2003 CHRYSLER CARAVAN Service Manual

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Page 1249 of 2177

CHRYSLER CARAVAN 2003 Service Manual BALANCE SHAFT CARRIER
The following components will remain intact dur-
ing carrier removal: Gear cover, gears, balance shafts
and the rear cover (Fig. 130).
(1) Drain engine oil.
(2) Remove the oil pa

Page 1250 of 2177

CHRYSLER CARAVAN 2003 Service Manual Fig. 131 Chain Cover, Guide and Tensioner
1 - STUD
2 - TENSIONER (ADJUSTER)
3 - GEAR COVER
4 - ADJUST SCREW
5 - PIVOT SCREW
6 - CHAIN COVER (CUTAWAY)
7 - GUIDE
Fig. 132 Drive Chain and Sprockets
1 - N

Page 1251 of 2177

CHRYSLER CARAVAN 2003 Service Manual INSTALLATION
BALANCE SHAFT INSTALLATION/TIMING
Balance shaft and carrier assembly installation is
the reverse of the removal procedure.During instal-
lation crankshaft-to-balance shaft timing must
be

Page 1252 of 2177

CHRYSLER CARAVAN 2003 Service Manual (9) With balance shaft keyways pointing up (12
oclock) slide the balance shaft sprocket onto the nose
of the balance shaft. The balance shaft may have to
be pushed in slightly to allow for clearance.

Page 1253 of 2177

CHRYSLER CARAVAN 2003 Service Manual ENGINE 3.3/3.8L
TABLE OF CONTENTS
page page
ENGINE 3.3/3.8L
DESCRIPTION.........................76
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION...........76
DIAGNOSIS

ENGINE 3.3/3.8L
TABLE OF CONTENTS
page page
ENGINE 3.3/3.8L
DESCRIPTION.........................76
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION...........76
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - PERFORMANCE...........78
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - MECHANICAL.............80
DIAGNOSIS AND TESTING - ENGINE OIL
LEAK INSPECTION....................82
DIAGNOSIS AND TESTING - CYLINDER
COMPRESSION PRESSURE TEST........83
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE
TEST...............................83
STANDARD PROCEDURE
STANDARD PROCEDURE - MEASURING
BEARING CLEARANCE USING
PLASTIGAGE........................84
STANDARD PROCEDURE - FORM-IN-
PLACE GASKETS AND SEALERS.........84
STANDARD PROCEDURE - ENGINE
GASKET SURFACE PREPARATION........85
STANDARD PROCEDURE - HYDROSTATIC
LOCKED ENGINE.....................85
STANDARD PROCEDURE - REPAIR OF
DAMAGED OR WORN THREADS.........86
STANDARD PROCEDURE - ENGINE CORE
AND OIL GALLERY PLUGS..............86
REMOVAL - ENGINE ASSEMBLY...........86
INSTALLATION - ENGINE ASSEMBLY........89
SPECIFICATIONS
3.3/3.8L ENGINE......................91
SPECIFICATIONS - TORQUE............95
SPECIAL TOOLS
3.3/3.8L ENGINE......................95
AIR CLEANER ELEMENT
REMOVAL.............................98
INSTALLATION.........................98
AIR CLEANER HOUSING
REMOVAL.............................99
INSTALLATION.........................99
CYLINDER HEAD
DESCRIPTION.........................99
DIAGNOSIS AND TESTINGÐCYLINDER HEAD
GASKET............................99
REMOVAL - CYLINDER HEAD............100
CLEANING...........................100INSPECTION.........................101
INSTALLATION - CYLINDER HEAD.........101
CYLINDER HEAD COVER(S)
DESCRIPTION........................102
CYLINDER HEAD COVER - RIGHT
REMOVAL............................102
INSTALLATION........................103
CYLINDER HEAD COVER - LEFT
REMOVAL............................103
INSTALLATION........................103
INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION........................104
OPERATION..........................104
STANDARD PROCEDURE - REFACING
VALVESANDVALVESEATS ............104
REMOVAL............................105
CLEANING...........................105
INSPECTION.........................105
INSTALLATION........................106
VALVE SPRINGS
DESCRIPTION........................106
OPERATION..........................106
REMOVAL
REMOVAL - CYLINDER HEAD OFF.......106
REMOVAL - CYLINDER HEAD ON........106
INSPECTION.........................108
INSTALLATION
INSTALLATION - CYLINDER HEAD OFF . . . 108
INSTALLATION - CYLINDER HEAD ON....108
ROCKER ARMS
DESCRIPTION
DESCRIPTION - ROCKER ARMS.........109
DESCRIPTION - PUSHRODS...........109
OPERATION
OPERATION - ROCKER ARMS..........109
OPERATION - PUSHRODS.............109
REMOVAL - ROCKER ARMS AND SHAFT....109
DISASSEMBLY - ROCKER ARMS AND SHAFT. . 109
ASSEMBLY - ROCKER ARMS AND SHAFT . . . 109
INSTALLATION - ROCKER ARMS AND SHAFT..110
VALVE STEM SEALS
DESCRIPTION........................111
REMOVAL............................112
INSTALLATION........................112
ENGINE BLOCK
DESCRIPTION........................112
STANDARD PROCEDURE - CYLINDER BORE
HONING............................112
CLEANING...........................112
9 - 74 ENGINE 3.3/3.8LRS
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Page 1254 of 2177

