body CHRYSLER CARAVAN 2005 Service Manual

Calibrate the tester according to the manufactur-
er's instructions. The shop air source for testing
should maintain 483 kPa (70 psi) minimum, 1,379
kPa (200 psi) maximum, with 552 kPa (80 psi) rec-
ommended.
Perform the test procedures on each cylinder
according to the tester manufacturer's instructions.
While testing, listen for pressurized air escaping
through the throttle body, tailpipe and oil filler cap
opening. Check for bubbles in the coolant.
All gauge pressure indications should be equal,
with no more than 25% leakage per cylinder.
FOR EXAMPLE:At 552 kPa (80 psi) input pres-
sure, a minimum of 414 kPa (60 psi) should be main-
tained in the cylinder.
STANDARD PROCEDURE
STANDARD PROCEDURE - MEASURING
BEARING CLEARANCE USING PLASTIGAGE
Engine crankshaft bearing clearances can be deter-
mined by use of Plastigage or equivalent. The follow-
ing is the recommended procedure for the use of
Plastigage:
(1) Remove oil film from surface to be checked.
Plastigage is soluble in oil.
(2) Place a piece of Plastigage across the entire
width of the bearing shell in the cap approximately
6.35 mm (1/4 in.) off center and away from the oil
holes (Fig. 3). (In addition, suspected areas can be
checked by placing the Plastigage in the suspected
area). Torque the bearing cap/bed plate bolts of the
bearing being checked to the proper specifications.
(3) Remove the bearing cap and compare the
width of the flattened Plastigage with the metric
scale provided on the package. Locate the band clos-est to the same width. This band shows the amount
of clearance in thousandths of a millimeter. Differ-
ences in readings between the ends indicate the
amount of taper present. Record all readings taken.
Compare the clearance measurements to specsifica-
tions found in the engine specifications table(Refer to
9 - ENGINE - SPECIFICATIONS).Plastigage gen-
erally is accompanied by two scales. One scale
is in inches, the other is a metric scale.
NOTE: Plastigage is available in a variety of clear-
ance ranges. Use the most appropriate range for
the specifications you are checking.
(4) Install the proper crankshaft bearings to
achieve the specified bearing clearances.
FORM-IN-PLACE GASKETS AND SEALERS
There are numerous places where form-in-place
gaskets are used on the engine. Care must be taken
when applying form-in-place gaskets to assure
obtaining the desired results.Do not use form-in-
place gasket material unless specified.Bead size,
continuity, and location are of great importance. Too
thin a bead can result in leakage while too much can
result in spill-over which can break off and obstruct
fluid feed lines. A continuous bead of the proper
width is essential to obtain a leak-free gasket.
There are numerous types of form-in-place gasket
materials that are used in the engine area. Mopart
Engine RTV GEN II, MopartATF-RTV, and Mopart
Gasket Maker gasket materials, each have different
properties and can not be used in place of the other.
MOPARtENGINE RTV GEN IIis used to seal
components exposed to engine oil. This material is a
specially designed black silicone rubber RTV that
retains adhesion and sealing properties when
exposed to engine oil. Moisture in the air causes the
material to cure. This material is available in three
ounce tubes and has a shelf life of one year. After one
year this material will not properly cure. Always
inspect the package for the expiration date before
use.
MOPARtATF RTVis a specifically designed
black silicone rubber RTV that retains adhesion and
sealing properties to seal components exposed to
automatic transmission fluid, engine coolants, and
moisture. This material is available in three ounce
tubes and has a shelf life of one year. After one year
this material will not properly cure. Always inspect
the package for the expiration date before use.
MOPARtGASKET MAKERis an anaerobic type
gasket material. The material cures in the absence of
air when squeezed between two metallic surfaces. It
will not cure if left in the uncovered tube. The
anaerobic material is for use between two machined
surfaces. Do not use on flexible metal flanges.
Fig. 3 Plastigage Placed in Lower ShellÐTypical
1 - PLASTIGAGE
9 - 86 ENGINE 3.3/3.8LRS
ENGINE 3.3/3.8L (Continued)

(3) Place a shop towel around the spark plugs
when removing them from the engine. This will catch
any fluid that may possibly be in the cylinder under
pressure.
