2003 CHRYSLER CARAVAN Service Manual

night vision heater clock setting coolant reservoir oil change tire pressure

Page 1281 of 2177

CHRYSLER CARAVAN 2003 Service Manual NOTE: Bolt torque after 1/4 turn should be over 122
N´m (90 ft. lbs.). If not, replace the bolt.
(6) Inspect push rods and replace worn or bent
rods.
(7) Install the push rods.
(8) Install the rocker

NOTE: Bolt torque after 1/4 turn should be over 122
N´m (90 ft. lbs.). If not, replace the bolt.
(6) Inspect push rods and replace worn or bent
rods.
(7) Install the push rods.
(8) Install the rocker arm and shaft assemblies.
(Refer to 9 - ENGINE/CYLINDER HEAD/ROCKER
ARMS - INSTALLATION)
(9) Install the cylinder head covers. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION)
(10) Install the exhaust manifolds. (Refer to 9 -
ENGINE/MANIFOLDS/EXHAUST MANIFOLD -
INSTALLATION)
(11) Install new O-ring on dipstick tube. Install
dipstick tube assembly (Fig. 18).
(12) Install the spark plugs.
(13) Install upper and lower intake manifolds.
(Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANI-
FOLD - INSTALLATION)
(14) Fill the cooling system. (Refer to 7 - COOL-
ING - STANDARD PROCEDURE)
(15) Connect negative cable to battery.
CYLINDER HEAD COVER(S)
DESCRIPTION
The cylinder head covers are made of stamped
steel. The covers are sealed with steel reinforced sil-
icon rubber gaskets. The cylinder head cover uses
rubber isolators at each fastener location (Fig. 23).
NOTE: Due to the tight packaging near the cylinder
head covers, which makes spill clean-up difficult, a
spill during an engine oil change may be misinter-
preted as an oil leak. When investigating an oil leak
in the location of the cylinder head covers and
intake manifold, follow the procedure found in Oil
Leak Diagnosis (Refer to 9 - ENGINE - DIAGNOSIS
AND TESTING) for determining the source of a leak.
CYLINDER HEAD COVER -
RIGHT
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove the wiper module. (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
REMOVAL)
(3) Disconnect spark plug wires from plugs.
(4) Disconnect PCV hose from cylinder head cover
(Fig. 24).
(5) Remove cylinder head cover bolts.
(6) Remove cylinder head cover and gasket (Fig.
23).
Fig. 21 Checking Bolts for Stretching (Necking)
1 - STRETCHED BOLT
2 - THREADS ARE NOT STRAIGHT ON LINE
3 - THREADS ARE STRAIGHT ON LINE
4 - UNSTRETCHED BOLT
Fig. 22 CYLINDER HEAD TIGHTENING SEQUENCE
Fig. 23 Cylinder Head Cover
1 - CYLINDER HEAD COVER
2 - BOLT
9 - 102 ENGINE 3.3/3.8LRS
CYLINDER HEAD (Continued)
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Page 1282 of 2177

CHRYSLER CARAVAN 2003 Service Manual INSTALLATION
(1) Clean cylinder head and cover mating surfaces.
Inspect cylinder head cover surface for flatness.
Replace gasket as necessary.
(2) Inspect seal on the cover bolt for wear or dam-
age (

Page 1283 of 2177

CHRYSLER CARAVAN 2003 Service Manual (2) Assemble gasket to cylinder cover by inserting
the fasteners through each bolt hole on cover and
gasket (Fig. 25).
(3) Install the cylinder head cover and bolts (Fig.
26).
(4) Tighten cylinder hea

