Chrysler Town, Dodge Caravan. Manual - part 318

(8) Install the generator and wiring harness (Refer

to 8 - ELECTRICAL/CHARGING/GENERATOR -
INSTALLATION).

(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).

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

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ENGINE 3.3/3.8L

RS

ENGINE 3.3/3.8L (Continued)

(47) Connect the radiator upper hose.
(48) Connect the heater hoses. Remove pinch-off

pliers from the rear heater hoses (if equipped).

(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

DESCRIPTION

SPECIFICATION

General Specification

Type

60° V-6 Engine

Number of Cylinders

6

Displacement

—3.3L

3.3 Liters

(201 cu. in.)

—3.8L

3.8 Liters

(231 cu. in.)

Bore

—3.3L

93.0 mm

(3.66 in.)

—3.8L

96.0 mm

(3.779 in.)

Stroke

—3.3L

81.0 mm

(3.188 in.)

—3.8L

87.0 mm

(3.425 in.)

Compression Ratio

—3.3L

9.35:1

—3.8L

9.6:1

DESCRIPTION

SPECIFICATION

Firing Order

1-2-3-4-5-6

Cylinder Number (Front
to Rear)

—Front Bank

2,4,6

—Rear Bank

1,3,5

Compression Pressure—
Minimum

689.5 kPa

(100 psi)

Max. Variation Between
Cylinders

25%

Cylinder Block

Cylinder Bore Diameter
(Standard)

—3.3L

92.993–93.007 mm

(3.661–3.6617 in.)

—3.8L

95.993–96.007 mm

(3.7792–3.780 in.)

Out-of-Round (Service
Limits)

0.076 mm

(0.003 in.)

Taper (Service Limits)

0.051 mm

(0.002 in.)

Lifter Bore Diameter

22.980–23.010 mm

(0.905–0.906 in.)

Deck Surface Flatness
(Max.)

0.1 mm

(0.004 in.)

Pistons

Piston Diameter

—3.3L —Measured 39.8

mm (1.567 in.) from

piston top

92.968–92.998 mm

(3.660–3.661 in.)

—3.8L —Measured 33.01

mm (1.30 in.) from piston

top

95.968–95.998 mm

(3.778–3.779 in.)

Clearance in Bore @
Size Location (New)

-0.005–0.039 mm

(-0.0002–0.0015 in.)

Weight

—3.3L

362 ±5 grams

(12.77 ±0.1764 oz.)

—3.8L

426 ±5 grams

(15.03 ±0.1764 oz.)

Piston Pins

Type

Press Fit in Rod

(Serviced as an

Assembly)

RS

ENGINE 3.3/3.8L

9 - 91

ENGINE 3.3/3.8L (Continued)

DESCRIPTION

SPECIFICATION

Clearance in Piston @
21° C (70° F)

0.006–0.019 mm

(0.0002–0.0007 in.)

Clearance in Connecting
Rod

(Interference Fit)

Diameter

22.87–22.88 mm

(0.9007–0.9009 in.)

Length

—3.3L

67.25–67.75 mm

(2.648–2.667 in.)

—3.8L

71.25–71.75

(2.805–2.824 in.)

Piston Rings

Ring End Gap—Top
Compression Ring

0.18–0.38 mm

(0.007–0.015 in.)

Wear Limit

1.0 mm

(0.039 in.)

Ring End Gap—2nd
Compression Ring

0.28–0.57 mm

(0.011–0.022 in.)

Wear Limit

1.0 mm

(0.039 in.)

Ring End Gap—Oil
Control Steel Rails

0.23–0.78 mm

(0.009–0.030 in.)

Wear Limit

1.88 mm

(0.074 in.)

Ring Side Clearance—
Top Compression Ring

—3.3L

0.030–0.080 mm

(0.0012–0.0031 in.)

—3.8L

0.030–0.069 mm

(0.0012–0.0027 in.)

Wear Limit

0.10 mm

(0.004 in.)

Ring Side Clearance—
2nd Compression Ring

—3.3L

0.030–0.095 mm

(0.0012–0.0037 in.)

—3.8L

0.041–0.085 mm

(0.0016–0.0033 in.)

Wear Limit

0.13 mm

(0.005 in.)

DESCRIPTION

SPECIFICATION

Ring Side Clearance—Oil
Ring Pack

0.039–0.200 mm

(0.0015–0.0078 in.)

