battery location CHRYSLER CARAVAN 2002 Owners Manual

tion of the service manual for complete IPM circuit
schematics.
REMOVAL
(1) Disconnect the negative and positive battery
cables.
(2) Remove the battery thermal guard from the
vehicle. Refer to the Battery section for the proce-
dure.
(3) Remove the battery from the vehicle. Refer to
the Battery section for the procedure.
(4) Using a flat-bladed screwdriver, twist the Inte-
grated Power Module (IPM) bracket retaining latch
outward to free the intelligent power module from its
mounting bracket (Fig. 3).
(5) Rotate the IPM counter-clockwise to access and
disconnect the various electrical connectors (Fig. 4).
(6) Free the IPM from its mounting bracket by
removing the IPM bracket clips from the hinge. A
screwdriver slipped up from under the hinge will free
the clips.
INSTALLATION
(1) Snap the left side of the Integrated Power Mod-
ule (IPM) housing in its mounting bracket and con-
nect the various electrical connectors. Care must be
taken that the Connector Positive Assurance (CPA)
on the five-pin B+ connector is positively engaged to
prevent generating a Diagnostic Trouble Code (DTC).
NOTE: IPM electrical connectors are color coded to
ease location reference.(2) Being certain no wires are stressed or pinched,
rotate the IPM clock-wise until secured in mounting
bracket. An audible click may be heard.
(3) Install the battery in the vehicle. Refer to the
Battery section for the procedure.
(4) Install the battery thermal guard in the vehi-
cle. Refer to the Battery section for the procedure.
(5)
Connect the negative and positive battery cables.
(6) Using a diagnostic scan tool, check for any
stored diagnostic trouble codes and correct, check
that all vehicle options are operational before return-
ing the vehicle to service.
IOD FUSE
DESCRIPTION
All vehicles are equipped with an Ignition-Off
Draw (IOD) fuse that is removed from its normal
cavity in the Integrated Power Module (IPM) when
the vehicle is shipped from the factory. Dealer per-
sonnel are to remove the IOD fuse from the storage
location and install it into the IPM fuse cavity
marked IOD as part of the preparation procedures
performed just prior to new vehicle delivery.
The IPM has a molded plastic cover that can be
removed to provide service access to all of the fuses
and relays in the IPM. An integral latch and hinges
are molded into the IPM cover for easy removal. A
fuse layout map is integral to the underside of the
IPM cover to ensure proper fuse and relay identifica-
Fig. 3 RELEASING INTEGRATED POWER MODULE
FROM ITS MOUNTING BRACKET
Fig. 4 DISCONNECTING IPM
1 - INTEGRATED POWER MODULE FUSE & RELAY CENTER
8W - 97 - 4 8W-97 POWER DISTRIBUTION SYSTEMRS
INTEGRATED POWER MODULE (Continued)
ProCarManuals.com

tion. The IOD fuse is a 15 ampere blade-type car-
tridge fuse and, when removed, it is stored in a fuse
cavity adjacent to the washer fuse within the IPM.
OPERATION
The term ignition-off draw identifies a normal con-
dition where power is being drained from the battery
with the ignition switch in the Off position. The IOD
fuse feeds the memory and sleep mode functions for
some of the electronic modules in the vehicle as well
as various other accessories that require battery cur-
rent when the ignition switch is in the Off position,
including the clock. The only reason the IOD fuse is
removed is to reduce the normal IOD of the vehicle
electrical system during new vehicle transportation
and pre-delivery storage to reduce battery depletion,
while still allowing vehicle operation so that the
vehicle can be loaded, unloaded and moved as needed
by both vehicle transportation company and dealer
personnel.
The IOD fuse is removed from the IPM fuse cavity
when the vehicle is shipped from the assembly plant.
Dealer personnel must install the IOD fuse when the
vehicle is being prepared for delivery in order to
restore full electrical system operation. Once the
vehicle is prepared for delivery, the IOD function of
this fuse becomes transparent and the fuse that has
been assigned the IOD designation becomes only
another Fused B(+) circuit fuse. The IOD fuse serves
no useful purpose to the dealer technician in the ser-
vice or diagnosis of any vehicle system or condition,
other than the same purpose as that of any other
standard circuit protection device.
