2003 CHRYSLER CARAVAN battery

(12) Lower vehicle and remove the power steering
pump support strut upper bolt (Fig. 125).
(13) Remove bolts attaching exhaust manifold to
cylinder head and remove manifold (Fig. 127).
(14) Inspect and clean manifold. (Refer to 9 -
ENGINE/MANIFOLDS/EXHAUST MANIFOLD -
CLEANING) (Refer to 9 - ENGINE/MANIFOLDS/
EXHAUST MANIFOLD - INSPECTION)
CLEANING
(1) Discard gasket (if equipped) and clean all sur-
faces of manifold and cylinder head.
INSPECTION
Inspect exhaust manifolds for damage or cracks
and check distortion of the cylinder head mounting
surface and exhaust crossover mounting surface with
a straightedge and thickness gauge (Fig. 128).
Manifold surface flatness limits should not exceed
1.0 mm (0.039 in.).
INSTALLATION
(1) Position exhaust manifold on cylinder head and
install bolts to center runner (cylinder #3) and initial
tighten to 2.8 N´m (25 in. lbs.) (Fig. 127)
(2) Using a new gasket, attach crossover pipe to
exhaust manifold and tighten bolts to 41 N´m (30 ft.
lbs.) (Fig. 124).NOTE: Inspect crossover pipe fasteners for damage
from heat and corrosion. The cross-over bolts are
made of a special stainless steel alloy. If replace-
ment is required, OEM bolts are highly recom-
mended.
(3) Install the remaining manifold attaching bolts.
Tighten all bolts to 23 N´m (200 in. lbs.).
(4) Position the power steering pump support strut
and install upper bolt (Fig. 125).
(5) Install heat shield and attaching screws (Fig.
127).
(6) Install and connect upstream oxygen sensor
(Fig. 127).
(7) Raise the vehicle.
(8) Attach catalytic converter pipe to exhaust man-
ifold using new gasket and tighten bolts to 37 N´m
(27 ft. lbs.) (Fig. 126).
(9) Connect downstream oxygen sensor connector.
(10) Tighten the power steering pump support
strut lower bolt (Fig. 125).
(11) Install the belt splash shield and lower the
vehicle.
(12) Install the wiper module. (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
INSTALLATION)
(13) Connect battery negative cable.
Fig. 127 EXHAUST MANIFOLD - RIGHT
1 - SCREW - HEAT SHIELD
2 - HEAT SHIELD - UPPER
3 - BOLT - EXHAUST MANIFOLD
4 - HEAT SHIELD - LOWER
5 - EXHAUST MANIFOLD - RIGHT
6 - OXYGEN SENSOR - UPSTREAM
Fig. 128 Check Exhaust Manifold Mounting
1 - STRAIGHT EDGE
2 - CROSSOVER PIPE MOUNTING SURFACE
3 - FEELER GAUGE
RSENGINE 3.3/3.8L9 - 151
EXHAUST MANIFOLD - RIGHT (Continued)
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EXHAUST MANIFOLD - LEFT
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove bolts attaching crossover pipe to
exhaust manifold (Fig. 129).
(3) Disconnect left cylinder bank spark plug wires.
(4) Remove heat shield attaching bolts (Fig. 130).
(5) Remove bolts attaching exhaust manifold to
cylinder head (Fig. 130).
(6) Remove the exhaust manifold (Fig. 130).(7) Inspect and clean manifold. (Refer to 9 -
ENGINE/MANIFOLDS/EXHAUST MANIFOLD -
INSPECTION) (Refer to 9 - ENGINE/MANIFOLDS/
EXHAUST MANIFOLD - CLEANING)
CLEANING
(1) Discard gasket (if equipped) and clean all sur-
faces of manifold and cylinder head.
INSPECTION
Inspect exhaust manifolds for damage or cracks
and check distortion of the cylinder head mounting
surface and exhaust crossover mounting surface with
a straightedge and thickness gauge (Fig. 131).
Manifold surface flatness limits should not exceed
1.0 mm (0.039 in.).
INSTALLATION
(1) Position exhaust manifold on cylinder head
(Fig. 130). Install bolts to center runner (cylinder #4)
and initial tighten to 2.8 N´m (25 in. lbs.).
(2) Using a new gasket, attach crossover pipe to
exhaust manifold and tighten bolts to 41 N´m (30 ft.
lbs.) (Fig. 129).
NOTE: Inspect crossover pipe fasteners for damage
from heat and corrosion. The cross-over bolts are
made of a special stainless steel alloy. If replace-
ment is required, OEM bolts are highly recom-
mended.
