2003 CHRYSLER CARAVAN engine

INSTALLATION
CAUTION: If burr or scratch is present on the
crankshaft edge (chamfer), cleanup with 400 grit
sand paper to prevent seal damage during installa-
tion of new seal.
(1) Place Special Tool 6926-1 magnetic pilot tool on
crankshaft (Fig. 81).
(2) Place seal over Special Tool 6926-1 Pilot. Using
Special Tool 6926-2 Installer with C-4171 Handle,
drive seal into the retainer housing (Fig. 81).
(3) Install the flex plate. (Refer to 9 - ENGINE/
ENGINE BLOCK/FLEX PLATE - INSTALLATION)
(4) Install transaxle. Refer to TRANSAXLE AND
POWER TRANSFER UNIT for procedure.
CRANKSHAFT REAR OIL SEAL
RETAINER
REMOVAL
(1) Remove crankshaft rear oil seal (Refer to 9 -
ENGINE/ENGINE BLOCK/CRANKSHAFT OIL
SEAL - REAR - REMOVAL).
(2) Remove oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - REMOVAL).
(3) Remove oil seal retainer screws (Fig. 82).
(4) Remove oil seal retainer (Fig. 82).
(5) Clean engine block and retainer of oil and gas-
ket material. Make sure surfaces are clean and free
of oil.
INSTALLATION
(1) Position new gasket and install retainer on
block (Fig. 82). Tighten attaching screws to 12 N´m
(105 in. lbs.).
(2) Install oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION).
(3) Install oil seal (Refer to 9 - ENGINE/ENGINE
BLOCK/CRANKSHAFT OIL SEAL - REAR -
INSTALLATION).
Fig. 81 Rear Crankshaft Oil SealÐInstallation
1 - SPECIAL TOOLS:
2 - C-4171 HANDLE
3 - 6926±2 INSTALLER
4 - 6926±1 GUIDE
5 - SEAL
Fig. 82 CRANKSHAFT REAR OIL SEAL
1 - OIL SEAL
2 - BOLT
3 - RETAINER - OIL SEAL
4 - GASKET
RSENGINE 3.3/3.8L9 - 129
CRANKSHAFT OIL SEAL - REAR (Continued)
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VIBRATION DAMPER
REMOVAL
(1) Disconnect negative cable from battery.
(2) Raise vehicle on hoist.
(3) Remove the right front wheel and inner splash
shield.
(4) Remove the accessory drive belt. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)
(5) Remove vibration damper bolt.
(6) Insert Special Tool 8450 into crankshaft nose
(Fig. 83).
(7) Position 3-jaw puller Special Tool 1026 on
damper as shown in (Fig. 83). Turn puller forcing
screw until damper releases from crankshaft.
(8) Remove the crankshaft vibration damper.
INSTALLATION
(1) Install crankshaft vibration damper using the
forcing screw, nut, and thrust bearing/washer from
Special Tool 8452 (Fig. 84).NOTE: To minimize friction and prolong tool life,
lubricate the threads on the forcing screw of Spe-
cial Tool 8452.
(2) Position vibration damper on crankshaft.
(3) Screw Special Tool 8452 into crankshaft until
the bolt seats. Turn the nut to install damper until it
seats fully.
(4) Remove Special Tool 8452.
(5) Install vibration damper bolt. Torque bolt to 54
N´m (40 ft. lbs.).
(6) Install the accessory drive belt. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION)
(7) Install inner splash shield and right front
wheel.
(8) Connect negative cable to battery.
Fig. 83 Vibration Damper - Removal
1 - SPECIAL TOOL 8450 - INSERT
2 - SPECIAL TOOL 1026-3JAWPULLER
Fig. 84 Vibration Damper - Installation
1 - FORCING SCREW / NUT FROM SPECIAL TOOL 8452
2 - VIBRATION DAMPER
3 - THRUST BEARING / WASHER
9 - 130 ENGINE 3.3/3.8LRS
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FLEX PLATE
REMOVAL
(1) Remove the transaxle (Refer to 21 - TRANS-
MISSION/TRANSAXLE/AUTOMATIC - 41TE -
REMOVAL).
(2) Remove flex plate attaching bolts.
(3) Remove the flex plate (Fig. 85).
INSTALLATION
(1) Position flex plate with backing plate on the
crankshaft (Fig. 85).
(2) Apply MopartLock & Seal Adhesive to the flex
plate bolts.
(3) Install flex plate bolts (Fig. 85). Tighten bolts
to 95 N´m (70 ft. lbs.).
(4) Install the transaxle (Refer to 21 - TRANSMIS-
SION/TRANSAXLE/AUTOMATIC - 41TE - INSTAL-
LATION).