The IOD fuse can be used by the vehicle owner as
a convenient means of reducing battery depletion
when a vehicle is to be stored for periods not to
exceed about thirty days. However, it must be
remembered that removing the IOD fuse will not
eliminate IOD, but only reduce this normal condition.
If a vehicle will be stored for more than about thirty
days, the battery negative cable should be discon-
nected to eliminate normal IOD; and, the battery
should be tested and recharged at regular intervals
during the vehicle storage period to prevent the bat-
tery from becoming discharged or damaged. Refer to
Battery Systemfor additional service information.
REMOVAL
(1) Turn the ignition switch to the Off position.
(2) Unlatch and open the cover of the intelligent
power module.
(3) Remove the IOD fuse from fuse location
markedIODof the Integrated Power Module (IPM).
(4) Store the removed IOD fuse by installing it in
the unused fuse storage markedSPAREof the IPM.
(5) Close and latch the IPM.
INSTALLATION
(1) Be certain the ignition switch is in the Off posi-
tion.
(2) Unlatch and open the cover of the Integrated
Power Module (IPM).
(3) Remove the stored 15 amp IOD fuse from fuse
storage markedSPAREof the IPM.
(4) Use a thumb to press the IOD fuse firmly down
into IPM fuse cavity markedIOD.
(5) Close and latch the IPM cover.
POWER OUTLET
DESCRIPTION
Accessory power outlets are standard equipment on
this model. Two power outlets are installed in the
instrument panel center lower bezel, which is located
near the bottom of the instrument panel center stack
area. Two additional power outlets are also incorpo-
rated into the vehicle, one on the left rear C-pillar
trim and the other in the center console, if equipped.
The power outlets bases are secured by a snap fit in
the appropriate bezels. A hinged plug flips closed to
conceal and protect the power outlet base when the
power outlet is not being used.
The power outlet receptacle unit and the power
outlet plugs are each available for service replace-
ment.
OPERATION
The power outlet base or receptacle shell is con-
nected to ground, and an insulated contact in the
bottom of the shell is connected to battery current.
The power outlet on the instrument panel marked
with a battery receives battery voltage from a fuse in
the Integrated Power Module (IPM) at all times. The
other power outlet on the instrument panel marked
with a key receives battery voltage only when the
key is in the on position.
The power outlet located in the center console
receives battery voltage all the time when positioned
between thefront seatsand key-on voltage when
positioned between therear seats. The power outlet
located on the C-pillar receives battery voltage only
when the key is in the on position.
DIAGNOSIS AND TESTING
DIAGNOSIS & TESTING - POWER OUTLET
For complete circuit diagrams, refer toCigar
Lighter/Power Outletin Wiring Diagrams.
RS8W-97 POWER DISTRIBUTION SYSTEM8W-97-5
IOD FUSE (Continued)
ProCarManuals.com

CONDITION POSSIBLE CAUSES CORRECTION
OIL CONSUMPTION OR SPARK
PLUGS FOULED1. PCV system malfunction. 1. Check system and repair as
necessary. (Refer to 25 -
EMISSIONS CONTROL/
EVAPORATIVE EMISSIONS/PCV
VALVE - DIAGNOSIS AND
TESTING)
2. Worn, scuffed or broken rings. 2. Hone cylinder bores. Install new
rings.
3. Carbon in oil ring slots. 3. Install new rings.
4. Rings fitted too tightly in grooves. 4. Remove rings and check
grooves. If groove is not proper
width, replace piston.
5. Worn valve guide(s). 5. Replace cylinder head assembly.
6. Valve stem seal(s) worn or
damaged.6. Replace seal(s).
DIAGNOSIS AND TESTING - ENGINE OIL LEAK
INSPECTION
Begin with a thorough visual inspection of the
engine, particularly at the area of the suspected leak.
If an oil leak source is not readily identifiable, the
following steps should be followed:
(1) Do not clean or degrease the engine at this
time because some solvents may cause rubber to
swell, temporarily stopping the leak.
(2) Add an oil soluble dye (use as recommended by
manufacturer). Start the engine and let idle for
approximately 15 minutes. Check the oil dipstick to
make sure the dye is thoroughly mixed as indicated
with a bright yellow color under a black light.