(3) Position heat shield on manifold (Fig. 130).
(4) Install the remaining manifold attaching bolts.
Tighten all bolts to 23 N´m (200 in. lbs.).
(5) Install and tighten heat shield attaching nut to
12 N´m (105 in. lbs.) (Fig. 130).
(6) Connect battery negative cable.
Fig. 129 CROSS-OVER PIPE
1 - CROSS-OVER PIPE
2 - BOLT
3 - GASKET
4 - FLAG NUT
Fig. 130 EXHAUST MANIFOLD - LEFT
1 - EXHAUST MANIFOLD - LEFT BANK
2 - HEAT SHIELD
3 - NUT - HEAT SHIELD
4 - BOLT - EXHAUST MANIFOLD
Fig. 131 Check Exhaust Manifold Mounting
1 - STRAIGHT EDGE
2 - CROSSOVER PIPE MOUNTING SURFACE
3 - FEELER GAUGE
9 - 152 ENGINE 3.3/3.8LRS
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VALVE TIMING
STANDARD PROCEDURE
STANDARD PROCEDURE - VALVE TIMING
VERIFICATION
(1) Remove front cylinder head cover and all 6
spark plugs.
(2) Rotate engine until the #2 piston is at TDC of
the compression stroke.
(3) Install a degree wheel on the crankshaft pulley.
(4) With proper adaptor, install a dial indicator
into #2 spark plug hole. Using the indicator find TDC
on the compression stroke.
(5) Position the degree wheel to zero.
(6) Remove dial indicator from spark plug hole.
(7) Place a 5.08 mm (0.200 in.) spacer between the
valve stem tip of #2 intake valve and rocker arm pad.
Allow tappet to bleed down to give a solid tappet
effect.
(8) Install a dial indicator so plunger contacts the
#2 intake valve spring retainer as nearly perpendic-
ular as possible. Zero the indicator.
(9) Rotate the engine clockwise until the intake
valve has lifted .254 mm (0.010 in.).
CAUTION: Do not turn crankshaft any further clock-
wise as intake valve might bottom and result in
serious damage.
(10) Degree wheel should read 6 degrees BTDC to
6 degrees ATDC.
STANDARD PROCEDURE - MEASURING
TIMING CHAIN WEAR
NOTE: This procedure must be performed with the
timing chain cover removed (Refer to 9 - ENGINE/
VALVE TIMING/TIMING CHAIN COVER - REMOVAL).
(1) Position a scale next to timing chain so that
any movement of chain may be measured (Fig. 132).
(2) Position a torque wrench and socket on the
camshaft sprocket attaching bolt. Apply force in the
direction of crankshaft rotation to take up slack to
the following torque:
²41 N´m (30 ft. lb.) with cylinder heads installed
²20 N´m (15 ft. lb.) with cylinder heads removed
NOTE: With torque applied to the camshaft
sprocket bolt, crankshaft should not be permitted to
move. It may be necessary to block crankshaft to
prevent rotation.
(3) Holding a measuring scale along edge of chain
links (Fig. 132).(4) Apply force in the reverse direction to the fol-
lowing torque:
²41 N´m (30 ft. lb.) with cylinder heads installed
²20 N´m (15 ft. lb.) with cylinder heads removed
(5) Measure amount of sprocket/chain movement.
(6) Install a new timing chain and sprockets if
movement exceeds 3.175 mm (1/8 in.).
TIMING CHAIN COVER
REMOVAL
(1) Disconnect negative cable from battery.
(2) Drain cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(3) Raise vehicle on hoist.
(4) Drain engine oil.
(5) Remove right wheel and inner splash shield.
(6) Remove oil pan. (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - REMOVAL)
(7) Remove oil pick-up tube (Fig. 133).
(8) Remove accessory drive belt. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)
(9) Remove A/C compressor and set aside.
(10) Remove crankshaft vibration damper. (Refer
to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL)
(11) Remove radiator lower hose.
(12) Remove heater hose from timing chain cover
housing (Fig. 134) or water pump inlet tube (if
engine oil cooler equipped) (Fig. 135).
(13) Remove the right side engine mount. (Refer to
9 - ENGINE/ENGINE MOUNTING/RIGHT MOUNT
- REMOVAL)
(14) Remove idler pulley from engine bracket (Fig.
136).
(15) Remove the engine mount bracket (Fig. 136).
Fig. 132 Measuring Timing Chain Wear
1 - TORQUE WRENCH
RSENGINE 3.3/3.8L9 - 153
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(17) Remove the water pump for cover removal
clearance. (Refer to 7 - COOLING/ENGINE/WATER
PUMP - REMOVAL)
(18) Remove the bolt attaching the power steering
pump support strut to the front cover (Fig. 137).