Wear Limit

0.266 mm

(0.009 in.)

Ring Width—Top
Compression Ring

—3.3L

1.46–1.49 mm

(0.0575–0.058 in.)

—3.8L

1.175–1.190 mm

(0.0462–0.0468 in.)

Ring Width—2nd
Compression Ring
—3.3/3.8L

1.46–1.49 mm

(0.0575–0.058 in.)

Ring Width—Oil Ring
(Steel Rails)

—3.3L

0.435–0.490 mm

(0.017–0.019 in.)

—3.8L

0.435–0.510 mm

(0.017–0.020 in.)

Connecting Rod

Bearing Clearance

0.019–0.065 mm

(0.0008–0.0026 in.)

Wear Limit

0.074 mm

(0.003 in.)

Side Clearance

0.13–0.32 mm

(0.005–0.013 in.)

Wear Limit

0.38 mm

(0.015 in.)

Crankshaft

Material

Nodular Iron

Connecting Rod Journal
Diameter

57.979–58.005 mm

(2.2827–2.2837 in.)

Main Bearing Journal
Diameter

63.993–64.013 mm

(2.5194–2.5202 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.)

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RS

ENGINE 3.3/3.8L (Continued)

DESCRIPTION

SPECIFICATION

Main Bearing Diametrical
Clearance

—No. 1, 2, 3, 4

0.011–0.055 mm

(0.0005–0.0022 in.)

Wear Limit

0.076 mm

(0.003 in.)

Camshaft

Journal Diameter

No.1

50.724–50.775 mm

(1.997–1.999 in.)

No.2

50.317–50.368 mm

(1.9809–1.9829 in.)

No.3

49.936–49.987 mm

(1.9659–1.9679 in.)

No.4

49.530–49.581 mm

(1.9499–1.9520 in.)

Bearing Clearance—
Diametrical

0.025–0.101 mm

(0.001–0.004 in.)

Bearing Clearance (Max.
allowable)

0.127 mm

(0.005 in.)

End Play

0.254–0.508 mm

(0.010–0.020 in.)

(Max. allowable)

0.304 mm

(0.012 in.)

Camshaft Bearing
Diameter

No. 1

50.800–50.825 mm

(1.9999–2.0009 in.)

No. 2

50.393–50.419 mm

(1.9839–1.9849 in.)

No. 3

50.013–50.038 mm

(1.9690–1.9699 in.)

No. 4

49.606–49.632 mm

(1.9529–1.954 in.)

Exhaust Valve Timing

Closes—3.3L (ATDC)

13°

Closes—3.8L (ATDC)

18°

Opens—3.3L (BBDC)

43°

Opens—3.8L (BBDC)

46°

Duration—3.3L

236°

Duration—3.8L

244°

DESCRIPTION

SPECIFICATION

Intake Valve Timing

Closes—3.3L (ABDC

52°

Closes—3.8L (ABDC

63°

Opens—3.3L (ATDC)

6°

Opens—3.8L (ATDC)

1°

Duration—3.3L

226°

Duration—3.8L

242°

Valve Overlap—3.3L

7°

Valve Overlap—3.8L

17°

Lifters

Type

Hydraulic Roller

Diameter O.D.

22.949–22.962 mm

(0.903–0.904 in.)

Clearance In Block

0.020–0.061 mm

0.0007–0.0024 in.)

Cylinder Head

Gasket Thickness
(Compressed)

0.65–0.75 mm

(0.025–0.029 in.)

Valve Seat

Angle

44.5–45°

Valve Seat Runout
(Service Limits)

0.0762 mm

(0.003 in.)

Valve Seat Width—Intake
& Exhaust

1.50–2.00 mm

(0.057–0.078 in.)

Valve Guide

Guide Bore Diameter
(Std.)

6.975–7.00 mm

(0.274–0.275 in.)

Valves

Valve Lift (Zero
Lash)—Intake & Exhaust

—3.3L

9.80 mm

(0.385 in.)

—3.8L

11.0 mm

(0.433 in.)

Face Angle—Intake

45–45.5°

Face Angle—Exhaust

45–45.5°

Head Diameter—Intake

47.87–48.13 mm

(1.88–1.89 in.)

Head Diameter—Exhaust

35.37–35.63 mm

(1.39–1.40 in.)

RS

ENGINE 3.3/3.8L

9 - 93

ENGINE 3.3/3.8L (Continued)