(3) Using a black light, inspect the entire engine
for fluorescent dye, particularly at the suspected area
of oil leak. If the oil leak is found and identified,
repair as necessary.
(4) If dye is not observed, drive the vehicle at var-
ious speeds for approximately 24 km (15 miles), and
repeat inspection.
(5)If the oil leak source is not positively
identified at this time, proceed with the air leak
detection test method as follows:
²Disconnect the fresh air hose (make-up air) at
the cylinder head cover and plug or cap the nipple on
the cover.
²Remove the PCV valve hose from the cylinder
head cover. Cap or plug the PCV valve nipple on the
cover.
²Attach an air hose with pressure gauge and reg-
ulator to the dipstick tube.
CAUTION: Do not subject the engine assembly to
more than 20.6 kpa (3 PSI) of test pressure.²Gradually apply air pressure from 1 psi to 2.5
psi maximum while applying soapy water at the sus-
pected source. Adjust the regulator to the suitable
test pressure that provides the best bubbles which
will pinpoint the leak source. If the oil leak is
detected and identified, repair per service manual
procedures.
²If the leakage occurs at the crankshaft rear oil
seal area, refer to the section, Inspection for Rear
Seal Area Leak.
(6) If no leaks are detected, turn off the air supply.
Remove the air hose, all plugs, and caps. Install the
PCV valve and fresh air hose (make-up air). Proceed
to next step.
(7) Clean the oil off the suspect oil leak area using
a suitable solvent. Drive the vehicle at various
speeds approximately 24 km (15 miles). Inspect the
engine for signs of an oil leak by using a black light.
NOTE: If oil leakage is observed at the dipstick tube
to block location; remove the tube, clean and reseal
using MoparTStud & Bearing Mount (press fit tube
applications only), and for O-ring style tubes,
remove tube and replace the O-ring seal.
INSPECTION FOR REAR SEAL AREA LEAKS
Since it is sometimes difficult to determine the
source of an oil leak in the rear seal area of the
engine, a more involved inspection is necessary. The
following steps should be followed to help pinpoint
the source of the leak.
If the leakage occurs at the crankshaft rear oil seal
area:
(1) Disconnect the battery.
(2) Raise the vehicle.
9 - 8 ENGINE 2.4LRS
ENGINE 2.4L (Continued)
ProCarManuals.com

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 - 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.
MOPARtBED PLATE SEALANTis a unique
(green-in-color) anaerobic type gasket material that
is specially made to seal the area between the bed-plate and cylinder block without disturbing the bear-
ing clearance or alignment of these components. The
material cures slowly in the absence of air when
torqued between two metallic surfaces, and will rap-
idly cure when heat is applied.
MOPARtGASKET SEALANTis a slow drying,
permanently soft sealer. This material is recom-
mended for sealing threaded fittings and gaskets
against leakage of oil and coolant. Can be used on
threaded and machined parts under all tempera-
tures. This material is used on engines with multi-
layer steel (MLS) cylinder head gaskets. This
material also will prevent corrosion. MopartGasket
Sealant is available in a 13 oz. aerosol can or 4oz./16
oz. can w/applicator.
SEALER APPLICATION
MopartGasket Maker material should be applied
sparingly 1 mm (0.040 in.) diameter or less of sealant
to one gasket surface. Be certain the material sur-
rounds each mounting hole. Excess material can eas-
ily be wiped off. Components should be torqued in
place within 15 minutes. The use of a locating dowel
is recommended during assembly to prevent smear-
ing material off the location.
MopartEngine RTV GEN II or ATF RTV gasket
material should be applied in a continuous bead
approximately 3 mm (0.120 in.) in diameter. All
mounting holes must be circled. For corner sealing, a
3.17 or 6.35 mm (1/8 or 1/4 in.) drop is placed in the
center of the gasket contact area. Uncured sealant
may be removed with a shop towel. Components
should be torqued in place while the sealant is still
wet to the touch (within 10 minutes). The usage of a
locating dowel is recommended during assembly to
prevent smearing material off the location.
MopartGasket Sealant in an aerosol can should be
applied using a thin, even coat sprayed completely
over both surfaces to be joined, and both sides of a
gasket. Then proceed with assembly. Material in a
can w/applicator can be brushed on evenly over the
sealing surfaces. Material in an aerosol can should be
used on engines with multi-layer steel gaskets.