(19) Remove the timing chain cover fasteners.
Remove timing chain cover (Fig. 138).
INSTALLATION
(1) Be sure mating surfaces of chain case cover
and cylinder block are clean and free from burrs.
Crankshaft oil seal must be removed to insure cor-
rect oil pump engagement.
NOTE: DO NOT USE SEALER ON COVER GASKET
(2) Position new gasket on timing cover (Fig. 138).
Adhere new gasket to chain case cover, making sure
that the lower edge of the gasket is flush to 0.5 mm
(0.020 in.) passed the lower edge of the cover.
(3) Rotate crankshaft so that the oil pump drive
flats are in the vertical position.
(4) Position oil pump inner rotor so the mating
flats are in the same position as the crankshaft drive
flats (Fig. 138).
CAUTION: Make sure the oil pump is engaged on
the crankshaft correctly or severe damage may
result.
(5) Install timing cover (Fig. 138).
(6) Install timing chain cover bolts. Tighten M8
bolts to 27 N´m (20 ft. lbs.) and M10 bolts to 54 N´m
(40 ft. lbs.) (Fig. 139).
(7) Install crankshaft front oil seal. (Refer to 9 -
ENGINE/ENGINE BLOCK/CRANKSHAFT OIL
SEAL - FRONT - INSTALLATION)
(8) Install water pump and pulley. (Refer to 7 -
COOLING/ENGINE/WATER PUMP - INSTALLA-
TION)(9) Install crankshaft vibration damper. (Refer to 9
- ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
INSTALLATION)
(10) Install engine mount bracket (Fig. 136) and
tighten M10 to 54 N´m (40 ft. lbs.), M8 bolt to 28
N´m (21 ft. lb. lbs.).
(11) Install idler pulley on engine mount bracket
(Fig. 136).
(12) Install right side engine mount. (Refer to 9 -
ENGINE/ENGINE MOUNTING/RIGHT MOUNT -
INSTALLATION)
(13) Install camshaft position sensor (Refer to 8 -
ELECTRICAL/IGNITION CONTROL/CAMSHAFT
POSITION SENSOR - INSTALLATION).
(14) Connect the heater return hose at rear of tim-
ing chain cover (Fig. 134) or at water pump inlet
tube (if engine oil cooler equipped) (Fig. 135).
(15) Connect the radiator lower hose.
(16) Install A/C compressor.
(17) Install accessory drive belt. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION)
(18) Install oil pump pick-up tube with new
O-ring. Tighten attaching bolt to 28 N´m (250 in.
lbs.).
(19) Install oil pan. (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION)
(20) Install inner splash shield and right front
wheel.
(21) Fill crankcase with engine oil to proper level.
(22) Fill cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(23) Connect negative cable to battery.
Fig. 137 Power Steering Pump Strut
1 - BOLT - LOWER
2 - STRUT - P/S PUMP
3 - BOLT - UPPER
Fig. 138 Timing Chain Cover and Gasket
1 - GASKET
2 - TIMING CHAIN COVER
RSENGINE 3.3/3.8L9 - 155
TIMING CHAIN COVER (Continued)
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TIMING CHAIN AND
SPROCKETS
REMOVAL
REMOVAL - TIMING CHAIN AND CAMSHAFT
SPROCKET
(1) Disconnect negative cable from battery.
(2) Remove the timing chain cover. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL)
(3) Rotate engine by turning crankshaft until the
timing marks are aligned as shown in (Fig. 140).
(4) Remove camshaft sprocket attaching bolt.
(5) Remove the timing chain with camshaft
sprocket.(6) Remove the crankshaft sprocket. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - REMOVAL)
REMOVAL - CRANKSHAFT SPROCKET
(1) Remove the timing chain. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - REMOVAL)
(2) Using Special Tools 8539, 5048-6, and 5048-1,
remove the crankshaft sprocket while holding the
crankshaft from turning (Fig. 141). Be careful not to
damage the crankshaft surfaces.
INSTALLATION
INSTALLATION - CRANKSHAFT SPROCKET
(1) Position the sprocket on the crankshaft (timing
mark out) with the timing slot aligned with the tim-
ing pin.
Fig. 139 TIMING CHAIN COVER BOLT LOCATIONS
1 - BOLT - M8 x 1.25 x 95 4 - BOLT - M8 x 1.25 x 80
2 - BOLT - M10 x 1.5 x 100 5 - BOLT - M8 x 1.25 x 45
3 - BOLT - M10 x 1.5 x 85
9 - 156 ENGINE 3.3/3.8LRS
TIMING CHAIN COVER (Continued)
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(2) Install sprocket using Special Tool 8452 (Fig.
