2003 CHRYSLER CARAVAN weight

(1) Install the main bearing upper shells with the
lubrication groove and oil hole in the engine block
(Fig. 49).
(2) Make certain oil holes in block line up with oil
hole in bearings and bearing tabs seat in the block
tab slots.
CAUTION: Do not get oil on the bedplate mating
surface. It will affect the sealer ability to seal the
bedplate to cylinder block.
(3) Oil the bearings and journals. Install crank-
shaft.
CAUTION: Use only the specified anaerobic sealer
on the bedplate or damage may occur to the
engine.
(4) Apply 1.5 to 2.0 mm (0.059 to 0.078 in.) bead of
MopartBed Plate Sealant to cylinder block as shown
in (Fig. 50).(5) Install lower main bearings into main bearing
cap/bedplate. Make certain the bearing tabs are
seated into the bedplate slots. Install the main bear-
ing/bedplate into engine block.
(6) Before installing the bolts the threads should
be oiled with clean engine oil, wipe off any excess oil.
(7) Install main bearing bedplate to engine block
bolts 11, 17, and 20 finger tight. Tighten these bolts
down together until the bedplate contacts the cylin-
der block.
(8) To ensure correct thrust bearing alignment,
perform the following steps:
²Step 1: Rotate crankshaft until number 4 piston
is at TDC.
²Step 2: Move crankshaft rearward to limits of
travel.
²Step 3: Then, move crankshaft forward to limits
of travel.
²Step 4: Wedge an appropriate tool between the
rear of the cylinder block(NOT BED PLATE)and
the rear crankshaft counterweight. This will hold the
crankshaft in it's furthest forward position.
²Step 5: Install and tighten bolts (1±10) in
sequence shown in (Fig. 51) to 41 N´m (30 ft. lbs.).
²Step 6: Remove wedge tool used to hold crank-
shaft.
(9) Tighten bolts (1±10) again to 41 N´m (30 ft.
lbs.) in sequence shown in (Fig. 51).
CAUTION: Do Not use a torque wrench for the fol-
lowing step.
(10) Turn bolts (1±10) an additional 1/4 turn in
sequence shown in (Fig. 51).
(11) Install main bearing bedplate to engine block
bolts (11±20), and torque each bolt to 28 N´m (250 in.
lbs.) in sequence shown in (Fig. 51).
(12) Tighten bolts (11±20) again to 28 N´m (250 in.
lbs.) in sequence shown in (Fig. 51).
Fig. 49 Installing Main Bearing Upper Shell
1 - LUBRICATION GROOVES
2 - OIL HOLES
Fig. 50 Bedplate Sealing
Fig. 51 Bedplate Bolt Torque Sequence
RSENGINE 2.4L9-39
CRANKSHAFT (Continued)
ProCarManuals.com

(41) Disconnect the knock sensor electrical connec-
tor (3.8L only).
(42) Disconnect the engine block heater electrical
connector (if equipped).
(43) Remove the accessory belt splash shield.
(44) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(45) Disconnect the radiator lower hose.
(46) Remove air conditioning compressor from
engine.
(47) Remove the generator (Refer to 8 - ELECTRI-
CAL/CHARGING/GENERATOR - REMOVAL).
(48)
Remove the water pump pulley attaching bolts
and position pulley between pump hub and housing.
(49) Disconnect the oil pressure switch electrical
connector.
(50) Disconnect wiring harness support clip from
engine oil dipstick tube.
(51) Install Special Tools 6912 and 8444 Adapters
on the right side (rear) of engine block (Fig. 9).
(52) Lower the vehicle.
(53) Remove the power steering pump and set
aside.
(54) Raise vehicle enough to allow engine dolly
Special Tool 6135 and cradle Special Tool 6710 withpost Special Tool 6848 and adaptor Special Tool 6909
to be installed under vehicle (Fig. 12).
(55) Loosen cradle/post mounts to allow movement
for positioning posts into locating holes on the engine
(Fig. 10) and (Fig. 11). Slowly lower vehicle and posi-
tion cradle/post mounts until the engine is resting on
posts. Tighten all cradle/post mounts to cradle frame.
This will keep mounts from moving when removing
or installing engine and transmission.
(56) Lower vehicle so the weight ofONLY THE
ENGINE AND TRANSMISSIONis on the cradle.
(57) Install and secure the safety straps to the cra-
dle fixture and around the engine (Fig. 12).
