lock CHRYSLER CARAVAN 2003 Service Manual

(5)Remove the oil pan and oil pick-up tube (Refer to
9 - ENGINE/LUBRICATION/OIL PAN - REMOVAL).
(6) Remove the timing chain cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING CHAIN COVER -
REMOVAL).
(7) Remove timing chain and sprockets (Refer to 9
- ENGINE/VALVE TIMING/TIMING CHAIN AND
SPROCKETS - REMOVAL).
(8) Remove crankshaft rear oil seal and retainer
(Refer to 9 - ENGINE/ENGINE BLOCK/CRANK-
SHAFT OIL SEAL - REAR - REMOVAL).
(9) Rotate the crankshaft until connecting rod cap
is accessible.
(10) Mark connecting rod cap position using a suit-
able marker/scribe tool.
(11)
Remove connecting rod bearing cap. Use care to
prevent damage to the crankshaft bearing surfaces.
(12) Repeat removal procedure for each connecting
rod cap.
(13) Remove and discard the main bearing cross
bolts and washers (3.8L engine only) (Fig. 76).
NOTE: Install new cross bolt and washer assembly
(3.8L engine only) upon reassembly.
(14) Remove the main bearing cap bolts
(15) Remove the main bearing caps.
(16) Remove the crankshaft from engine block
(Fig. 75) or (Fig. 76).
INSTALLATION
(1) For main bearing identification, refer to (Fig.
68). Lubricate with engine oil and install the crank-
shaft main bearing halves in the engine block.
(2) Position the crankshaft in engine block (Fig.
75) or (Fig. 76).
(3) Perform main bearing fitting procedure (Refer
to 9 - ENGINE/ENGINE BLOCK/CRANKSHAFT
MAIN BEARINGS - STANDARD PROCEDURE).
(4) Inspect main cap bolts for stretching (Fig. 74).
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. 74).
(5) Install the main bearing caps and bolts.
Tighten bolts to 41 N´m (30 ft. lbs.) plus
1¤4turn.
NOTE: Install new cross bolt and washer assembly
(3.8L engine only) upon reassembly.
(6) Install and tighten the NEW cross bolts and
washer assemblies (3.8L engine only) to 61 N´m (45
ft. lbs.) (Fig. 76).
Fig. 74 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. 75 CRANKSHAFT AND BLOCK - 3.3L
1 - MAIN BEARING CAP No. 4
2 - MAIN BEARING CAP No. 3
3 - MAIN BEARING CAP No. 2
4 - MAIN BEARING CAP BOLT (QTY. 2 PER CAP)
5 - MAIN BEARING CAP No. 1
6 - LOWER MAIN BEARING - THRUST
7 - UPPER MAIN BEARING - THRUST
8 - ENGINE BLOCK
9 - UPPER MAIN BEARINGS
10 - CRANKSHAFT
11 - LOWER MAIN BEARINGS
9 - 126 ENGINE 3.3/3.8LRS
CRANKSHAFT (Continued)
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(7) Position and install the connecting rod and
bearing caps on the crankshaft (Refer to 9 -
ENGINE/ENGINE BLOCK/CONNECTING ROD
BEARINGS - STANDARD PROCEDURE).
(8) Install the crankshaft rear oil seal (Refer to 9 -
ENGINE/ENGINE BLOCK/CRANKSHAFT OIL
SEAL - REAR - INSTALLATION).
(9) Install the crankshaft sprocket (Refer to 9 -
ENGINE/VALVE TIMING/TIMING CHAIN AND
SPROCKETS - INSTALLATION).
(10) Install the timing chain and camshaft
sprocket (Refer to 9 - ENGINE/VALVE TIMING/TIM-
ING CHAIN AND SPROCKETS - INSTALLATION).
(11) Install the timing chain cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING CHAIN COVER -
INSTALLATION).(12) Install the oil pick-up tube and oil pan (Refer
to 9 - ENGINE/LUBRICATION/OIL PAN - INSTAL-
LATION).