CHRYSLER CARAVAN 2003 Service Manual INSPECTION..........................112
HYDRAULIC LIFTERS (CAM IN BLOCK)
DESCRIPTION........................113
DIAGNOSIS AND TESTING - HYDRAULIC
LIFTERS...........................113
REMOVAL.........

INSPECTION..........................112
HYDRAULIC LIFTERS (CAM IN BLOCK)
DESCRIPTION........................113
DIAGNOSIS AND TESTING - HYDRAULIC
LIFTERS...........................113
REMOVAL............................114
INSTALLATION........................114
CAMSHAFT & BEARINGS (IN BLOCK)
DESCRIPTION........................115
OPERATION..........................115
REMOVAL............................115
INSPECTION..........................115
INSTALLATION........................115
PISTON & CONNECTING ROD
DESCRIPTION........................116
STANDARD PROCEDURE
STANDARD PROCEDURE - FITTING
CONNECTING RODS..................116
STANDARD PROCEDURE - FITTING
PISTONS...........................117
REMOVAL............................117
INSTALLATION........................118
CONNECTING ROD BEARINGS
STANDARD PROCEDURE - MEASURING
CONNECTING ROD BEARING CLEARANCE
. . 120
PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING............................121
REMOVAL............................121
INSTALLATION........................121
CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDURE - MAIN BEARING
FITTING............................123
REMOVAL - CRANKSHAFT MAIN BEARINGS . 124
INSTALLATION - CRANKSHAFT MAIN
BEARINGS..........................124
CRANKSHAFT
DESCRIPTION
DESCRIPTION - 3.3L..................125
DESCRIPTION - 3.8L..................125
STANDARD PROCEDURE - MEASURING
CRANKSHAFT END PLAY..............125
REMOVAL............................125
INSTALLATION........................126
CRANKSHAFT OIL SEAL - FRONT
REMOVAL............................127
INSTALLATION........................127
CRANKSHAFT OIL SEAL - REAR
REMOVAL............................128
INSTALLATION........................129
CRANKSHAFT REAR OIL SEAL RETAINER
REMOVAL............................129
INSTALLATION........................129
VIBRATION DAMPER
REMOVAL............................130
INSTALLATION........................130FLEX PLATE
REMOVAL............................131
INSTALLATION........................131
ENGINE MOUNTING
DESCRIPTION........................131
FRONT MOUNT
REMOVAL............................131
INSTALLATION........................131
LEFT MOUNT
REMOVAL............................133
INSTALLATION........................133
REAR MOUNT
REMOVAL............................133
INSTALLATION........................134
RIGHT MOUNT
REMOVAL............................135
INSTALLATION........................135
LUBRICATION
DESCRIPTION........................136
OPERATION..........................136
DIAGNOSIS AND TESTING - ENGINE OIL
PRESSURE.........................136
OIL
STANDARD PROCEDURE
STANDARD PROCEDURE - ENGINE OIL
AND FILTER CHANGE.................137
STANDARD PROCEDURE - ENGINE OIL
LEVEL CHECK.......................137
OIL COOLER & LINES
DESCRIPTION........................138
OPERATION..........................138
REMOVAL............................138
INSTALLATION........................138
OIL FILTER
REMOVAL............................139
INSTALLATION........................139
OIL FILTER ADAPTER
REMOVAL............................139
INSTALLATION........................139
OIL PAN
REMOVAL............................140
CLEANING...........................140
INSPECTION.........................140
INSTALLATION........................140
OIL PRESSURE RELIEF VALVE
REMOVAL............................141
INSTALLATION........................141
OIL PRESSURE SWITCH
DESCRIPTION........................141
OPERATION..........................141
REMOVAL............................141
INSTALLATION........................141
OIL PUMP
DESCRIPTION........................142
REMOVAL............................142
DISASSEMBLY........................142
CLEANING...........................142
RSENGINE 3.3/3.8L9-75
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Page 1255 of 2177