142). Install sprocket until it is fully seats on the
crankshaft.(3) Install the timing chain and camshaft sprocket.
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT/CHAIN AND SPROCKETS - INSTALLATION)
INSTALLATION - TIMING CHAIN AND
CAMSHAFT SPROCKET
(1) Rotate crankshaft so the timing arrow is to the
12 o'clock position (Fig. 140).
NOTE: Lubricate timing chain and sprockets with
clean engine oil before installation.
(2) While holding camshaft sprocket and chain in
hand, place timing chain around the sprocket, align-
ing the plated link with the dot on the sprocket. Posi-
tion the timing arrow to the 6 o'clock position (Fig.
140).
(3) Place timing chain around crankshaft sprocket
with the plated link lined up with the dot on the
sprocket. Install camshaft sprocket into position.
(4) Use a straight edge to check alignment of tim-
ing marks.
(5) Install camshaft sprocket bolt and washer.
Tighten bolt to 54 N´m (40 ft. lbs.).
(6) Rotate crankshaft 2 revolutions and check tim-
ing mark alignment (Fig. 140). If timing marks do
not line up, remove camshaft sprocket and realign.
(7) Install the timing chain cover. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION)
(8) Connect negative cable to battery.
Fig. 140 Timing Mark Alignment
1 - CAMSHAFT SPROCKET TIMING MARK (DOT)
2 - PLATED LINK
3 - CRANKSHAFT SPROCKET TIMING MARK (DOT)
4 - ARROWS
Fig. 141 CRANKSHAFT SPROCKET - REMOVAL
1 - SPECIAL TOOL 5048-6
2 - SPECIAL TOOL 5048-1
3 - SPECIAL TOOL 8450
4 - CRANKSHAFT SPROCKET
5 - SPECIAL TOOL 8539
Fig. 142 CRANKSHAFT SPROCKET - INSTALLATION
1 - SPECIAL TOOL 8452-3
2 - SPECIAL TOOL 8452-1
3 - CRANKSHAFT SPROCKET
4 - THRUST BEARING / WASHER
RSENGINE 3.3/3.8L9 - 157
TIMING CHAIN AND SPROCKETS (Continued)
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Visually inspect the catalytic converter element by
using a borescope or equivalent. Remove oxygen sen-
sor(s) and insert borescope. If borescope is not avail-
able, remove converter and inspect element using a
flashlight. Inspect element for cracked or melted sub-
strate.
NOTE: Before replacing a catalytic converter, deter-
mine the root cause of failure. Most catalytic con-
verter failures are caused by air, fuel or ignition
problems. (Refer to Appropriate Diagnostic Informa-
tion) for test procedures.
INSTALLATION
(1) Position new gasket onto the manifold flange
and install catalytic converter (Fig. 5). Tighten fas-
teners to 37 N´m (325 in. lbs.).
NOTE: Be careful not to twist or kink the oxygen
sensor wires.
(2) Install (if removed) and connect the down-
stream oxygen sensor (Fig. 4).
(3) Install the muffler/resonator assembly. (Refer
to 11 - EXHAUST SYSTEM/MUFFLER - INSTALLA-
TION)
CROSS-OVER PIPE - 3.3/3.8L
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove the fasteners attaching the left bank
manifold connection to cross-over pipe (Fig. 6).
(3) Raise vehicle and remove the left front wheel.
(4) Access the lower right bank pipe connection
fastener through the left front wheel opening using a
long ratchet extension. Loosen and remove the lower
fastener.
(5) Remove the upper right bank pipe connection
fastener by accessing though the catalytic converter
floor pan tunnel.
(6) Lower the vehicle.
(7) Remove the cross-over pipe (Fig. 6).
(8) Remove gaskets and discard (Fig. 6).
INSTALLATION
(1) Position cross-over pipe to the manifold connec-
tions (Fig. 6).
(2) Position new gasket on left bank (front) pipe
connection and loosely install fasteners (Fig. 6).
(3) Raise the vehicle.
(4) Position new gasket on the right bank pipe con-
nection and install fasteners.
(5) Tighten right bank upper fastener to 41 N´m
(30 ft. lbs.).(6) Tighten right bank lower fastener to 41 N´m
(30 ft. lbs.) using a long ratchet extension accessing
through the left wheel opening.
(7) Install the left front wheel and lower vehicle.
(8) Tighten the left bank pipe connection fasteners
to 41 N´m (30 ft. lbs.) (Fig. 6).