(13) Install the transaxle to the engine.
(14) Install the engine assembly (Refer to 9 -
ENGINE - INSTALLATION).
CRANKSHAFT OIL SEAL -
FRONT
REMOVAL
(1) Disconnect negative cable from battery.
(2) Raise vehicle on hoist. Remove right wheel and
inner splash shield.
(3) Remove accessory drive belt. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)
(4) Remove crankshaft damper. (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL)
(5) Position Special Tool 6341A on crankshaft nose.
Carefully screw the tool into the seal until it engages
firmly (Fig. 77). Be careful not to damage that crank-
shaft seal surface of cover
(6) Remove oil seal by turning the forcing screw
until the seal disengages from the cover (Fig. 78).
INSTALLATION
(1) Position Special Tool C-4992-2 Guide, on the
crankshaft nose (Fig. 79).
(2) Position new seal over the guide with the seal
spring in the direction of the engine front cover (Fig.
79).
(3) Install seal using Special Tool C-4992-1 until
seal is flush with cover. (Fig. 79).
Fig. 76 CRANKSHAFT AND BLOCK - 3.8L
1 - MAIN BEARING CAP No. 4
2 - MAIN BEARING CAP No. 3
3 - MAIN BEARING CAP No. 2
4 - MAIN BEARING CAP BOLT
5 - MAIN BEARING CAP No. 1
6 - THRUST MAIN BEARING - LOWER
7 - THRUST MAIN BEARING - UPPER
8 - MAIN BEARING CAP CROSS BOLT
9 - ENGINE BLOCK
10 - MAIN BEARING - UPPER
11 - CRANKSHAFT
12 - MAIN BEARING - LOWER
Fig. 77 Engaging Tool into Seal
1 - SEAL
2 - SPECIAL TOOL 6341A
RSENGINE 3.3/3.8L9 - 127
CRANKSHAFT (Continued)
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(4) Install crankshaft damper. (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
INSTALLATION)
(5) Install accessory drive belt. (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION)
(6) Install inner splash shield and right front
wheel.
(7) Lower vehicle and connect negative cable to
battery.
CRANKSHAFT OIL SEAL -
REAR
REMOVAL
(1) Remove the transaxle. Refer to TRANSAXLE
AND POWER TRANSFER UNIT for procedure.
(2) Remove the flex plate. (Refer to 9 - ENGINE/
ENGINE BLOCK/FLEX PLATE - REMOVAL)
(3) Insert a 3/16 flat bladed pry tool between the
dust lip and the metal case of the crankshaft seal.
Angle the pry tool (Fig. 80) through the dust lip
against metal case of the seal. Pry out seal.
CAUTION: Do not permit the pry tool blade to con-
tact crankshaft seal surface. Contact of the pry tool
blade against crankshaft edge (chamfer) is permit-
ted.
Fig. 78 Crankshaft Front Seal Removal
1 - SEAL
2 - SPECIAL TOOL 6341A
Fig. 79 CRANKSHAFT FRONT SEAL INSTALLATION
1 - SPECIAL TOOL C-4992-1
2 - SEAL
3 - SPECIAL TOOL C-4992-2
4 - CRANKSHAFT
Fig. 80 Crankshaft Rear Oil Seal - Removal
1 - REAR CRANKSHAFT SEAL
2 - ENGINE BLOCK
3 - ENGINE BLOCK
4 - REAR CRANKSHAFT SEAL METAL CASE
5 - PRY IN THIS DIRECTION
6 - CRANKSHAFT
7 - SCREWDRIVER
8 - REAR CRANKSHAFT SEAL DUST LIP
9 - SCREWDRIVER
9 - 128 ENGINE 3.3/3.8LRS
CRANKSHAFT OIL SEAL - FRONT (Continued)
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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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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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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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OIL COOLER & LINES
DESCRIPTION
An engine oil cooler is used on 3.3/3.8L engines
(Heavy Duty Cooling Only) (Fig. 98). The cooler is a
coolant-to-oil type and mounted between the oil filter
and engine block.