(4) With all spark plugs removed, rotate engine
crankshaft using a breaker bar and socket.
(5) Identify the fluid in the cylinder(s) (i.e., cool-
ant, fuel, oil or other).
(6) Make sure all fluid has been removed from the
cylinders. Inspect engine for damage (i.e., connecting
rods, pistons, valves, etc.)
(7) Repair engine or components as necessary to
prevent this problem from re-occurring.
CAUTION: Squirt approximately one teaspoon of oil
into the cylinders, rotate engine to lubricate the cyl-
inder walls to prevent damage on restart.
(8) Install new spark plugs.
(9) Drain engine oil and remove oil filter.
(10) Install a new oil filter.
(11) Fill engine with specified amount of approved
oil.
(12) Connect negative battery cable.
(13) Start engine and check for any leaks.
STANDARD PROCEDURE - REPAIR OF
DAMAGED OR WORN THREADS
Damaged or worn threads (excluding spark plug
and camshaft bearing cap attaching threads) can be
repaired. Essentially, this repair consists of drilling
out worn or damaged threads, tapping the hole with
a special Heli-Coil Tap, (or equivalent) and installing
an insert into the tapped hole. This brings the hole
back to its original thread size.
CAUTION: Be sure that the tapped holes maintain
the original center line.
Heli-Coil tools and inserts are readily available
from automotive parts jobbers.
STANDARD PROCEDURE - ENGINE CORE AND
OIL GALLERY PLUGS
Using a blunt tool such as a drift and a hammer,
strike the bottom edge of the cup plug. With the cup
plug rotated, grasp firmly with pliers or other suit-
able tool and remove plug (Fig. 5).
CAUTION: Do not drive cup plug into the casting as
restricted cooling can result and cause serious
engine problems.
Thoroughly clean inside of cup plug hole in cylin-
der block or head. Be sure to remove old sealer.
Lightly coat inside of cup plug hole with Mopart
Stud and Bearing Mount. Make certain the new plugis cleaned of all oil or grease. Using proper drive
plug, drive plug into hole so that the sharp edge of
the plug is at least 0.5 mm (0.020 in.) inside the
lead-in chamfer.
It is not necessary to wait for curing of the sealant.
The cooling system can be refilled and the vehicle
placed in service immediately.
REMOVAL - ENGINE ASSEMBLY
(1) Perform fuel pressure release procedure (Refer
to 14 - FUEL SYSTEM/FUEL DELIVERY - STAN-
DARD PROCEDURE).
(2) Disconnect negative battery cable.
(3) Remove air cleaner and hoses.
(4) Disconnect the fuel line from fuel rail (Refer to
14 - FUEL SYSTEM/FUEL DELIVERY/QUICK
CONNECT FITTING - STANDARD PROCEDURE).
(5) Remove the wiper module (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
REMOVAL).
(6) Block off heater hoses to the rear heater sys-
tem using pinch-off pliers (if equipped).
(7) Drain the cooling system (Refer to 7 - COOL-
ING - STANDARD PROCEDURE).
(8) Disconnect the heater hoses.
(9) Remove the radiator upper support crossmem-
ber (Refer to 23 - BODY/EXTERIOR/GRILLE OPEN-
ING REINFORCEMENT - REMOVAL).
(10) Remove the radiator fans (Refer to 7 - COOL-
ING/ENGINE/RADIATOR FAN - REMOVAL).
(11) Disconnect the throttle cables from the throt-
tle body.
(12) Disconnect the MAP, IAC, and TPS electrical
connectors.
Fig. 5 Core Hole Plug Removal
1 - CYLINDER BLOCK
2 - REMOVE PLUG WITH PLIERS
3 - STRIKE HERE WITH HAMMER
4 - DRIFT PUNCH
5 - CUP PLUG
9 - 88 ENGINE 3.3/3.8LRS
ENGINE 3.3/3.8L (Continued)

(13) Disconnect the EGR transducer electrical con-
nector (if equipped).
(14) Disconnect the vacuum hoses from throttle
body.
