2005 CHRYSLER CARAVAN Service Manual

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Page 1249 of 2339

CHRYSLER CARAVAN 2005 Service Manual Fig. 134 Balance Shafts and Carrier Assembly
1 - SPROCKET 7 - GEARS
2 - TENSIONER 8 - GEAR COVER
3 - PLUG 9 - CHAIN COVER
4 - CARRIER 10 - SPROCKET
5 - REAR COVER 11 - GUIDE
6 - BALANCE SHAFTS 12 - CH

Page 1250 of 2339

CHRYSLER CARAVAN 2005 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 1251 of 2339

CHRYSLER CARAVAN 2005 Service Manual (6) Turn crankshaft until number 1 cylinder is at
top dead center (TDC). The timing marks on the
chain sprocket should line up with the parting line
on the left side of number one main bearing cap.
(F

Page 1252 of 2339

CHRYSLER CARAVAN 2005 Service Manual NOTE: THE TIMING MARK ON THE SPROCKET, THE
(LOWER) NICKEL PLATED LINK, AND THE ARROW
ON THE SIDE OF THE GEAR COVER SHOULD LINE
UP WHEN THE BALANCE SHAFTS ARE TIMED
CORRECTLY.
(10) If the sprockets are

Page 1253 of 2339

CHRYSLER CARAVAN 2005 Service Manual ENGINE 3.3/3.8L
TABLE OF CONTENTS
page page
ENGINE 3.3/3.8L
DESCRIPTION.........................78
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION...........78
DIAGNOSIS

ENGINE 3.3/3.8L
TABLE OF CONTENTS
page page
ENGINE 3.3/3.8L
DESCRIPTION.........................78
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION...........78
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - PERFORMANCE...........80
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - MECHANICAL.............82
DIAGNOSIS AND TESTING - ENGINE OIL
LEAK INSPECTION....................84
DIAGNOSIS AND TESTING - CYLINDER
COMPRESSION PRESSURE TEST........85
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE
TEST...............................85
STANDARD PROCEDURE
STANDARD PROCEDURE - MEASURING
BEARING CLEARANCE USING
PLASTIGAGE........................86
FORM-IN-PLACE GASKETS AND SEALERS . 86
STANDARD PROCEDURE - ENGINE
GASKET SURFACE PREPARATION........87
HYDROSTATIC LOCKED ENGINE.........87
STANDARD PROCEDURE - REPAIR OF
DAMAGED OR WORN THREADS.........88
STANDARD PROCEDURE - ENGINE CORE
AND OIL GALLERY PLUGS..............88
REMOVAL - ENGINE ASSEMBLY...........88
INSTALLATION - ENGINE ASSEMBLY........91
SPECIFICATIONS
3.3/3.8L ENGINE......................93
SPECIFICATIONS - TORQUE............97
SPECIAL TOOLS
3.3/3.8L ENGINE......................98
AIR CLEANER ELEMENT
REMOVAL............................101
INSTALLATION........................101
AIR CLEANER HOUSING
REMOVAL............................101
INSTALLATION........................102
CYLINDER HEAD
DESCRIPTION........................102
DIAGNOSIS AND TESTINGÐCYLINDER HEAD
GASKET...........................102
REMOVAL - CYLINDER HEAD............103
CLEANING...........................103
INSPECTION.........................104
INSTALLATION - CYLINDER HEAD.........104CYLINDER HEAD COVER(S)
DESCRIPTION........................105
CYLINDER HEAD COVER - RIGHT
REMOVAL............................106
INSTALLATION........................106
CYLINDER HEAD COVER - LEFT
REMOVAL............................107
INSTALLATION........................107
INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION........................107
OPERATION..........................107
STANDARD PROCEDURE - REFACING
VALVESANDVALVESEATS ............107
REMOVAL............................108
CLEANING...........................108
INSPECTION.........................108
INSTALLATION........................109
VALVE SPRINGS
DESCRIPTION........................109
OPERATION..........................109
REMOVAL
REMOVAL - CYLINDER HEAD OFF.......109
REMOVAL - CYLINDER HEAD ON........111
INSPECTION..........................111
INSTALLATION
INSTALLATION - CYLINDER HEAD OFF . . . 111
INSTALLATION - CYLINDER HEAD ON....111
ROCKER ARMS
DESCRIPTION
DESCRIPTION - ROCKER ARMS.........112
DESCRIPTION - PUSHRODS............112
OPERATION
OPERATION - ROCKER ARMS..........112
OPERATION - PUSHRODS.............112
REMOVAL - ROCKER ARMS AND SHAFT....112
DISASSEMBLY - ROCKER ARMS
AND SHAFT.........................113
ASSEMBLY - ROCKER ARMS AND SHAFT . . . 113
INSTALLATION - ROCKER ARMS
AND SHAFT.........................113
VALVE STEM SEALS
DESCRIPTION........................114
REMOVAL............................115
INSTALLATION........................115
ENGINE BLOCK
DESCRIPTION........................115
STANDARD PROCEDURE - CYLINDER BORE
HONING............................115
CLEANING...........................115
9 - 76 ENGINE 3.3/3.8LRS