STANDARD PROCEDURE - ENGINE GASKET
SURFACE PREPARATION
To ensure engine gasket sealing, proper surface
preparation must be performed, especially with the
use of aluminum engine components and multi-layer
steel cylinder head gaskets.
Neveruse the following to clean gasket surfaces:
²Metal scraper
²Abrasive pad or paper to clean cylinder block
and head
²High speed power tool with an abrasive pad or a
wire brush (Fig. 3)
RSENGINE 2.4L9-11
ENGINE 2.4L (Continued)
ProCarManuals.com

INSTALLATION
(1) Clean and check filter mounting surface. The
surface must be smooth, flat and free of debris or
pieces of gasket.
(2) Lubricate new oil filter gasket with clean
engine oil.
(3) Screw oil filter (Fig. 88) on until the gasket
contacts base. Tighten to 12 N´m (105 in. lbs.).
OIL PAN
REMOVAL
(1) Raise vehicle on hoist and drain engine oil.
(2) Remove structural collar. (Refer to 9 -
ENGINE/ENGINE BLOCK/STRUCTURAL COVER -
REMOVAL)
(3) Remove air conditioning compressor bracket to
oil pan bolt.
(4) Remove bolts attaching oil pan.
(5) Remove oil pan.
(6) Clean oil pan and all gasket surfaces.
INSTALLATION
(1) Apply MopartEngine RTV GEN II at the oil
pump to engine block parting line (Fig. 89).
(2) Install the oil pan gasket to the block.
(3) Install pan and tighten the screws to 12 N´m
(105 in. lbs.).
(4) Install air conditioning compressor bracket to
oil pan bolt.
(5) Install structural collar. (Refer to 9 - ENGINE/
ENGINE BLOCK/STRUCTURAL COVER - INSTAL-
LATION)
(6) Lower vehicle and fill engine crankcase with
proper oil to correct level.
OIL PRESSURE SWITCH
REMOVAL
(1) Raise vehicle.
(2) Position oil collecting container under pressure
switch location.
(3) Disconnect oil pressure switch electrical con-
nector and remove switch (Fig. 90).
INSTALLATION
(1) Install oil pressure switch. Torque switch to 21
N´m (190 in. lbs.) (Fig. 90).
(2) Connect electrical connector
(3) Lower vehicle.
(4) Start engine and allow to run a minimum of 2
minutes.
(5) Shut engine off and check engine oil level.
Adjust level as necessary.
OIL PUMP
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
REMOVAL).
(3) Remove timing belt rear cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT COVER(S)
- REMOVAL).
(4) Remove oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - REMOVAL).
(5) Remove crankshaft sprocket using Special
Tools 6793 and C-4685-C2 (Fig. 91).
(6) Remove crankshaft key (Fig. 92).
(7) Remove oil pick-up tube.
(8) Remove oil pump (Fig. 93) and front crankshaft
seal.
Fig. 89 Oil Pan Sealing - Typical
1 - SEALER LOCATIONS
Fig. 90 Engine Oil Pressure Switch
RSENGINE 2.4L9-55
OIL FILTER (Continued)
ProCarManuals.com

CONDITION POSSIBLE CAUSES CORRECTION
OIL CONSUMPTION OR SPARK
PLUGS FOULED1. PCV system malfunction. 1. Check system and repair as
necessary. (Refer to 25 -
EMISSIONS CONTROL/
EVAPORATIVE EMISSIONS/PCV
VALVE - DIAGNOSIS AND
TESTING)
2. Worn, scuffed or broken rings. 2. Hone cylinder bores. Install new
rings.
3. Carbon in oil ring slots. 3. Install new rings.
4. Rings fitted too tightly in grooves. 4. Remove rings and check
grooves. If groove is not proper
width, replace piston.
5. Worn valve guide(s). 5. Replace cylinder head assembly.
6. Valve stem seal(s) worn or
damaged.6. Replace seal(s).
DIAGNOSIS AND TESTING - ENGINE OIL LEAK
INSPECTION
Begin with a thorough visual inspection of the
engine, particularly at the area of the suspected leak.