(2) Assemble gasket to cylinder cover by inserting
the fasteners through each bolt hole on cover and
gasket (Fig. 25).
(3) Install the cylinder head cover and bolts (Fig.
26).
(4) Tighten cylinder head cover bolts to 12 N´m
(105 in. lbs.) (Fig. 26).
(5) Connect crankcase vent hose.
(6) Connect spark plug wires to spark plugs.
INTAKE/EXHAUST VALVES &
SEATS
DESCRIPTION
The valves have chrome plated valve stems with
four-bead lock grooves. The valve stem seals are
made of Viton rubber.
OPERATION
The two valves per cylinder are opened using
hydraulic lifters, push rods, and rocker arms.
STANDARD PROCEDURE - REFACING VALVES
AND VALVE SEATS
The intake and exhaust valves and seats are
machined to specific angles (Fig. 27).
VALVES
(1) Inspect the remaining margin after the valves
are refaced (Fig. 28). (Refer to 9 - ENGINE - SPEC-
IFICATIONS)
VALVE SEATS
CAUTION: Remove metal from valve seat only. Do
not remove material from cylinder head (Fig. 29).
(1) When refacing valve seats, it is important that
the correct size valve guide pilot be used for reseat-ing stones. A true and complete surface must be
obtained.
(2) Measure the concentricity of valve seat using
dial indicator (Fig. 30). Total runout should not
exceed 0.051 mm (0.002 in.) total indicator reading.
(3) Inspect the valve seat using Prussian blue to
determine where the valve contacts the seat. To do
this, coat valve seatLIGHTLYwith Prussian blue
then set valve in place. Rotate the valve with light
pressure. If the blue is transferred to the center of
valve face, contact is satisfactory. If the blue is trans-
ferred to top edge of valve face, lower valve seat with
a 15 degree stone. If the blue is transferred to the
bottom edge of valve face raise valve seat with a 65
degrees stone.
NOTE: Valve seats which are worn or burned can
be reworked, provided that correct angle and seat
width are maintained. Otherwise cylinder head must
be replaced.
Fig. 27 Valve Face and Seat
1 - SEAT WIDTH
2 - FACE ANGLE
3 - SEAT ANGLE
4 - SEAT CONTACT AREA
Fig. 28 Valve Margin
1 - VALVE FACE
2 - VALVE MARGIN
Fig. 29 Refacing Valve Seats
1 - REFACING STONE MUST NOT CUT INTO CYLINDER HEAD
2-STONE
3 - PILOT
4 - SEAT
9 - 104 ENGINE 3.3/3.8LRS
CYLINDER HEAD COVER - LEFT (Continued)
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Page 1284 of 2177

CHRYSLER CARAVAN 2003 Service Manual (4) When seat is properly positioned the width of
intake and exhaust seats should be 1.50±2.00 mm
(0.059±0.078 in.) (Fig. 27).
(5) After grinding the valve seats or faces, install
the valve in cylin

(4) When seat is properly positioned the width of
intake and exhaust seats should be 1.50±2.00 mm
(0.059±0.078 in.) (Fig. 27).
(5) After grinding the valve seats or faces, install
the valve in cylinder head and check valve installed
height by measuring from valve tip to spring seat
(Fig. 31). Remove valve from cylinder head and grind
valve tip until within specifications. Check valve tip
for scoring. The tip chamfer should be reground (if
necessary) to prevent seal damage when the valve is
installed.
(6) Check the valve spring installed height after
refacing the valve and seat (Fig. 31).
If valves and/or seats are reground, measure
the installed height of springs (Fig. 31), make
sure measurements are taken from top of
spring seat to the bottom surface of spring
retainer. If height is greater than specifica-
tions, install a 0.794 mm (0.0312 in.) spacer in
head counterbore to bring spring height back
within specifications.
REMOVAL
(1) With cylinder head removed, compress valve
springs using Valve Spring Compressor Tool
C-3422-D with adapter 8464 (Refer to 9 - ENGINE -
SPECIAL TOOLS).
(2) Remove valve retaining locks.
(3) Slowly release valve spring compressor.
Remove valve spring retainer, valve spring, and valve
stem seal.
(4) Before removing valves,remove any burrs
from valve stem lock grooves to prevent dam-
age to the valve guides.Identify valves to insure
installation in original location.
CLEANING
(1) Clean all valves thoroughly and discard
burned, warped and cracked valves.
INSPECTION
VALVES
(1) Clean and inspect valves thoroughly. Replace
burned, warped and cracked valves.
(2) Measure valve stems for wear (Fig. 32). For
valve specifications, (Refer to 9 - ENGINE - SPECI-
FICATIONS).
NOTE: Valve stems are chrome plated and should
not be polished (Fig. 32).
VALVE GUIDES
(1) Remove carbon and varnish deposits from
inside of valve guides with a reliable guide cleaner.
(2) Measure valve stem-to-guide clearance as fol-
lows:
(3) Install valve into cylinder head so it is 15 mm
(0.590 inch.) off the valve seat. A small piece of hose
may be used to hold valve in place.
(4) Attach dial indicator Tool C-3339 to cylinder
head and set it at right angle of valve stem being
measured (Fig. 33).
(5) Move valve to and from the indicator. For cler-
ance specifications, (Refer to 9 - ENGINE - SPECIFI-
CATIONS).
Fig. 30 Measurement of Valve Seat Runout
1 - DIAL INDICATOR
Fig. 31 Checking Valve and Spring Installed Height
1 - SPRING RETAINER
2 - VALVE INSTALLED HEIGHT* - 48.1±49.7 mm (1.89±1.95 in.)
3 - CYINDER HEAD SURFACE
4 - SPRING INSTALLED HEIGHT* - 41.1±42.7 mm (1.61±1.68 in.)
*(MEASURED FROM TOP OF SPRING SEAT)
RSENGINE 3.3/3.8L9 - 105
INTAKE/EXHAUST VALVES & SEATS (Continued)
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Page 1285 of 2177