Page 1254 of 2339

CHRYSLER CARAVAN 2005 Service Manual INSPECTION..........................115
HYDRAULIC LIFTERS (CAM IN BLOCK)
DESCRIPTION........................116
DIAGNOSIS AND TESTING - HYDRAULIC
LIFTERS...........................116
REMOVAL.........

INSPECTION..........................115
HYDRAULIC LIFTERS (CAM IN BLOCK)
DESCRIPTION........................116
DIAGNOSIS AND TESTING - HYDRAULIC
LIFTERS...........................116
REMOVAL............................117
INSTALLATION........................117
CAMSHAFT & BEARINGS (IN BLOCK)
DESCRIPTION........................118
OPERATION..........................118
REMOVAL............................118
INSPECTION..........................118
INSTALLATION........................118
PISTON & CONNECTING ROD
DESCRIPTION........................119
STANDARD PROCEDURE
STANDARD PROCEDURE - FITTING
CONNECTING RODS..................119
STANDARD PROCEDURE - FITTING
PISTONS...........................120
REMOVAL............................120
INSTALLATION........................121
CONNECTING ROD BEARINGS
STANDARD PROCEDURE - MEASURING
CONNECTING ROD BEARING
CLEARANCE........................123
PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING............................124
REMOVAL............................124
INSTALLATION........................124
CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDURE - MAIN BEARING
FITTING............................125
REMOVAL - CRANKSHAFT MAIN BEARINGS . 127
INSTALLATION - CRANKSHAFT MAIN
BEARINGS..........................127
CRANKSHAFT
DESCRIPTION
DESCRIPTION - 3.3L..................128
DESCRIPTION - 3.8L..................128
STANDARD PROCEDURE - MEASURING
CRANKSHAFT END PLAY..............128
REMOVAL............................128
INSTALLATION........................129
CRANKSHAFT OIL SEAL - FRONT
REMOVAL............................130
INSTALLATION........................130
CRANKSHAFT OIL SEAL - REAR
REMOVAL............................131
INSTALLATION........................131
CRANKSHAFT REAR OIL SEAL RETAINER
REMOVAL............................132
INSTALLATION........................132
VIBRATION DAMPER
REMOVAL............................132
INSTALLATION........................132FLEX PLATE
REMOVAL............................133
INSTALLATION........................133
ENGINE MOUNTING
DESCRIPTION........................134
FRONT MOUNT
REMOVAL............................134
INSTALLATION........................134
LEFT MOUNT
REMOVAL............................136
INSTALLATION........................136
REAR MOUNT
REMOVAL............................136
INSTALLATION........................137
RIGHT MOUNT
REMOVAL............................138
INSTALLATION........................138
LUBRICATION
DESCRIPTION........................138
OPERATION..........................138
DIAGNOSIS AND TESTING - ENGINE OIL
PRESSURE.........................138
OIL
STANDARD PROCEDURE
STANDARD PROCEDURE - ENGINE OIL
AND FILTER CHANGE.................139
STANDARD PROCEDURE - ENGINE OIL
LEVEL CHECK.......................140
OIL COOLER & LINES
DESCRIPTION........................141
OPERATION..........................141
REMOVAL............................141
INSTALLATION........................141
OIL FILTER
REMOVAL............................141
INSTALLATION........................141
OIL FILTER ADAPTER
REMOVAL............................142
INSTALLATION........................142
OIL PAN
REMOVAL............................142
CLEANING...........................142
INSPECTION.........................143
INSTALLATION........................143
OIL PRESSURE RELIEF VALVE
REMOVAL............................143
INSTALLATION........................144
OIL PRESSURE SWITCH
DESCRIPTION........................144
OPERATION..........................144
REMOVAL............................144
INSTALLATION........................144
OIL PUMP
DESCRIPTION........................144
REMOVAL............................144
DISASSEMBLY........................145
CLEANING...........................145
RSENGINE 3.3/3.8L9-77

