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Overhaul - 3.8L Engine: Specifications Chrysler Pacifica CS

Mechanical 25 illustrations ~212 words

ENGINE SPECIFICATIONS

DESCRIPTIONSPECIFICATION
MetricStandard
Engine Type60° V-6 Engine
Number of Cylinders6
Displacement 3.8L3.8 Liters231 cu. in.
Bore 3.8L96.0 mm3.779 cu.in.
Stroke87 mm3.425 in.
Compression Ratio 3.8L9.6:1
Firing Order1-2-3-4-5-6
Compression Pressure-Minimum689.5 kPa100 psi.
Cylinder Compression (Max. Difference Between Cylinders25%

GENERAL DESCRIPTION

CYLINDER BLOCK SPECIFICATIONS

DESCRIPTIONSPECIFICATION
MetricStandard
Cylinder Bore Diameter (Standard) 3.8L95.993-96.007 mm3.7792-3.780 in.
Out of Round (Service Limits)0.076 mm0.003 in.
Taper (Service Limits)0.051 mm0.002 in.
Lifter Bore Diameter22.980-23.010 mm0.905-0.906 in.
Deck Surface Flatness (Max.)0.1 mm0.004 in.

CYLINDER BLOCK

CRANKSHAFT SPECIFICATIONS

DESCRIPTIONSPECIFICATION
MetricStandard
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 mm0.001 in.
Journal Taper (Max.)0.025 mm0.001 in
End Play0.09-0.24 mm0.0036-0.0095 in.
Wear Limit0.381 mm0.015 in.
Main Bearing Diametrical Clearance 1-2-3-40.011-0.055 mm0.0005-0.0022 in.
Wear Limit0.076 mm0.003 in.

CRANKSHAFT

CONNECTING RODS SPECIFICATIONS

DESCRIPTIONSPECIFICATION
MetricStandard
Bearing Clearance0.019-0.065 mm.0.017-0.020 in.
Wear Limit0.074 mm0.003 in.
Side Clearance0.13-0.32 mm0.005-0.013 in.
Wear Limit0.38 mm0.015 in.

CONNECTING RODS

ENGINE PISTON, PISTON RINGS AND PISTON PIN SPECIFICATIONS

DESCRIPTIONSPECIFICATION
MetricStandard
Piston Diameter 3.8L-Measured 33.01 mm (1.30 in) From Piston Top95.968-95.998 mm.3.778-3.779 in.
Clearance in Bore @ Size Location (New)0.005-0.039 mm0.0002-0.0015 in.
Weight 3.8L426 +/- 5 grams15.03 +/- 0.1764 oz.

PISTONS

DESCRIPTIONSPECIFICATION
MetricStandard
TypePress Fit in Rod (Serviced as a Assembly)
Clearance in Piston @ 21C (70°F)0.006-0.019 mm0.0002-0.0007 in.
Clearance in Connecting RodInterference Fit
Diameter22.87-22.88 mm0.9007-0.9009 in.
Length 3.8L71.25-71.75 mm2.805-2.824 in.

PISTON PINS

DESCRIPTIONSPECIFICATION
MetricStandard
Ring End Gap
Top Compression Ring0.18-0.38 mm0.007-0.015 in.
Second Compression Ring0.28-0.57 mm0.011-0.022 in.
Oil Control (Steel Rails)0.23-0.78 mm0.009-0.030 in.
Wear Limit-Compression Rings1.0 mm0.039 in.
Wear Limit-Oil Control Steel Rails1.88 mm0.074 in.
Ring Side Clearance.
Top Compression Ring 3.8L0.030-0.069 mm0.0012-0.0027 in.
Second Compression Ring 3.8L0.041-0.085 mm0.0016-0.0033 in.
Oil Ring (Steel Ring)0.039-0.200 mm0.0015-0.0078 in.
Wear Limit- Top Ring0.10 mm0.004 in.
Wear Limit-2nd Ring0.13 mm0.005
Wear Limit Oil Ring Pack0.266 mm0.009
Ring Width-Top Compression Ring 3.8L1.175-1.190 mm0.0462-0.0468
Ring Width-2nd Compression Ring 3.8L1.46-1.49 mm0.0575-0.058 in.
Ring Width-Oil Ring (Steel Rails) 3.8L0.435-0.510 mm0.017-0.020