CHRYSLER CARAVAN 2003 Service Manual NOTE: Replace cylinder head if stem-to-guide clear-
ance exceeds specifications, or if guide is loose in
cylinder head.
INSTALLATION
(1) Coat valve stems with clean engine oil and
insert them in cylin

Page 1286 of 2177

CHRYSLER CARAVAN 2003 Service Manual (3) Remove cylinder head cover(s). (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL)
(4) Remove rocker arms and shaft. (Refer to 9 -
ENGINE/CYLINDER HEAD/ROCKER ARMS -
REMOVAL)
(5)

Page 1287 of 2177

CHRYSLER CARAVAN 2003 Service Manual (11) Repeat procedure for each cylinder requiring
valve spring removal.
INSPECTION
Whenever valves have been removed for inspection,
reconditioning or replacement, valve springs should
be tested (Fig.

(11) Repeat procedure for each cylinder requiring
valve spring removal.
INSPECTION
Whenever valves have been removed for inspection,
reconditioning or replacement, valve springs should
be tested (Fig. 38).As an example;the compression
length of a spring to be tested is 38.00 mm (1.496
in.). Turn the table of Tool C-647 until surface is in
line with the 38.00 mm (1.496 in.) mark on the
threaded stud and the zero mark on the front. Place
spring over stud on the table and lift compressing
lever to set tone device. Pull on torque wrench until
ping is heard. Take reading on torque wrench at this
instant. Multiply this reading by two. This will give
the spring load at test length. Fractional measure-
ments are indicated on the table for finer adjust-
ments. Refer to Engine Specifications to obtain
specified height and allowable tensions (Refer to 9 -
ENGINE - SPECIFICATIONS). Replace any springs
that do not meet specifications.
INSTALLATION
INSTALLATION - CYLINDER HEAD OFF
(1) If removed, install a new valve stem seal (Refer
to 9 - ENGINE/CYLINDER HEAD/VALVE STEM
SEALS - INSTALLATION).
(2) Position valve spring and retainer on spring
seat.(3) Using Special Tool C-3422-D with 8464 Adapter
(Fig. 36), compress the spring only enough to install
the valve retainer locks. Install valve retainer locks.
(4) Slowly release the spring tension. Ensure the
retainer locks are seated properly.
INSTALLATION - CYLINDER HEAD ON
(1) The intake valve stem seals should be pushed
firmly and squarely over the valve guide using the
valve stem as guide.Do Not Forceseal against top
of guide. When installing the valve retainer locks,
compress the springonly enoughto install the
locks.
CAUTION: Do not pinch seal between retainer and
top of valve guide.
(2) Follow the same procedure on the remaining 5
cylinders using the firing sequence 1-2-3-4-5-6.Make
sure piston in cylinder is at TDC on the valve
spring that is being covered.
(3) Remove spark plug adapter tool.
(4) Install rocker arms and shaft assembly. (Refer
to 9 - ENGINE/CYLINDER HEAD/ROCKER ARMS -
INSTALLATION)
(5) Install cylinder head covers. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION)
(6) Install spark plugs and connect wires.
(7) Connect negative cable to battery.
Fig. 37 VALVE SPRING - REMOVE/INSTALL (HEAD
ON)
1 - SPECIAL TOOL 8453
2 - BOLTS - SPECIAL TOOL ATTACHING
3 - AIR SUPPLY HOSE ADAPTER
Fig. 38 TESTING VALVE SPRING
1 - SPECIAL TOOL C-647
9 - 108 ENGINE 3.3/3.8LRS
VALVE SPRINGS (Continued)
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Page 1288 of 2177