(58) Remove the engine right side mount to engine
attaching bolts (Fig. 13).
(59) Remove the left mount through bolt (Fig. 14).
(60) Raise vehicle slowly. It is necessary to move
the engine/transmission assembly with the dolly to
allow for removal around body flanges.
Fig. 8 POWERTRAIN SUPPORTS AND DUST COVER
1 - BRACKET - ENGINE REAR MOUNT
2 - BOLT - TRANSAXLE CASE COVER
3 - STRUT - TRANSAXLE TO ENGINE HORIZONTAL
4 - BOLT - HORIZONTAL STRUT
5 - BOLT - STRUT TO TRANSAXLE
6 - COVER - TRANSAXLE CASE LOWER
7 - STRUT - TRANSAXLE TO ENGINE
8 - BOLT - STRUT TO ENGINE
9 - BOLT - ENGINE REAR MOUNT BRACKET
Fig. 9 ADAPTER TOOLS MOUNTED ON BLOCK
1 - SPECIAL TOOL 6912
2 - SPECIAL TOOL 8444
Fig. 10 Positioning Special Tool 6848 for use with
Adapters 8444 & 6912
1 - SLOTS
2 - SPECIAL TOOLS 6848
9 - 88 ENGINE 3.3/3.8LRS
ENGINE 3.3/3.8L (Continued)
ProCarManuals.com

(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.
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
DESCRIPTION SPECIFICATION
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.)
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)
RSENGINE 3.3/3.8L9-91
ENGINE 3.3/3.8L (Continued)
ProCarManuals.com

CRANKSHAFT MAIN
BEARINGS
STANDARD PROCEDURE - MAIN BEARING
FITTING
Bearing caps are not interchangeable and should
be marked at removal to insure correct assembly
(Fig. 67). Upper and lower bearing halves are NOT
interchangeable. Lower main bearing halves of 1, 3
and 4 are interchangeable. Upper main bearing
halves of 1, 3 and 4 are interchangeable.
Upper and lower number 2 bearing halves are
flanged to carry the crankshaft thrust loads and are
NOT interchangeable with any other bearing halves
in the engine (Fig. 68). All bearing cap bolts removed
during service procedures are to be cleaned and
lubricated with engine oil before installation. Bearing
shells are available in standard and the following
undersizes: 0.025 mm (0.001 in.) and 0.254 mm
(0.010 in). Never install an undersize bearing that
will reduce clearance below specifications.
CRANKSHAFT BEARING OIL CLEARANCE
Inspect the crankshaft bearing journals. (Refer to 9
- ENGINE/ENGINE BLOCK/CRANKSHAFT -
INSPECTION)
Engine crankshaft bearing clearances can be deter-
mined by use of Plastigage or the equivalent. The fol-
lowing is the recommended procedures for the use of
Plastigage with the engine in the vehicle or engine
on a repair stand.PLASTIGAGE METHODÐENGINE IN-VEHICLE
NOTE: The total clearance of the main bearings can
only be determined with the engine in the vehicle
by removing the weight of the crankshaft. This can
be accomplished by either of two following meth-
ods:
(1) Preferred method:
a. Shim the bearings adjacent to the bearing to be
checked in order to remove the clearance between
upper bearing shell and the crankshaft. This can be
accomplished by placing a minimum of 0.254 mm
(0.010 in.) shim (e. g. cardboard, matchbook cover,
etc.) between the bearing shell and the bearing cap
on the adjacent bearings and tightening bolts to
14±20 N´m (10±15 ft. lbs.).
²When checking #1 main bearing shim #2 main
bearing.
²When checking #2 main bearing shim #1 & #3
main bearing.
²When checking #3 main bearing shim #2 & #4
main bearing.
²When checking #4 main bearing shim #3 main
bearing.
NOTE: Remove all shims before reassembling
engine.
(2) Alternative Method:
a. Support the weight of the crankshaft with a
jack under the counterweight adjacent to the bearing
being checked.
(3) Remove oil film from surface to be checked.
Plastigage is soluble in oil.
Fig. 67 Main Bearing Cap Identification
Fig. 68 Main Bearing Identification
1 - OIL GROOVES
2 - OIL HOLES
3 - UPPER BEARINGS
4 - LOWER BEARINGS
RSENGINE 3.3/3.8L9 - 123
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(1) For main bearing fitting procedure, (Refer to 9
- ENGINE/ENGINE BLOCK/CRANKSHAFT MAIN
BEARINGS - STANDARD PROCEDURE)
(2) Start bearing in place, and insert Main Bearing
Tool C-3059 into oil hole of crankshaft (Fig. 71).