OPERATION
Engine oil travels from the oil filter and into the
oil cooler. Engine oil then exits the cooler into the
main gallery. Engine coolant flows into the cooler
from the heater return tube and exits into the water
pump inlet.
REMOVAL
(1) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE - COOLING SYSTEM
DRAINING).
(2) Disconnect oil cooler inlet and outlet hoses
(Fig. 97).
(3) Remove oil filter.
(4) Remove oil cooler attachment fitting (Fig. 98).
(5) Remove oil cooler.
INSTALLATION
(1) Lubricate seal and position oil cooler to connec-
tor fitting on oil filter adapter (Fig. 98).NOTE: Position the flat side of oil cooler parallel to
oil pan rail.
(2) Install oil cooler attachment fitting and tighten
to 27 N´m (20 ft. lbs.) (Fig. 98).
(3) Install oil filter.
(4) Connect oil cooler inlet and outlet hoses (Fig.
97).
Fig. 96 Engine Oil Level Dipstick and Fill Locations
1 - COOLANT RECOVERY CONTAINER 3 - ENGINE OIL LEVEL DIPSTICK
2 - ENGINE OIL FILL CAP 4 - RADIATOR PRESSURE CAP
Fig. 97 Engine Oil Cooler Hoses
1 - OIL COOLER INLET TUBE
2 - INLET HOSE
3 - OIL COOLER OUTLET TUBE
4 - OUTLET HOSE
5 - WATER PUMP INLET TUBE
9 - 138 ENGINE 3.3/3.8LRS
OIL (Continued)
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(5) Fill cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE - COOLING SYSTEM
FILLING).
OIL FILTER
REMOVAL
CAUTION: When servicing the oil filter avoid
deforming the filter can by installing the remove/in-
stall tool band strap against the can-to-base lock
seam. The lock seam joining the can to the base is
reinforced by the base plate.
(1) Using suitable oil filter wrench, turn filter
counterclockwise to remove from oil filter adapter
(Fig. 99). Properly discard used oil filter.
INSTALLATION
(1) Wipe oil filter adapter base clean and inspect
gasket contact surface.
(2) Lubricate gasket of new filter with clean
engine oil.
(3) Install new filter until gasket contacts base
(Fig. 99). Tighten filter 1 turn or 20 N´m (15 ft. lbs.).
Use filter wrench if necessary.
(4) Start engine and check for leaks.
OIL FILTER ADAPTER
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove the oil filter.
(3) Disconnect oil pressure switch electrical con-
nector.
(4) Remove oil filter adapter attaching bolts (Fig.
99).
(5) Remove oil filter adapter and seal (Fig. 99).
INSTALLATION
(1) Clean oil filter adapter and install new seal.
(2) Position adapter on engine block and install
bolts (Fig. 99).
(3) Tighten adapter bolts to 28 N´m (250 in. lbs.).
(4) Connect oil pressure switch electrical connector
(Fig. 99).
(5) Install the oil filter.
(6) Lower vehicle on hoist.
(7) Start engine and allow to run approximately 2
minutes.
(8) Turn off engine and check oil level. Adjust oil
level as necessary.
Fig. 98 Engine Oil Cooler - 3.3/3.8L (Heavy Duty
Cooling)
1 - OIL FILTER ADAPTER
2 - CONNECTOR
3 - ENGINE OIL COOLER
4 - OIL COOLER ATTACHMENT FITTING
5 - OIL FILTER
Fig. 99 OIL FILTER ADAPTER
1 - SEAL
2 - OIL FILTER ADAPTER
3 - OIL FILTER
4 - BOLT
5 - OIL PRESSURE SWITCH
6 - BOLT
RSENGINE 3.3/3.8L9 - 139
OIL COOLER & LINES (Continued)
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OIL PAN
REMOVAL
(1) Disconnect negative cable from battery and
remove engine oil dipstick.