(15) Disconnect the brake booster and speed con-
trol vacuum hoses.
(16) Disengage wire harness clip from the right
side engine mount.
(17) Remove the power steering reservoir from
mounting position and set aside.Do notdisconnect
hose.
(18) Disconnect ground strap from rear of cylinder
head.
(19) Disconnect engine coolant temperature (ECT)
sensor and ignition coil electrical connectors.
(20) Disconnect the fuel injector electrical harness
connector and disengage clip from support bracket.
(21) Disconnect camshaft and crankshaft position
sensor electrical connectors.
(22) Evacuate air conditioning system. Refer to 24
- HEATING & AIR CONDITIONING.
(23) Disconnect A/C compressor electrical connec-
tor.
(24) Disconnect the A/C lines from compressor.
Cover and seal all openings of hoses and compressor.
(25) Remove the radiator upper hose.
(26) Disengage electrical harness clip at transaxle
dipstick tube.
(27) Remove transaxle dipstick tube. Seal opening
using a suitable plug.
NOTE: When the transaxle cooler lines are removed
from the rolled-groove type fittings at the transaxle,
damage to the inner wall of the hose will occur. To
prevent prevent potential leakage, the cooler hoses
must be cut off flush at the transaxle fitting, and a
service cooler hose splice kit must be installed
upon reassembly.
(28) Using a blade or suitable hose cutter, cut
transaxle oil cooler lines off flush with fittings. Plug
cooler lines and fittings to prevent debris from enter-
ing transaxle or cooler circuit. A service splice kit will
be installed upon reassembly.
(29) Disconnect transaxle shift linkage and electri-
cal connectors.
(30) Raise vehicle on hoist and drain the engine
oil.
(31) Remove the axle shafts. (Refer to 3 - DIFFER-
ENTIAL & DRIVELINE/HALF SHAFT - REMOVAL)
(32) Remove crossmember cradle plate (Fig. 6).
(33)AWD equipped:Remove the power transfer
unit (PTU) (Refer to 21 - TRANSMISSION/TRANS-
AXLE/POWER TRANSFER UNIT - REMOVAL).
(34) Disconnect exhaust pipe from the manifold
(Fig. 7).(35) Remove front engine mount and bracket as an
assembly.
(36) Remove the engine rear mount bracket.
(37) Remove the engine to transaxle struts (Fig. 8).
(38) Remove transaxle case cover (Fig. 8).
(39) Remove flex plate to torque converter bolts.
Mark torque converter to flex plate for orientation for
reassembly.
(40) Remove the power steering pressure hose sup-
port clip attaching bolt.
Fig. 6 Crossmember Cradle Plate
1 - CRADLE PLATE
Fig. 7 Catalytic Converter to Exhaust Manifold
1 - FLAG NUT
2 - GASKET
3 - BOLT
4 - CATALYTIC CONVERTER
RSENGINE 3.3/3.8L9-89
ENGINE 3.3/3.8L (Continued)

(60) Raise vehicle slowly. It is necessary to move
the engine/transmission assembly with the dolly to
allow for removal around body flanges.
INSTALLATION - ENGINE ASSEMBLY
(1) Position engine and transmission assembly
under vehicle. Slowly lower the vehicle down over the
engine and transmission. It is necessary to move the
engine/transmission assembly with the dolly for
clearance around body flanges.
(2) Align engine and transmission mounts to
attaching points. Install mounting bolts at the right
engine mount (Fig. 13) and left transmission mount
(Fig. 14).
(3) Remove the safety straps from around engine.
(4) Slowly raise vehicle enough to remove the
engine dolly and cradle Special Tools 6135, 6710,
6848 and 6909 (Fig. 12).
(5) Remove Special Tools 6912 and 8444 (Fig. 9).
(6) Lower the vehicle.
(7) Install power steering pump and pressure line
support.
(8) Install the generator and wiring harness (Refer
to 8 - ELECTRICAL/CHARGING/GENERATOR -
INSTALLATION).