(3) Slowly rotate crankshaft counterclockwise slid-
ing the bearing into position. Remove Special Main
Bearing Tool C-3059.
(4) Inspect main cap bolts for stretching (Fig. 72).
Replace bolts that are stretched.
NOTE: The main cap bolts should be examined
before reuse. Bolt stretch can be checked by hold-
ing a scale or straight edge against the threads. If
all the threads do not contact the scale the bolt
must be replaced (Fig. 72).
(5) Install each main cap and tighten bolts finger
tight.
(6) Tighten number 1, 3 and 4 main cap bolts to 41
N´m + 1/4 Turn (30 ft. lbs.+ 1/4 Turn).
(7) Rotate the crankshaft until the number 6 pis-
ton is at TDC.
(8) To ensure correct thrust bearing alignment the
following procedure must be done:
a. Move crankshaft all the way to the rear of its
travel.
b. Then, move crankshaft all the way to the front
of its travel.
c. Wedge an appropriate tool between the rear of
the cylinder block and rear crankshaft counter-
weight. This will hold the crankshaft in it's most for-
ward position.
d. Tighten the #2 Thrust Bearing cap bolts to 41
N´m + 1/4 Turn (30 ft. lbs.+ 1/4 Turn). Remove the
holding tool.
(9) Install oil pan. (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION)
(10) Fill engine crankcase with proper oil to cor-
rect level.CRANKSHAFT
DESCRIPTION
DESCRIPTION - 3.3L
The nodular iron crankshaft is supported by four
main bearings, with number two position the thrust
bearing (Fig. 75). Crankshaft end sealing is provided
by front and rear rubber seals.
DESCRIPTION - 3.8L
The nodular iron crankshaft is supported by four
main bearings, with number two position providing
thrust bearing location (Fig. 76). Each main bearing
cap has two vertical retaining bolts. The two center
main caps have horizontal bolts to add increased
rigidity to the lower engine block (Fig. 76). Crank-
shaft end sealing is provided by front and rear rub-
ber seals.
STANDARD PROCEDURE - MEASURING
CRANKSHAFT END PLAY
(1) Mount a dial indicator to front of engine with
the locating probe on nose of crankshaft (Fig. 73).
(2) Move crankshaft all the way to the rear of its
travel.
(3) Zero the dial indicator.
(4) Move crankshaft all the way to the front and
read the dial indicator. (Refer to 9 - ENGINE -
SPECIFICATIONS) for end play specification.
REMOVAL
(1) Remove the engine assembly (Refer to 9 -
ENGINE - REMOVAL).
(2) Separate transaxle from engine.
(3) Mount engine on an engine stand.
(4) Remove the oil filter.
Fig. 72 Check for Stretched (Necked) Bolts
1 - STRETCHED BOLT
2 - THREADS ARE NOT STRAIGHT ON LINE
3 - THREADS ARE STRAIGHT ON LINE
4 - UNSTRETCHED BOLT
Fig. 73 Checking Crankshaft End PlayÐTypical
RSENGINE 3.3/3.8L9 - 125
CRANKSHAFT MAIN BEARINGS (Continued)
ProCarManuals.com

OPERATION
Heat shields are needed to protect both the vehicle
and the environment from the high temperatures
developed near the catalytic converter.
Avoid application of rust prevention com-
pounds or undercoating materials to exhaust
system floor pan heat shields on cars so
equipped. Light over spray near the edges is
permitted. Application of coating will greatly
reduce the efficiency of the heat shields result-
ing in excessive floor pan temperatures and
objectionable fumes.
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove fasteners attaching applicable heat
shield (Fig. 7), (Fig. 8), or (Fig. 9).
(3) Remove heat shield(s).
INSTALLATION
(1) Position heat shield(s) to underbody.
(2) Install heat shield fasteners and tighten to 2.6
N´m (23 in. lbs.) (Fig. 7), (Fig. 8), or (Fig. 9).
(3) Lower vehicle.
MUFFLER
REMOVAL
(1) Raise vehicle on a body contact type hoist.
NOTE: To provide removal clearance between muf-
fler/resonator pipe and rear axle parts, the rear sus-
pension must be relieved of all body weight.