If an oil leak source is not readily identifiable, the
following steps should be followed:
(1) Do not clean or degrease the engine at this
time because some solvents may cause rubber to
swell, temporarily stopping the leak.
(2) Add an oil soluble dye (use as recommended by
manufacturer). Start the engine and let idle for
approximately 15 minutes. Check the oil dipstick to
make sure the dye is thoroughly mixed as indicated
with a bright yellow color under a black light.
(3) Using a black light, inspect the entire engine
for fluorescent dye, particularly at the suspected area
of oil leak. If the oil leak is found and identified,
repair as necessary.
(4) If dye is not observed, drive the vehicle at var-
ious speeds for approximately 24 km (15 miles), and
repeat inspection.
(5)If the oil leak source is not positively
identified at this time, proceed with the air leak
detection test method as follows:
²Disconnect the fresh air hose (make-up air) at
the cylinder head cover and plug or cap the nipple on
the cover.
²Remove the PCV valve hose from the cylinder
head cover. Cap or plug the PCV valve nipple on the
cover.
²Attach an air hose with pressure gauge and reg-
ulator to the dipstick tube.
CAUTION: Do not subject the engine assembly to
more than 20.6 kpa (3 PSI) of test pressure.²Gradually apply air pressure from 1 psi to 2.5
psi maximum while applying soapy water at the sus-
pected source. Adjust the regulator to the suitable
test pressure that provides the best bubbles which
will pinpoint the leak source. If the oil leak is
detected and identified, repair per service manual
procedures.
²If the leakage occurs at the crankshaft rear oil
seal area, refer to the section, Inspection for Rear
Seal Area Leak.
(6) If no leaks are detected, turn off the air supply.
Remove the air hose, all plugs, and caps. Install the
PCV valve and fresh air hose (make-up air). Proceed
to next step.
(7) Clean the oil off the suspect oil leak area using
a suitable solvent. Drive the vehicle at various
speeds approximately 24 km (15 miles). Inspect the
engine for signs of an oil leak by using a black light.
NOTE: If oil leakage is observed at the dipstick tube
to block location; remove the tube, clean and reseal
using MoparTStud & Bearing Mount (press fit tube
applications only), and for O-ring style tubes,
remove tube and replace the O-ring seal.
INSPECTION FOR REAR SEAL AREA LEAKS
Since it is sometimes difficult to determine the
source of an oil leak in the rear seal area of the
engine, a more involved inspection is necessary. The
following steps should be followed to help pinpoint
the source of the leak.
If the leakage occurs at the crankshaft rear oil seal
area:
(1) Disconnect the battery.
(2) Raise the vehicle.
9 - 82 ENGINE 3.3/3.8LRS
ENGINE 3.3/3.8L (Continued)
ProCarManuals.com

²Step 2: Bolts1±8to88N´m(65ft.lbs.)
²Step 3: Bolts1±8(again) to 88 N´m (65 ft. lbs.)
²Step 4: Bolts1±8turn an additional 1/4 Turn.
(Do not use a torque wrench for this step.)
NOTE: Bolt torque after 1/4 turn should be over 122
N´m (90 ft. lbs.). If not, replace the bolt.
(6) Inspect push rods and replace worn or bent
rods.
(7) Install the push rods.
(8) Install the rocker arm and shaft assemblies.
(Refer to 9 - ENGINE/CYLINDER HEAD/ROCKER
ARMS - INSTALLATION)
(9) Install the cylinder head covers. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION)
(10) Install the exhaust manifolds. (Refer to 9 -
ENGINE/MANIFOLDS/EXHAUST MANIFOLD -
INSTALLATION)
(11) Install new O-ring on dipstick tube. Install
dipstick tube assembly (Fig. 18).
(12) Install the spark plugs.
(13) Install upper and lower intake manifolds.
(Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANI-
FOLD - INSTALLATION)
(14) Fill the cooling system. (Refer to 7 - COOL-
ING - STANDARD PROCEDURE)
(15) Connect negative cable to battery.
CYLINDER HEAD COVER(S)
DESCRIPTION
The cylinder head covers are made of stamped
steel. The covers are sealed with steel reinforced sil-
icon rubber gaskets. The cylinder head cover uses
rubber isolators at each fastener location (Fig. 23).