ENGINE MOUNTING
DESCRIPTION
The engine mounting system consist of four
mounts; right and a left side support the powertrain,
and a front and a rear mount control powertrain
torque. The right side mount is a hydro-type (Fig.
86), all others are of molded rubber material.
FRONT MOUNT
REMOVAL
(1) Support the engine and transmission assembly
with a floor jack so it will not rotate.
(2) Remove the front engine mount through bolt
from the insulator and front crossmember mounting
bracket (Fig. 87).
(3) Remove six screws from air dam to allow
access to the front mount screws.
(4) Remove the front engine mount screws and
remove the insulator assembly (Fig. 87).
(5) Remove the front mounting bracket, if neces-
sary (Fig. 87).
INSTALLATION
(1) Install the front mounting bracket, if removed
(Fig. 87).
(2) Install the front engine mount through bolt
from the insulator and front crossmember mounting
bracket (Fig. 87).
(3) Install the insulator assembly and mounting
screws (Fig. 87).
Fig. 85 FLEX PLATE
1 - FLEX PLATE
2 - BOLT (QTY. 8)
3 - BACKING PLATE
Fig. 86 Engine Hydro-type Mount - Right Side
1 - BOLT
2 - BOLT
3 - FRAME RAIL
4 - RIGHT MOUNT - 2.4L ENGINE
5 - RIGHT MOUNT - 3.3/3.8L ENGINE
RSENGINE 3.3/3.8L9 - 131
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Fig. 87 Engine Mounting - Front
1 - CROSSMEMBER 5 - BOLT 54 N´m (40 ft. lbs.)
2 - BOLT - 68 N´m (50 ft. lbs.) 6 - NUT - 68 N´m (50 ft. lbs.)
3 - BOLT - 102 N´m (75 ft. lbs.) 7 - MOUNT - ENGINE FRONT
4 - BOLT - 68 N´m (50 ft. lbs.) 8 - BRACKET - ENGINE FRONT MOUNT
9 - 132 ENGINE 3.3/3.8LRS
FRONT MOUNT (Continued)
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LEFT MOUNT
REMOVAL
(1) Raise the vehicle on hoist.
(2) Remove the left front wheel.
(3) Remove the left mount through bolt access
cover.
(4) Support the transaxle with a suitable jack.
(5) Remove the engine front mount through bolt to
allow left mount removal clearance (Fig. 87).
(6) Remove the left mount through frame rail bolt
(Fig. 88).
(7) Lower transaxle for access to horizontal bolts.
(8) Remove the horizontal bolts from the mount to
the transaxle (Fig. 89).
NOTE: To remove mount, additional lowering of
transaxle may be required.
(9) Remove left mount.
INSTALLATION
(1) Install left mount on transaxle (Fig. 89).
(2) Raise transaxle with jack until left mount is in
position.
(3) Install left mount through bolt (Fig. 88).
(4) Install left mount through bolt access cover.
(5) Install front mount through bolt (Fig. 87).
(6) Install left front wheel.
(7) Lower vehicle.
REAR MOUNT
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove the rear mount heat shield (Fig. 90).
(3) Remove the through bolt from the mount and
rear mount bracket (Fig. 91).
(4) Remove the mount bolts (Fig. 91).
(5) Remove the rear mount (Fig. 91).
(6) For rear mount bracket removal, remove the
bolts attaching bracket to transaxle (Fig. 92).
(7) Remove rear mount bracket.
Fig. 88 LEFT MOUNT TO BRACKET
1 - BOLT - BRACKET TO FRAME RAIL 68 N´m (50 ft. lbs.)
2 - BOLT - MOUNT TO RAIL THRU 75 N´m (55 ft. lbs.)
3 - BOLT - LEFT MOUNT TO TRANSAXLE 54 N´m (40 ft. lbs.)
4 - TRANSAXLE
5 - MOUNT - LEFT
6 - BRACKET - LEFT MOUNT
Fig. 89 LEFT MOUNT - 41TE TRANSAXLE
1 - LEFT MOUNT ASSEMBLY
2 - BOLT - 54 N´m (40 ft. lbs.)
3 - TRANSAXLE - 41TE
Fig. 90 REAR MOUNT HEAT SHIELD
1 - BOLT - HEAT SHIELD 11 N´m (100 in. lbs.)
2 - HEAT SHIELD
3 - CLIP
4 - REAR MOUNT
RSENGINE 3.3/3.8L9 - 133
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INSTALLATION
(1) Install rear mount bracket, if removed (Fig.
92).
(2) Install the rear mount and bolts (Fig. 91).
