring is machined off.
OPERATION
The camshaft is driven by the crankshaft through
a timing chain and sprockets. The camshaft has pre-cisely machined (egg-shaped) lobes to provide accu-
rate valve timing and duration.
REMOVAL
(1) Remove the engine assembly from vehicle.
(Refer to 9 - ENGINE - REMOVAL)
Remove the cylinder heads. (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL)
(2) Remove the timing chain and camshaft
sprocket. (Refer to 9 - ENGINE/VALVE TIMING/
TIMING BELT/CHAIN AND SPROCKETS -
REMOVAL)
(3) Remove the hydraulic lifters. (Refer to 9 -
ENGINE/ENGINE BLOCK/HYDRAULIC LIFTERS
(CAM IN BLOCK) - REMOVAL). Identify each tappet
for reinstallation in original location.
Fig. 46 Checking Cylinder Bore Size
Fig. 47 CAMSHAFT AND BEARINGS
1 - CAMSHAFT
2 - THRUST PLATE
3 - BOLT
4 - CAMSHAFT BEARINGS (SERVICED WITH BLOCK)
Fig. 48 CAMSHAFT IDENTIFICATION
1 - CAMSHAFT - 3.3L ENGINE
2 - CAST-IN RING
3 - CAMSHAFT - 3.8L ENGINE
4 - MACHINED CAST-IN RING
9 - 114 ENGINE 3.3/3.8LRS
ENGINE BLOCK (Continued)
ProCarManuals.com