Page 1255 of 2339

CHRYSLER CARAVAN 2005 Service Manual INSPECTION.........................145
ASSEMBLY...........................146
INSTALLATION........................146
INTAKE MANIFOLD
DESCRIPTION........................147
DIAGNOSIS AND TESTING - INT

INSPECTION.........................145
ASSEMBLY...........................146
INSTALLATION........................146
INTAKE MANIFOLD
DESCRIPTION........................147
DIAGNOSIS AND TESTING - INTAKE
MANIFOLD LEAKS....................147
INTAKE MANIFOLD - UPPER
STANDARD PROCEDURE
STANDARD PROCEDURE - MANIFOLD
STRIPPED THREAD REPAIR............147
STANDARD PROCEDURE - INTAKE
MANIFOLD VACUUM PORT REPAIR......148
REMOVAL - UPPER INTAKE MANIFOLD.....148
CLEANING...........................148
INSPECTION.........................149
INSTALLATION - UPPER INTAKE MANIFOLD . 149
INTAKE MANIFOLD - LOWER
REMOVAL - LOWER INTAKE MANIFOLD....150
CLEANING...........................151
INSPECTION.........................151
INSTALLATION - LOWER INTAKE MANIFOLD . 151
EXHAUST MANIFOLD - RIGHT
REMOVAL............................152
CLEANING...........................153
INSPECTION.........................153INSTALLATION........................153
EXHAUST MANIFOLD - LEFT
REMOVAL............................154
CLEANING...........................154
INSPECTION.........................155
INSTALLATION........................155
VALVE TIMING
STANDARD PROCEDURE
STANDARD PROCEDURE - VALVE TIMING
VERIFICATION.......................155
STANDARD PROCEDURE - MEASURING
TIMING CHAIN WEAR.................155
TIMING CHAIN COVER
REMOVAL............................156
INSTALLATION........................157
TIMING CHAIN AND SPROCKETS
REMOVAL
REMOVAL - TIMING CHAIN AND
CAMSHAFT SPROCKET...............159
REMOVAL - CRANKSHAFT SPROCKET . . . 159
INSTALLATION
INSTALLATION - CRANKSHAFT
SPROCKET.........................160
INSTALLATION - TIMING CHAIN AND
CAMSHAFT SPROCKET...............160
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 - 78 ENGINE 3.3/3.8LRS

Page 1256 of 2339

CHRYSLER CARAVAN 2005 Service Manual Fig. 1 3.3/3.8L V-6 Engines
Fig. 2 Engine Identification
RSENGINE 3.3/3.8L9-79
ENGINE 3.3/3.8L (Continued)

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