Tighten bolts to 54 N´m (40 ft. lbs.).
(3) Install the mount through bolt to the mount
and bracket (Fig. 91). Tighten through bolt to 54 N´m
(40 ft. lbs.).
(4) Install the rear mount heat shield (Fig. 90).
(5) Lower vehicle on hoist.
Fig. 91 REAR MOUNT
1 - BOLT 54 N´m (40 ft. lbs.)
2 - REAR MOUNT BRACKET
3 - THRU-BOLT 54 N´m (40 ft. lbs.)
4 - REAR MOUNT
Fig. 92 REAR MOUNT BRACKET - (all engines)
1 - BOLT - VERTICAL 102 N´m (75 ft. lbs.)
2 - BRACKET - REAR MOUNT
3 - BOLT - HORIZONTAL 102 N´m (75 ft. lbs.)
9 - 134 ENGINE 3.3/3.8LRS
REAR MOUNT (Continued)
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RIGHT MOUNT
REMOVAL
(1) Remove air cleaner housing lid and clean air
hose from throttle body.
(2) Remove air cleaner element and housing.
(3) Disconnect make-up air hose from cylinder
head cover.
(4) Remove the load on the right engine mount by
carefully supporting the engine assembly with a floor
jack.
(5) Disconnect electrical harness support clips from
engine mount bracket.
(6) Remove the bolts attaching the engine mount
to the frame rail (Fig. 93).
(7) Remove the three bolts attaching the engine
mount to the engine bracket (Fig. 93).
(8) Remove the right engine mount (Fig. 93).
INSTALLATION
(1) Install engine bracket (if removed). Tighten
bolts to 33 N´m (24 ft. lbs.).
(2) Position right engine mount and install frame
rail to mount bolts (Fig. 93). Tighten bolts to 68 N´m
(50 ft. lbs.).
(3) Install the mount to engine bracket bolts and
tighten to 54 N´m (40 ft. lbs.). (Fig. 93)
(4) Connect electrical harness support clips to
engine mount bracket.
(5) Remove jack from under engine.
(6) Connect make-up air hose to cylinder head
cover.
(7) Install air cleaner housing and element.
(8) Install air cleaner housing lid and clean air
tube to throttle body.
Fig. 93 Right Engine Mount
1 - RIGHT ENGINE MOUNT
2 - BOLT - MOUNT TO FRAME RAIL
3 - BOLT - MOUNT TO ENGINE
4 - ENGINE MOUNT BRACKET
5 - RIGHT FRAME RAIL
RSENGINE 3.3/3.8L9 - 135
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LUBRICATION
DESCRIPTION
The lubrication system is a full flow filtration pres-
sure feed type. The oil pump is mounted in the tim-
ing chain cover and is driven by the crankshaft
OPERATION
Oil from the oil pan is pumped by a internal gear
type oil pump directly coupled to the crankshaft. The
pressure is regulated by a relief valve located in the
timing chain cover. The oil is pumped through an oil
filter and feeds a main oil gallery. This oil gallery
feeds oil under pressure to the main and rod bear-
ings, camshaft bearings. Passages in the cylinder
block feed oil to the hydraulic lifters and rocker shaft
brackets which feeds the rocker arm pivots (Fig. 94).
DIAGNOSIS AND TESTING - ENGINE OIL
PRESSURE
(1) Disconnect and remove oil pressure switch
(Refer to 9 - ENGINE/LUBRICATION/OIL PRES-
SURE SENSOR/SWITCH - REMOVAL).
(2) Install Special Tools C-3292 Gauge with 8406
Adaptor. For Special Tool identification, (Refer to 9 -
ENGINE - SPECIAL TOOLS).
(3) Start engine and record oil pressure. Refer to
Oil Pressure in Engine Specifications for the correct
pressure (Refer to 9 - ENGINE - SPECIFICATIONS).
Fig. 94 Engine Oiling System
1 - OIL SUPPLY FOR BALL SOCKET THROUGH PUSH ROD 7 - OUTER ROTOR
2 - OIL SUPPLY PASSAGE FROM SHAFT TO ROCKER ARM 8 - INNER ROTOR
3 - ROCKER SHAFT 9 - RELIEF VALVE
4 - OIL FLOWS TO ONLY ONE PEDASTAL ON EACH HEAD; THIRD
FROM REAR ON RIGHT HEAD, THIRD FROM FRONT ON LEFT
HEAD10 - OIL PAN
5 - ROCKER SHAFT TOWER 11 - OIL SCREEN
6 - CRANKSHAFT 12 - OIL PUMP CASE
9 - 136 ENGINE 3.3/3.8LRS
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