Fig. 12 Positioning Engine Cradle Support Post Mounts
1 - SPECIAL TOOL 8444
2 - SPECIAL TOOLS 6848
3 - SPECIAL TOOL 6912
4 - SPECIAL TOOLS 6135 & 67105 - SPECIAL TOOLS 6848
6 - SAFETY STRAPS
7 - SPECIAL TOOLS 6909
Fig. 11 Special Tools 6848 with Adapters 6909
1 - OIL FILTER
2 - SPECIAL TOOLS 6909
3 - OIL PAN
4 - SPECIAL TOOLS 6848
RSENGINE 3.3/3.8L9-91
ENGINE 3.3/3.8L (Continued)

(9) Raise vehicle.
(10) Attach wiring harness support clip to the
engine oil dipstick tube.
(11) Connect oil pressure switch electrical connec-
tor.
(12) Install the A/C compressor.
(13) Install the water pump pulley.
(14) Connect the radiator lower hose.
(15) Install the accessory drive belt and splash
shield (Refer to 7 - COOLING/ACCESSORY DRIVE/
DRIVE BELTS - INSTALLATION).(16) Connect the engine block heater electrical con-
nector (if equipped).
(17) Connect the knock sensor electrical connector
(3.8L only).
(18) Install the torque converter to flex plate bolts.
(19) Install the transaxle case cover (Fig. 8).
(20) Install the powertrain struts (Fig. 8).
(21) Install the engine rear mount bracket.
(22) Install the engine front mount and bracket
assembly.
(23)AWD equipped;Install the power transfer
unit (PTU) (Refer to 21 - TRANSMISSION/TRANS-
AXLE/POWER TRANSFER UNIT - INSTALLA-
TION).
(24) Install the axle shafts (Refer to 3 - DIFFER-
ENTIAL & DRIVELINE/HALF SHAFT - INSTALLA-
TION).
(25) Connect exhaust pipe to manifold (Fig. 7).
(26) Install crossmember cradle plate (Fig. 6).
(27) Lower vehicle.
(28) Connect transaxle shift linkage.
(29) Connect transaxle electrical connectors.
(30) Remove plugs from transmission cooler hoses
and install transaxle oil cooler line service splice kit.
Refer to instructions included with kit.
(31) Install transaxle dipstick tube and attach
electrical harness clip.
(32) Connect the A/C lines to compressor.
(33) Connect the A/C compressor electrical connec-
tor.
(34) Evacuate and recharge A/C system.
(35) Connect crankshaft and camshaft position
sensors.
(36) Connect the fuel injector electrical harness
connector and engage clip to support bracket.
(37) Connect engine coolant temperature (ECT)
sensor and ignition coil electrical connectors.
(38) Connect the ground strap to rear of cylinder
head.
(39) Install power steering reservoir.
(40) Engage wire harness clip to engine right side
mount.
(41) Connect the brake booster and speed control
vacuum hoses.
(42) Connect the vacuum hoses to the throttle
body.
(43) Connect the EGR transducer electrical connec-
tor (if equipped).
(44) Connect the TPS, IAC, and MAP sensor elec-
trical connectors.
(45) Connect throttle cables to throttle body.
(46) Install the radiator fans (Refer to 7 - COOL-
ING/ENGINE/RADIATOR FAN - INSTALLATION).
(47) Connect the radiator upper hose.
(48) Connect the heater hoses. Remove pinch-off
pliers from the rear heater hoses (if equipped).
Fig. 13 Right Mount to Engine
1 - BOLT
2 - MOUNT BRACKET
3 - ENGINE RIGHT MOUNT ASSEMBLY
Fig. 14 LEFT MOUNT TO FRAME BRACKET
1 - FRAME BRACKET
2 - FRAME RAIL - LEFT
3 - BOLT
4 - TRANSAXLE MOUNT
9 - 92 ENGINE 3.3/3.8LRS
ENGINE 3.3/3.8L (Continued)

(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
GENERAL DESCRIPTION
DESCRIPTION SPECIFICATION
Metric Standard
Engine Type 60É V-6 Engine
Number of
Cylinders6
Displacement
3.3L3.3Liters 201 cu.in.
Displacement
3.8L3.8 Liters 231 cu. in.
Bore 3.3L 93.0 mm 201 cu.in.