(2) Raise vehicle on hoist and drain engine oil.
(3) Remove drive belt splash shield.
(4) Remove strut to transaxle attaching bolt (Fig.
100). Loosen strut to engine block attaching bolts.
(5) Remove transaxle case cover (Fig. 100).
(6) Remove oil pan fasteners (Fig. 101).
(7) Remove the oil pan and gasket (Fig. 101).
CLEANING
(1) Clean oil pan with solvent and wipe dry with a
clean cloth.
(2) Clean all gasket material from mounting sur-
faces of pan and block.
(3) Clean oil screen and pick-up tube in clean sol-
vent.
INSPECTION
(1) Inspect oil drain plug and plug hole for
stripped or damaged threads and repair as necessary.
Install a new drain plug gasket. Tighten to 27 N´m
(20 ft. lbs.).
(2) Inspect oil pan mounting flange for bends or
distortion. Straighten flange if necessary.
(3) Inspect condition of oil screen and pick-up tube.
INSTALLATION
(1) Clean sealing surfaces and apply a 1/8 inch
bead of MopartEngine RTV GEN II at the parting
line of the chain case cover and the rear seal retainer
(Fig. 102).
(2) Position a new pan gasket on oil pan (Fig. 101).
(3) Install oil pan and tighten fasteners to 12 N´m
(105 in. lbs.) (Fig. 101).
(4) Install cover to transaxle case (Fig. 100).
(5) Install the strut bolt to transaxle housing (Fig.
100). Tighten all bending brace bolts.
(6) Install the drive belt splash shield.
Fig. 100 Powertrain Struts and Transaxle Case
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. 101 OIL PAN
1 - GASKET
2 - BOLT
3 - OIL PAN
4 - NUT
9 - 140 ENGINE 3.3/3.8LRS
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²Mounting surface distortion by using a straight-
edge and thickness gauge.
INSTALLATION - UPPER INTAKE MANIFOLD
(1) If the following components were removed from
manifold, install and tighten to specifications:
CAUTION: The special screws used for the compos-
ite manifold attached components must be installed
slowly using hand tools only. This requirement is to
prevent the melting of material that causes stripped
threads. If threads become stripped, an oversize
repair screw is available. For more information and
procedure (Refer to 9 - ENGINE/MANIFOLDS/IN-
TAKE MANIFOLD - STANDARD PROCEDURE - MAN-
IFOLD STRIPPED THREAD REPAIR).
²MAP sensor - 1.7 N´m (15 in. lbs.)
²Throttle cable bracket - 5.6 N´m (50 in. lbs.)
(2) Remove covering on lower intake manifold and
clean surfaces.
(3) Inspect manifold gasket condition. Gaskets can
be re-used, if not damaged. To replace, remove gasket
from upper manifold (Fig. 117). Position new gasket
in seal channel and press lightly in-place. Repeat
procedure for each gasket position.
(4) Position upper manifold on lower manifold (Fig.
117). Apply MopartLock & Seal Adhesive (Medium
Strength Threadlocker) to each upper intake mani-
fold bolt. Install and tighten bolts to 12 N´m (105 in.
lbs.) following torque sequence in (Fig. 118).
(5) Connect the MAP sensor electrical connector.(6) Connect the brake booster and LDP vacuum
hose to intake manifold (Fig. 116).
Fig. 116 BRAKE BOOSTER & LDP VACUUM HOSES
1 - LDP & SPEED CONTROL VACUUM HOSE
2 - BRAKE BOOSTER VACUUM HOSE
3 - MAP SENSOR
Fig. 117 INTAKE MANIFOLD - UPPER
1 - BOLT
2 - MAP SENSOR
3 - SCREW
4 - MANIFOLD - UPPER
5 - WIRE HARNESS
6 - GASKET (3 PER CYL. BANK)
Fig. 118 UPPER MANIFOLD TIGHTENING
SEQUENCE
RSENGINE 3.3/3.8L9 - 147
INTAKE MANIFOLD - UPPER (Continued)
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