CHRYSLER CARAVAN 2003 Service Manual INSPECTION.........................142
ASSEMBLY...........................143
INSTALLATION........................144
INTAKE MANIFOLD
DESCRIPTION........................144
DIAGNOSIS AND TESTING - INT

INSPECTION.........................142
ASSEMBLY...........................143
INSTALLATION........................144
INTAKE MANIFOLD
DESCRIPTION........................144
DIAGNOSIS AND TESTING - INTAKE
MANIFOLD LEAKS....................145
INTAKE MANIFOLD - UPPER
STANDARD PROCEDURE
STANDARD PROCEDURE - MANIFOLD
STRIPPED THREAD REPAIR............145
STANDARD PROCEDURE - INTAKE
MANIFOLD VACUUM PORT REPAIR......145
REMOVAL - UPPER INTAKE MANIFOLD.....145
CLEANING...........................146
INSPECTION.........................146
INSTALLATION - UPPER INTAKE MANIFOLD . 147
INTAKE MANIFOLD - LOWER
REMOVAL - LOWER INTAKE MANIFOLD....148
CLEANING...........................148
INSPECTION.........................148
INSTALLATION - LOWER INTAKE MANIFOLD . 149
EXHAUST MANIFOLD - RIGHT
REMOVAL............................150
CLEANING...........................151INSPECTION.........................151
INSTALLATION........................151
EXHAUST MANIFOLD - LEFT
REMOVAL............................152
CLEANING...........................152
INSPECTION.........................152
INSTALLATION........................152
VALVE TIMING
STANDARD PROCEDURE
STANDARD PROCEDURE - VALVE TIMING
VERIFICATION.......................153
STANDARD PROCEDURE - MEASURING
TIMING CHAIN WEAR.................153
TIMING CHAIN COVER
REMOVAL............................153
INSTALLATION........................155
TIMING CHAIN AND SPROCKETS
REMOVAL
REMOVAL - TIMING CHAIN AND
CAMSHAFT SPROCKET...............156
REMOVAL - CRANKSHAFT SPROCKET . . . 156
INSTALLATION
INSTALLATION - CRANKSHAFT SPROCKET. . 156
INSTALLATION - TIMING CHAIN AND
CAMSHAFT SPROCKET...............157
ENGINE 3.3/3.8L
DESCRIPTION
The 3.3 Liter (201 cu. in.) and 3.8 Liter (231 cu.
in.) engines are 60É V-6 engines with cast iron cylin-
der blocks and aluminum cylinder heads (Fig. 1). The
engine uses a single, block mounted camshaft with
pushrods to actuate the valves. These engines do not
have provisions for a free wheeling valve train.
The firing order is 1±2±3±4±5±6. The cylinders are
numbered from the front of the engine to the rear.
The front cylinder bank is numbered 2, 4, and 6. The
rear cylinder bank is numbered 1, 3, and 5.
The engine identification number is located on the
rear of the cylinder block just below the cylinder
head (Fig. 2).
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION
Engine diagnosis is helpful in determining the
causes of malfunctions not detected and remedied by
routine maintenance.These malfunctions may be classified as either
mechanical (e.g., a strange noise), or performance
(e.g., engine idles rough and stalls).
Refer to the Engine Mechanical and the Engine
Performance diagnostic charts, for possible causes
and corrections of malfunctions (Refer to 9 - ENGINE
- DIAGNOSIS AND TESTING - MECHANICAL)
(Refer to 9 - ENGINE - DIAGNOSIS AND TESTING
- PERFORMANCE).
For fuel system diagnosis, (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY - DIAGNOSIS AND
TESTING).
Additional tests and diagnostic procedures may be
necessary for specific engine malfunctions that can-
not be isolated with the Service Diagnosis charts.
Information concerning additional tests and diagno-
sis is provided within the following:
²Cylinder Compression Pressure Test
²Cylinder Combustion Pressure Leakage Test
²Engine Cylinder Head Gasket Failure Diagnosis
²Intake Manifold Leakage Diagnosis
²Hydraulic Lash Adjuster Noise Diagnosis
²Engine Oil Leak Inspection
9 - 76 ENGINE 3.3/3.8LRS
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Page 1256 of 2177

CHRYSLER CARAVAN 2003 Service Manual Fig. 1 3.3/3.8L V-6 Engines
Fig. 2 Engine Identification
RSENGINE 3.3/3.8L9-77
ENGINE 3.3/3.8L (Continued)
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