(2) Apply a penetrating oil to clamp nuts of com-
ponent requiring removal.
CAUTION: When servicing the exhaust system, care
must be exercised not to dent or bend the bellows
of the flex-joint. Should this occur, the flex-joint will
eventually fail, requiring replacement of the cata-
lytic converter.
(3) Disconnect the right side axle half shaft from
the rear differential module (AWD equipped only).
(4) Loosen the band clamp (Fig. 10) at the muffler
to converter pipe connection.
(5) Remove the exhaust hangers to body screws
(Fig. 10).
(6) Separate muffler pipe from converter pipe.
(7) Remove muffler/resonator assembly by moving
assembly forward and guiding the resonator through
the rear axle to body opening.
(8) Clean ends of pipes or muffler to assure mat-
ing of all parts. Discard broken or worn insulators,
rusted clamps, supports and attaching parts.When
replacement is required on any component of
the exhaust system, it is important that original
equipment parts (or equivalent) be used for the
following conditions:
²Ensure proper alignment with other components
in the system.
²Provide acceptable exhaust noise levels.
²Provide proper exhaust system back pressure for
maintaining emission and performance levels.
INSTALLATION
(1) Install the muffler/resonator assembly by guid-
ing resonator between the rear axle and body.
(2) Connect the muffler pipe to the converter pipe
but do not tighten band clamp (Fig. 10).
(3) Position hangers to body and install screws
starting at the resonator working forward (Fig. 10).
Tighten hanger screws to 28 N´m (250 in. lbs.).
Fig. 8 MUFFLER HEAT SHIELD
1 - HEAT SHIELD - MUFFLER
2 - SCREW (QTY. 6)
Fig. 9 RESONATOR PIPE HEAT SHIELD
1 - SCREW (QTY. 3)
2 - HEAT SHIELD - RESONATOR PIPE
3 - MUFFLER
RSEXHAUST SYSTEM11-7
HEAT SHIELDS (Continued)
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(4) Tighten strap bolts to 54 N´m (40 ft. lbs.)
torque. Tighten T strap bolt to 28.2 N´m (250 in.
lbs.). Remove transmission jack.
(5) Tighten filler hose clamp to 3.3 N´m (30 in.
lbs.).
CAUTION: Ensure straps are not twisted or bent
before or after tightening strap nuts.
(6) Connect fuel pump/module electrical connector.
Place retainer in locked position.
(7) Lubricate the fuel supply line with clean 30
weight engine oil, install the quick connect fuel fit-ting. Refer to Tube/Fitting Assembly in the Fuel
Delivery section of this section.
(8) Connect the control vapor line at rear of tank.
(9) Attach filler vent line to filler tube. Pull on
connector to make sure of connection.
(10) Fill fuel tank, replace cap, and connect bat-
tery negative cable.
(11) Use the DRBIIItscan tool to pressurize the
fuel system. Check for leaks.
FUEL TANK FILLER TUBE
REMOVAL
(1) Disconnect the negative battery cable.
(2) Remove the 3 screws at the filler door.
(3) Raise and support vehicle
(4) Remove the left rear tire.
(5) Remove the splash shield (Fig. 20) or (Fig. 21).
(6) Remove the canister from filler tube (Fig. 22).
(7) Disconnect the vent at the top of the filler tube.
(8) Remove the ground strap.
(9) Remove filler tube at tank.
INSTALLATION
(1) Install filler tube to tank (Fig. 20).
(2) Install the ground strap.
(3) Connect the vent at the top of the filler tube.
(4) Install the 3 screws at the filler door.
Fig. 18 Pump Module Connector Retainer and Lock
1 - PUSH DOWN ON RETAINER
2 - CONNECTOR LOCK
Fig. 19 VENT HOSE
Fig. 20 FUEL FILLER TUBE AND VENT TUBE (RG)
14 - 12 FUEL DELIVERYRS
FUEL TANK (Continued)
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WARNING: THE AIR BAG SYSTEM IS A SENSITIVE,
COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL
THE AIR BAG SYSTEM COMPONENTS YOU MUST
FIRST DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE. THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE. FAILURE TO DO SO COULD RESULT IN
ACCIDENTAL DEPLOYMENT OF THE AIR BAG AND
POSSIBLE PERSONAL INJURY. THE FASTENERS,
SCREWS, AND BOLTS, ORIGINALLY USED FOR
THE AIR BAG COMPONENTS, HAVE SPECIAL
COATINGS AND ARE SPECIFICALLY DESIGNED
FOR THE AIR BAG SYSTEM. THEY MUST NEVER
BE REPLACED WITH ANY SUBSTITUTES. ANYTIME
A NEW FASTENER IS NEEDED, REPLACE WITH
THE CORRECT FASTENERS PROVIDED IN THE
SERVICE PACKAGE OR FASTENERS LISTED IN
THE PARTS BOOKS.