NOTE: Due to the tight packaging near the cylinder
head covers, which makes spill clean-up difficult, a
spill during an engine oil change may be misinter-
preted as an oil leak. When investigating an oil leak
in the location of the cylinder head covers and
intake manifold, follow the procedure found in Oil
Leak Diagnosis (Refer to 9 - ENGINE - DIAGNOSISAND TESTING) for determining the source of a
leak.
CYLINDER HEAD COVER -
RIGHT
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove the wiper module. (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
REMOVAL)
(3) Disconnect spark plug wires from plugs.
(4) Disconnect power steering pump supply hose
support clip from cylinder head cover (Fig. 24).
(5) Disconnect PCV hose from cylinder head cover
(Fig. 25).
(6) Remove cylinder head cover bolts.
(7) Remove cylinder head cover and gasket (Fig.
23).
INSTALLATION
(1) Clean cylinder head and cover mating surfaces.
Inspect cylinder head cover surface for flatness.
Replace gasket as necessary.
(2) Inspect seal on the cover bolt for wear or dam-
age (Fig. 26). Replace bolt assembly as necessary.
NOTE: The cylinder head cover bolts contain a
torque limiter sleeve and a seal (Fig. 26). The seal
and torque sleeve is replaced with the bolt.
Fig. 22 CYLINDER HEAD TIGHTENING SEQUENCE
Fig. 23 Cylinder Head Cover
1 - CYLINDER HEAD COVER
2 - BOLT
RSENGINE 3.3/3.8L9 - 103
CYLINDER HEAD (Continued)
ProCarManuals.com

(2) Follow the same procedure on the remaining 5
cylinders using the firing sequence 1-2-3-4-5-6.Make
sure piston in cylinder is at TDC on the valve
spring that is being covered.
(3) Remove spark plug adapter tool.
(4) Install rocker arms and shaft assembly. (Refer
to 9 - ENGINE/CYLINDER HEAD/ROCKER ARMS -
INSTALLATION)
(5) Install cylinder head covers. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION)
(6) Install spark plugs and connect wires.
(7) Connect negative cable to battery.
ROCKER ARMS
DESCRIPTION
DESCRIPTION - ROCKER ARMS
The rocker arms are installed on the rocker arm
shaft. The rocker arms and shaft assembly is
attached to the cylinder head with seven bolts and
retainers. The rocker arms are made of stamped
steel.
DESCRIPTION - PUSHRODS
The pushrods are made of steel and are a hollow
design. The pushrods are positioned between the
hydraulic lifter and the rocker arm.
OPERATION
OPERATION - ROCKER ARMS
The rocker arm pivots on the rocker shaft. Rocker
arms are used to translate up and down motions pro-
vided by the camshaft, hydraulic lifter, and pushrod
on one end, into a down and up motions on the valve
stem on the opposing end.
OPERATION - PUSHRODS
The pushrod is a solid link between the hydraulic
lifter and the rocker arm. Also, the pushrod supplies
engine oil from the hydraulic lifter to the rocker arm.
REMOVAL - ROCKER ARMS AND SHAFT
(1) Remove the cylinder head cover(s). (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL)
NOTE: Rocker arm shaft bolts are captured to the
shaft.
(2) Loosen the rocker shaft bolts (Fig. 40), rotating
one turn each, until all valve spring pressure is
relieved.
(3) Remove the rocker arms and shaft assembly
(Fig. 40).
(4) For rocker arm disassembly procedures, (Refer
to 9 - ENGINE/CYLINDER HEAD/ROCKER ARMS -
DISASSEMBLY).
DISASSEMBLY - ROCKER ARMS AND SHAFT
CAUTION: Do not attempt to drive the bolt from the
rocker shaft. This can damage the retainer and bolt
assembly.
(1) Remove the rocker arm retainer and bolt by
performing the following procedure:
(a) Using adjustable pliers, grip the edges of the
retainer (Fig. 41).
(b) Apply an upward force with a slight rocking
motion until the retainer disengages from shaft
(Fig. 41).
(2) Remove rocker arms (Fig. 42). Identify the
component locations for reassembly in original loca-
tions.