CHRYSLER CARAVAN 2003 Service Manual ROCKER ARMS
DESCRIPTION
DESCRIPTION - ROCKER ARMS
The rocker arms are installed on the rocker arm
shaft. The rocker arms and shaft assembly is
attached to the cylinder head with seven bolts and
retain

ROCKER ARMS
DESCRIPTION
DESCRIPTION - ROCKER ARMS
The rocker arms are installed on the rocker arm
shaft. The rocker arms and shaft assembly is
attached to the cylinder head with seven bolts and
retainers. The rocker arms are made of stamped
steel.
DESCRIPTION - PUSHRODS
The pushrods are made of steel and are a hollow
design. The pushrods are positioned between the
hydraulic lifter and the rocker arm.
OPERATION
OPERATION - ROCKER ARMS
The rocker arm pivots on the rocker shaft. Rocker
arms are used to translate up and down motions pro-
vided by the camshaft, hydraulic lifter, and pushrod
on one end, into a down and up motions on the valve
stem on the opposing end.
OPERATION - PUSHRODS
The pushrod is a solid link between the hydraulic
lifter and the rocker arm. Also, the pushrod supplies
engine oil from the hydraulic lifter to the rocker arm.
REMOVAL - ROCKER ARMS AND SHAFT
(1) Remove the cylinder head cover(s). (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL)
NOTE: Rocker arm shaft bolts are captured to the
shaft.
(2) Loosen the rocker shaft bolts (Fig. 39), rotating
one turn each, until all valve spring pressure is
relieved.
(3) Remove the rocker arms and shaft assembly
(Fig. 39).
(4) For rocker arm disassembly procedures, (Refer
to 9 - ENGINE/CYLINDER HEAD/ROCKER ARMS -
DISASSEMBLY).
DISASSEMBLY - ROCKER ARMS AND SHAFT
CAUTION: Do not attempt to drive the bolt from the
rocker shaft. This can damage the retainer and bolt
assembly.
(1) Remove the rocker arm retainer and bolt by
performing the following procedure:
(a) Using adjustable pliers, grip the edges of the
retainer (Fig. 40).
(b) Apply an upward force with a slight rocking
motion until the retainer disengages from shaft
(Fig. 40).
(2) Remove rocker arms (Fig. 41). Identify the
component locations for reassembly in original loca-
tions.
ASSEMBLY - ROCKER ARMS AND SHAFT
(1) Install rocker arms on the shaft (Fig. 41).
Install in the orginal positions if re-used.Ensurethe
rocker shaft, all the retainers and washers are prop-
erly positioned and installed in the correct locations
(Fig. 41).
(2) Install rocker arms and shaft to the cylinder
head. (Refer to 9 - ENGINE/CYLINDER HEAD/
ROCKER ARMS - INSTALLATION)
Fig. 39 ROCKER ARMS AND SHAFT
1 - ROCKER ARMS AND SHAFT ASSEMBLY
2 - ROCKER SHAFT BOLTS
RSENGINE 3.3/3.8L9 - 109
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