WARNING: SAFETY GOGGLES SHOULD BE WORN
AT ALL TIMES WHEN WORKING ON STEERING
COLUMNS.
CAUTION: Disconnect negative (ground) cable from
the battery before servicing any column compo-
nent.
CAUTION: Do not attempt to remove the pivot pins
to disassemble the tilting mechanism. Damage will
occur.
DIAGNOSIS AND TESTING - STEERING
COLUMN
For diagnosis of conditions relating to the steering
column (Refer to 19 - STEERING - DIAGNOSIS AND
TESTING) and (Refer to 19 - STEERING - DIAGNO-
SIS AND TESTING).
REMOVAL
NOTE: Before proceeding, (Refer to 19 - STEERING/
COLUMN - WARNING).
(1) Make sure the front wheels of the vehicle are
in the STRAIGHT AHEAD position before beginning
the column removal procedure.
(2) Disconnect negative (ground) cable from the
battery and isolate cable from battery terminal.
(3) Remove the lower shroud (Refer to 19 -
STEERING/COLUMN/LOWER SHROUD - REMOV-
AL).
(4) Remove the traction off switch.
(5) Remove the upper shroud.
(6) Remove the cluster trim bezel (Refer to 23 -
BODY/INSTRUMENT PANEL/CLUSTER BEZEL -
REMOVAL).
(7) Remove the knee blocker (Refer to 23 - BODY/
INSTRUMENT PANEL/STEERING COLUMN
OPENING COVER - REMOVAL).
(8) Remove the parking brake handle link.
(9) Remove the knee blocker reinforcement (Refer
to 23 - BODY/INSTRUMENT PANEL/KNEE
BLOCKER - REMOVAL).
(10) Remove the airbag (Refer to 8 - ELECTRI-
CAL/RESTRAINTS/DRIVER AIRBAG - REMOVAL).
(11) Remove the steering wheel retaining nut.
(12) Remove the vibration damper weight.
(13) Remove the steering wheel (Refer to 19 -
STEERING/COLUMN/STEERING WHEEL -
REMOVAL). (Fig. 3)
(14) Disconnect the wiring harness connectors
from the clockspring, multi-function switch, halo
lamp, SKIM module, ignition switch and BTSI sole-
noid.
(15) Disconnect the shift cable at the lever. (Fig. 4)
(16) Remove the pinch side clip, then remove the
cable from the bracket on the column.
(17) Remove the pinch bolt coupling. (Fig. 5)
(18) Loosen the two lower mounting nuts.
(19) Remove the two upper mounting nuts
(20) Remove the steering column.
1 - CLOCKSPRING WIRING
2 - STEERING WHEEL
3 - UPPER SHROUD
4 - FIXED SHROUD
5 - SCREW
6 - STEERING COLUMN MOUNTING PLATE
7 - NUT
8 - DASH PANEL STEERING COLUMN MOUNTING BRACKET
9 - STUDS (4)
10 - STEERING COLUMN LOCKING PIN
11 - NUT/WASHER ASSEMBLY
12 - STEERING COLUMN ASSEMBLY
13 - LOWER SHROUD
14 - SCREWS
15 - STEERING WHEEL RETAINING NUT16 - STEERING WHEEL DAMPER
17 - CLOCKSPRING
18 - SCREW
19 - MULTI-FUNCTION SWITCH
20 - PINCH BOLT
21 - STEERING COLUMN COUPLER
22 - PINCH BOLT RETAINING PIN
23 - DASH PANEL
24 - SILENCER SHELL
25 - INTERMEDIATE SHAFT SHIELD AND SEAL
26 - INTERMEDIATE SHAFT
27 - ROLL PIN
28 - POWER STEERING GEAR
29 - FRONT SUSPENSION CRADLE/CROSSMEMBER
19 - 12 COLUMNRS
COLUMN (Continued)
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