Bore 3.8L 96.0 mm 3.779 cu.in.
Stroke 3.3L 81 mm 3.188 in.
Stroke 87 mm 3.425 in.
Compression
Ratio 3.3L- 9.35:1
Compression
Ratio 3.8L- 9.6:1
Firing Order - 1-2-3-4-5-6
Compression
Pressure-
Minimum689.5 kPa 100 psi.
Cylinder
Compression
(Max. Difference
Between
Cylinders- 25%
CYLINDER BLOCK
DESCRIPTION SPECIFICATION
Metric Standard
Cylinder Bore
Diameter
(Standard) 3.3L92.993-93.007
mm3.661-3.6617 in.
Cylinder Bore
Diameter
(Standard) 3.8L95.993-96.007
mm3.7792-3.780 in.
Out of Round
(Service Limits)0.076 mm 0.003 in.
Taper (Service
Limits)0.051 mm 0.002 in.
Lifter Bore
Diameter22.980-23.010
mm0.905-0.906 in.
Deck Surface
Flatness (Max.)0.1 mm 0.004 in.
CRANKSHAFT
DESCRIPTION SPECIFICATION
Metric Standard
Connecting Rod
Journal
Diameter57.979-58.005
mm2.2827-2.2837
in.
Main Bearing
Journal
Diameter63.993-64.013
mm2.5194-2.5202
in.
Journal
Out-of-Round
(Max.)0.025 mm 0.001 in.
Journal Taper
(Max.)0.025 mm 0.001 in
End Play 0.09-0.24 mm 0.0036-0.0095
in.
Wear Limit 0.381 mm 0.015 in.
Main Bearing
Diametrical
Clearance
1-2-3-40.011-0.055
mm0.0005-0.0022
in.
Wear Limit 0.076 mm 0.003 in.
RSENGINE 3.3/3.8L9-93
ENGINE 3.3/3.8L (Continued)

(2) Disconnect the inlet air temperature sensor
(Fig. 16).
(3) Remove the inlet hose to throttle body.
(4) Remove the bolt for air box at upper radiator
cross member.
(5) Pull air box up and off over the single locating
pin.
(6) Remove air box from vehicle
INSTALLATION
(1) Install air box into vehicle and onto the locat-
ing pin.
(2) Install bolt to hold air box to the upper radia-
tor cross member.
(3) Install the inlet hose to the throttle body.
(4) Connect the inlet air temperature sensor (Fig.
16).
(5) Connect the negative battery cable.
CYLINDER HEAD
DESCRIPTION
The aluminum cylinder heads (Fig. 17) are
designed to create high flow combustion chambers to
improve performance, while minimizing the change
to the burn rate in the chamber. The cylinder head
incorporates the combustion chamber. Two valves
per-cylinder are used with inserted valve seats and
guides. A multi-layer steel (MLS) type gasket is used
between the cylinder head and engine block.
DIAGNOSIS AND TESTINGÐCYLINDER HEAD
GASKET
A cylinder head gasket leak can be located between
adjacent cylinders or between a cylinder and the
adjacent water jacket.
Possible indications of the cylinder head gasket
leaking between adjacent cylinders are:
²Loss of engine power
²Engine misfiring
²Poor fuel economy
Possible indications of the cylinder head gasket
leaking between a cylinder and an adjacent water
jacket are:
²Engine overheating
²Loss of coolant
²Excessive steam (white smoke) emitting from
exhaust
²Coolant foaming
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determine if an engine cylinder head gasket is
leaking between adjacent cylinders, follow the proce-
dures in Cylinder Compression Pressure Test (Refer
to 9 - ENGINE - DIAGNOSIS AND TESTING). An
engine cylinder head gasket leaking between adja-
cent cylinders will result in approximately a 50±70%
reduction in compression pressure.
CYLINDER-TO-WATER JACKET LEAKAGE TEST
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING WITH COOLANT PRES-
SURE CAP REMOVED.
VISUAL TEST METHOD
With the engine cool, remove the coolant pressure
cap. Start the engine and allow it to warm up until
thermostat opens.
If a large combustion/compression pressure leak
exists, bubbles will be visible in the coolant.