Fig. 40 ROCKER ARMS AND SHAFT
1 - ROCKER ARMS AND SHAFT ASSEMBLY
2 - ROCKER SHAFT BOLTS
9 - 110 ENGINE 3.3/3.8LRS
VALVE SPRINGS (Continued)
ProCarManuals.com

STANDARD PROCEDURE
STANDARD PROCEDURE - FITTING
CONNECTING RODS
The bearing caps are not interchangeable or
reversible, and should be marked at removal to
ensure correct reassembly. The bearing shells must
be installed with the tangs inserted into the
machined grooves in the rods and caps. Install cap
with the tangs on the same side as the rod. For con-
necting rod bearing fitting (Refer to 9 - ENGINE/EN-
GINE BLOCK/CONNECTING ROD BEARINGS -
STANDARD PROCEDURE). Fit all connecting rods
on one bank until complete.
NOTE: The connecting rod cap bolts should be
examined before reuse. Bolt stretch can be checked
by holding a scale or straight edge against the
threads. If all the threads do not contact the scale
the bolt must be replaced (Fig. 74).
(1) Before installing the nuts the threads should
be oiled with engine oil.
(2) Install nuts finger tight on each bolt then alter-
nately torque each nut to assemble the cap properly.
(3) Tighten the nuts to 54 N´m PLUS 1/4 turn (40
ft. lbs. PLUS 1/4 turn).
(4) Using a feeler gauge, check connecting rod side
clearance (Fig. 75). Refer to Engine Specifications
(Refer to 9 - ENGINE - SPECIFICATIONS).
STANDARD PROCEDURE - FITTING PISTONS
The piston and cylinder wall must be clean and dry.
Piston diameter should be measured 90 degrees to pis-
ton pin at size location shown in (Fig. 76). Cylinder
bores should be measured halfway down the cylinder
bore and transverse to the engine crankshaft center line
shown in (Fig. 77). Refer to Engine Specifications (Refer
to 9 - ENGINE - SPECIFICATIONS).Pistons and cyl-
inder bores should be measured at normal room
temperature, 21ÉC (70ÉF).
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove the cylinder heads. (Refer to 9 -
ENGINE/CYLINDER HEAD - REMOVAL)
(3) Remove the oil pan. (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL)
(4) Remove the top ridge of cylinder bores with a
reliable ridge reamer, if necessary, before removing
pistons from cylinder block.Be sure to keep tops
of pistons covered during this operation. Pis-
tons and connecting rods must be removed
from top of cylinder block. When removing pis-
ton and connecting rod assemblies from the
engine, rotate crankshaft so that each connect-
ing rod is centered in cylinder bore.
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 Checking Connecting Rod Side Clearance
Fig. 76 Piston Measurement Locations
1 - 39.8 mm (1.56 in. ) 3.3L ENGINE
2 - 33.0 mm (1.29 in.) 3.8L ENGINE
RSENGINE 3.3/3.8L9 - 127
PISTON & CONNECTING ROD (Continued)
ProCarManuals.com

(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. 108).
(2) Position a new pan gasket on oil pan (Fig. 107).
(3) Install oil pan and tighten fasteners to 12 N´m
(105 in. lbs.) (Fig. 107).
(4) Install cover to transaxle case (Fig. 106).
(5) Install the strut bolt to transaxle housing (Fig.
106). Tighten all bending brace bolts.
(6) Install the drive belt splash shield.
(7) Lower vehicle and install oil dipstick.(8) Connect negative cable to battery.
(9) Fill crankcase with oil to proper level.
OIL PRESSURE RELIEF VALVE
REMOVAL
(1) Remove oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - REMOVAL).
(2) Drill a 3.175 mm (1/8 in.) hole in the center of
the retainer cap (Fig. 109). Insert a self-threading
sheet metal screw into the cap.
(3) Using suitable pliers, remove cap and discard.
(4) Remove spring and relief valve (Fig. 109).
Fig. 107 OIL PAN
1 - GASKET
2 - BOLT
3 - OIL PAN
4 - NUT
Fig. 108 Oil Pan Sealing
1 - SEALER LOCATIONS
Fig. 109 Oil Pressure Relief Valve
1 - RELIEF VALVE
2 - SPRING
3 - RETAINER CAP
9 - 142 ENGINE 3.3/3.8LRS
OIL PAN (Continued)
ProCarManuals.com