HEAT SHIELDS
DESCRIPTION
The exhaust system heat shields (Fig. 7), (Fig. 8),
or (Fig. 9) are attached to the under body of the vehi-
cle. On vehicles equipped with All Wheel Dive
(AWD), an additional heat shield is mounted to the
catalytic converter.
Fig. 6 CROSS-OVER PIPE
1 - CROSS-OVER PIPE
2 - BOLT
3 - GASKET
4 - FLAG NUT
Fig. 7 CATALYTIC CONVERTER HEAT SHIELD
1 - HEAT SHIELD - CATALYTIC CONVERTER
2 - SCREW (QTY. 4)
11 - 6 EXHAUST SYSTEMRS
CATALYTIC CONVERTER (Continued)
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FRONT CRADLE
CROSSMEMBER
DESCRIPTION
DESCRIPTION - FRONT CRADLE
CROSSMEMBER
This vehicle uses a one piece cast aluminum cradle
for the front cradle crossmember. The cradle cross-
member is used as the attaching points for the lower
control arms, stabilizer bar and steering gear. The
cradle also has the power steering hoses and the
chassis brake tubes attached to it.
WARNING: If a threaded hole in the suspension cra-
dle needs to be repaired, only use the type of
thread insert and installation procedure specified
for this application.
The threaded holes in the front cradle crossmem-
ber that are used for attachment of the lower control
arm rear bushing retainer, power steering hose and
chassis brake tubes can be repaired. The repair is
done by the installation of a Heli-Coiltthread insert
which has been specifically developed for this appli-
cation. Refer to the Mopar Parts Catalog for the spec-
ified Heli-Coiltthread insert to be used for this
application. The procedure for installing the Heli-
Coiltthread insert is detailed in the Service Proce-
dures section in this group of the service manual.
DESCRIPTION - FRONT CRADLE
CROSSMEMBER THREAD REPAIR
WARNING: When performing this procedure use
only the thread inserts which are specified in the
Mopar Parts Catalog for this repair procedure.
These thread inserts have been specifically devel-
oped for this application and use of other types of
thread inserts can result in an inferior long term
repair.
The threaded holes in the front cradle crossmem-
ber, if damaged, can repaired by installing a Heli-
Coiltthread insert.
The threaded holes that are repairable using the
thread insert, are the lower control arm rear bushing
retainer mounting bolt holes, routing bracket attach-
ing locations for the power steering hoses, and brake
hose attachment holes.
This repair procedure now allows the threaded
holes in the cradle crossmember to be repaired, elim-
inating the need to replace the cradle crossmember if
damage occurs to one of the threaded holes.The thread inserts for this application are specified
by part number in the Mopar Parts Catalog.Do not
use a substitute thread insert.
The specific tools and equipment required to install
the thread insert are listed below. Refer to the
instructions included with the thread insert for the
detailed procedure used for the installation of the
thread insert.
NOTE: The thread inserts for this application are for
the repair of M8x1.25 and M10x1.5 threads. Be sure
the correct tools are used for the required thread
insert size.
TOOL REQUIREMENT FOR M8x1.25 Thread
²8.3mm (5/16 in.) Drill Bit
²120É Countersink
²Heli-CoiltTap #4863-8
²Heli-CoiltGage #4624-8
²Heli-CoiltHand Inserting Tool 7751-8
²Needle Nose Pliers ± For Removal Of Thread
Insert Driving Tang
TOOL REQUIREMENT FOR M10x1.5 Thread
²10.5mm (25/64 in.) Drill Bit
²120É Countersink
²Heli-CoiltTap #4863-10
²Heli-CoiltGage #4624-10
²Heli-CoiltHand Inserting Tool 7751-10
²Needle Nose Pliers ± For Removal Of Thread
Insert Driving Tang
REMOVAL
The front cradle crossmember must be installed in
the design location to achieve proper front end sus-
pension alignment. If the cradle crossmember is
removed without applying reference marks on the
frame rails, align the cradle crossmember according
to the dimensions provided in this group.
NOTE: If the caged nuts in the frame rails become
damaged and cannot be reused, a replacement nut
can be obtained through MoparT.
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove steering column lower cover from
instrument panel (Refer to 23 - BODY/INSTRU-
MENT PANEL/STEERING COLUMN OPENING
COVER - REMOVAL).
(3) Remove steering column cover backing plate
(Refer to 23 - BODY/INSTRUMENT PANEL/STEER-
ING COLUMN COVER BACKING PLATE - REMOV-
AL).
RSFRAME & BUMPERS13-9
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