COOLING SYSTEM TESTER METHOD
WARNING: WITH COOLING SYSTEM TESTER IN
PLACE, PRESSURE WILL BUILD UP FAST. EXCES-
SIVE PRESSURE BUILT UP, BY CONTINUOUS
ENGINE OPERATION, MUST BE RELEASED TO A
SAFE PRESSURE POINT. NEVER PERMIT PRES-
SURE TO EXCEED 138 kPa (20 psi).
Install Cooling System Tester 7700 or equivalent to
pressure cap neck. Start the engine and observe the
tester's pressure gauge. If gauge pulsates with every
power stroke of a cylinder a combustion pressure
leak is evident.
Fig. 16 Inlet Air Temperature Sensor
9 - 102 ENGINE 3.3/3.8LRS
AIR CLEANER HOUSING (Continued)

46) (Refer to 9 - ENGINE - SPECIFICATIONS). If
the cylinder walls are badly scuffed or scored, the
cylinder block should be replaced, and new pistons
and rings fitted.
Measure the cylinder bore at three levels in direc-
tions A and B (Fig. 46). Top measurement should be
10 mm (3/8 in.) down and bottom measurement
should be 10 mm (3/8 in.) up from bottom of bore.
(Refer to 9 - ENGINE - SPECIFICATIONS).
HYDRAULIC LIFTERS (CAM IN
BLOCK)
DESCRIPTION
The hydraulic lifters are a roller type design and
are positioned in the cylinder block. The lifters are
aligned and retained by a yoke and a retainer (Fig.
48).
Lifter alignment is maintained by machined flats
on lifter body. Lifters are fitted in pairs into six
aligning yokes. The aligning yokes are secured by a
yoke retainer (Fig. 48).
DIAGNOSIS AND TESTING - HYDRAULIC
LIFTERS
HYDRAULIC LIFTERS DIAGNOSIS - PRELIMINARY
STEP
Before disassembling any part of the engine to cor-
rect lifter noise, check the engine oil pressure. (Referto 9 - ENGINE/LUBRICATION - DIAGNOSIS AND
TESTING)
Check engine oil level. The oil level in the pan
should never be above the MAX mark on dipstick, or
below the MIN mark. Either of these two conditions
could cause noisy lifters.
OIL LEVEL TOO HIGH
If oil level is above the MAX mark on dipstick, it is
possible for the connecting rods to dip into the oil
while engine is running and create foaming. Foam in
oil pan would be fed to the hydraulic lifters by the oil
pump causing them to become soft and allow valves
to seat noisily.
OIL LEVEL TOO LOW
Low oil level may allow pump to take in air which
when fed to the lifters it causes them to become soft
and allows valves to seat noisily. Any leaks on intake
side of pump, through which air can be drawn, will
create the same lifter noise. Check the lubrication
system from the intake strainer to the oil pump
cover, including the relief valve retainer cap. When
lifter noise is due to aeration, it may be intermittent
or constant, and usually more than one lifter will be
noisy. When oil level and leaks have been corrected,
the engine should be operated at fast idle to allow all
of the air inside of the lifters to be bled out.
VALVE TRAIN NOISE
To determine source of valve train noise, operate
engine at idle with cylinder head covers removed and
listen for source of the noise.
NOTE: Worn valve guides or cocked springs are
sometimes mistaken for noisy lifters. If such is the
case, noise may be dampened by applying side
thrust on the valve spring. If noise is not apprecia-
bly reduced, it can be assumed the noise is in the
tappet. Inspect the rocker arm push rod sockets
and push rod ends for wear.
Valve lifter noise ranges from light noise to a
heavy click. A light noise is usually caused by exces-
sive leak-down around the unit plunger which will
necessitate replacing the lifter, or by the plunger par-
tially sticking in the lifter body cylinder. A heavy
click is caused either by a lifter check valve not seat-
ing, or by foreign particles becoming wedged between
the plunger and the lifter body causing the plunger
to stick in the down position. This heavy click will be
accompanied by excessive clearance between the
valve stem and rocker arm as valve closes. In either
case, lifter assembly should be removed for inspec-
tion.
Fig. 46 Checking Cylinder Bore Size
9 - 116 ENGINE 3.3/3.8LRS
ENGINE BLOCK (Continued)

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. 94).
(7) Remove the three bolts attaching the engine
mount to the engine bracket (Fig. 94).
(8) Remove the right engine mount (Fig. 94).
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. 94). 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. 94)
(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.
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. 95).
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 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
9 - 138 ENGINE 3.3/3.8LRS

STANDARD PROCEDURE - INTAKE MANIFOLD
VACUUM PORT REPAIR
The composite intake manifold vacuum ports can
be repaired. Although, if the manifold plenum cham-
ber is damaged or cracked, the manifold must be
replaced.
To repair a broken or damaged vacuum nipple
(port) on the composite intake manifold, perform the
following procedure:
PARTS REQUIRED TOOLS REQUIRED
´ Brass Nipple ± 1/49
O.D. x 1/89pipe thread
(LDP/Speed Control Port)´ Pipe Tap ± 1/89-18
NPT
´ Drill Bit ± 11/329
´ File/Sandpaper
´ Brass Nipple ± 1/29
O.D. x 1/49pipe thread
(Brake Booster Port)´ Pipe Tap ± 1/49-18
NPT
´ Drill Bit ± 7/169
´ File/Sandpaper
NOTE: While performing this procedure, avoid get-
ting the manifold material residue into the plenum
chamber.
(1) File or sand the remaining port back until a
flat surface is obtained (plane normal to nipple (port)
axis).
(2) Drill out the nipple (port) base using a 7/16º
(brake booster port) or 11/32º (LDP/speed control port
) drill bit (Fig. 114).
(3) Using a 1/4º±18 NPT (brake booster port) or
1/8º±18 NPT (LDP/speed control port ) pipe tap, cut
internal threads (Fig. 114). Use caution to start tap
in a axis same as original nipple.
(4) Apply MopartThread Sealant to threads of
repair nipple(s).
(5) Install repair nipple(s). Do not over torque
repair nipple(s).
REMOVAL - UPPER INTAKE MANIFOLD
(1) Disconnect battery negative cable.
(2) Disconnect inlet air temperature (IAT) sensor
electrical connector.
(3) Remove air inlet resonator to throttle body
hose assembly.
(4) Disconnect throttle and speed control cables
from throttle body (Refer to 14 - FUEL SYSTEM/
FUEL INJECTION/THROTTLE CONTROL CABLE -
REMOVAL).
(5) Disconnect make-up air hose support clip from
throttle cable bracket.(6) Disconnect the automatic idle speed (AIS)
motor and throttle position sensor (TPS) wiring con-
nectors from throttle body.
(7) Disconnect the manifold absolute pressure
(MAP) sensor electrical connector.
(8) Disconnect the vapor purge vacuum hose from
throttle body.
(9) Disconnect the PCV hose (Fig. 115).
(10) Remove the power steering reservoir attach-
ing bolts and only loosen the nut (Fig. 116). Lift res-
ervoir up to disengage lower mount from stud. Set
reservoir aside.Do notdisconnect hose.
(11) Disconnect the brake booster and leak detec-
tion pump (LDP) hoses from intake manifold (Fig.
117).
(12) Remove intake manifold bolts and remove the
manifold (Fig. 118).
(13) Cover the lower intake manifold with a suit-
able cover while the upper manifold is removed.
(14) Clean and inspect the upper intake manifold
(Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANI-
FOLD - CLEANING) and (Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD - INSPECTION).
CLEANING
(1) Discard gasket(s).
(2) Clean all sealing surfaces.
Fig. 114 Intake Manifold Port Repair
1 - BRAKE BOOSTER PORT = 1/49±18 NPT PIPE TAP
1 - LDP/SPEED CONTROL PORT = 1/89±18 NPT PIPE TAP
2 - DRILL BIT = 7/169BRAKE BOOSTER PORT
2 - DRILL BIT = 11/329LDP/SPEED CONTROL PORT
3 - INTAKE MANIFOLD
9 - 148 ENGINE 3.3/3.8LRS
INTAKE MANIFOLD - UPPER (Continued)