PISTON RINGS

CAMSHAFT SPECIFICATIONS

DESCRIPTIONSPECIFICATION
MetricStandard
Journal Diameter.
#150.724-50.775 mm1.997-1.999 in.
#250.317-50.368 mm1.9809-1.9829 in.
#349.936-49.987 mm1.9659-1.9679 in.
#449.530-49.581 mm1.9499-1.9520 in.
Bearing Clearance-Diametrical0.025-0.101 mm0.001-0.004 in.
Bearing Clearance (Max.Allowable)0.127 mm0.005 in.
End Play0.254-0.508 mm0.010-0.020 in.
Camshaft Bearing Diameter.
#150.800-50.8251.9999-2.0009 in.
#250.393-50.419 mm1.9839-1.9849 in.
#350.013-50.038 mm1.9690-1.9699 in.
#449.606-49.632 mm1.9529-1.954 in.
Exhaust Valve Timing.
Closes-3.8L (ATDC)18°
Opens-3.8L (BBDC)46°
Duration-3.8L244°
Intake Valve Timing.
Closes-3.8L (ABDC)63°
Opens-3.8L (ATDC)1°
Duration-3.8L242°
Valve Overlap-3.8L17°

CAMSHAFT

HYDRAULIC LIFTER SPECIFICATIONS

DESCRIPTIONSPECIFICATION
MetricStandard
TypeHydraulic Roller
Outside Diameter22.949-22.962 mm0.903-0.904 in.
Clearance in Block0.020-0.061 mm0.0007-0.0024 in.

HYDRAULIC LIFTER

CYLINDER HEAD AND ENGINE VALVE SPECIFICATIONS

DESCRIPTIONSPECIFICATION
MetricStandard
Gasket Thickness (Compressed)0.65-0.75 mm0.0007-0.0024 in.

CYLINDER HEAD

DESCRIPTIONSPECIFICATION
MetricStandard
Face Angle-Intake45-45.5°
Face Angle-Exhaust45-45.5°
Head Diameter-Intake47.87-48.13 mm1.88-1.89 in.
Head Diameter-Exhaust35.37-35.63 mm1.39-1.40 in.
Valve Lift (Zero Lash)-Intake and Exhaust-3.8L11.0 mm0.433 in.
Valve Length-Intake125.84-126.6 mm4.95-4.98 in.
Valve Length-Exhaust127.20-127.965.00-5.04 in.
Valve Stem to Tip Height (valve tip to spring seat washer)-Intake48.1-49.7 mm1.89-1.95 in.
Valve Stem to Tip Height (valve tip to spring seat washer)-Exhaust48.53-50.09 mm1.91-1.97 in.

VALVES

DESCRIPTIONSPECIFICATION
MetricStandard
Angle44.5-45°
Run Out (Service Limits)0.0762 mm0.003 in.
Width-Intake and Exhaust1.50-2.00 mm0.057-0.078 in.

VALVE SEAT

DESCRIPTIONSPECIFICATION
MetricStandard
Guide Bore Diameter (Std.)6.975-7.00 mm0.274-0.275 in.

VALVE GUIDE

DESCRIPTIONSPECIFICATION
MetricStandard
Intake0.825-0.973 mm0.032-0.038 in.
Exhaust1.565-1.713 mm0.061-0.067 in.

VALVE MARGIN

DESCRIPTIONSPECIFICATION
MetricStandard
Intake (Standard)6.935-6.953 mm0.2718-0.2725 in.
Exhaust (Standard)6.906-6.924 mm0.2718-0.2725 in.

VALVE STEM DIAMETER

DESCRIPTIONSPECIFICATION
MetricStandard
Intake0.025-0.065 mm0.001-0.0025 in.
Exhaust0.059-0.094 mm0.002-0.0037 in.
Max Allowable-Intake (Rocking Method)0.247 mm0.010 in.
Max Allowable-Exhaust (Rocking Method)0.414 mm0.016 in.

VALVE STEM TO GUIDE CLEARANCE

DESCRIPTIONSPECIFICATION
MetricStandard
Free Length-Type A51.4 mm2.02 in.
Free Length-Type B53.4 mm2.10 in.
Wire Diameter Type A3.95-4.77 mm0.15-0.19 in.
Wire Diameter Type B4.19-4.29 mm0.16-0.17 in.
Number of Coils Type A7.52
Number of Coils Type B7.25
Spring Tension (Valve Closed) Type A376.4-424.4 N @ 41.9 mm84.6-95.6 lbs. @ 1.65 in.
Spring Tension (Valve Open) Type A863.9-959.9 N @ 41.9 mm194.2-215.8 lbs. @ 1.65 in.
Spring Tension (Valve Closed) Type B377-423 N @ 41.9 mm84.8-95.2 lbs. @ 1.65 in.
Spring Tension (Valve Open) Type B880-962 N @ 30.91 mm197.9-216.3 lbs. @ 122 in.
Installed Height41.1-42.7 mm1.61-1.68 in

VALVE SPRING

ENGINE PUSHROD SPECIFICATIONS

DESCRIPTIONSPECIFICATION
MetricStandard
Length135.438 mm5.33 in.

PUSH RODS

ENGINE OIL PRESSURE SPECIFICATIONS

DESCRIPTIONSPECIFICATION
MetricStandard
At Curb Idle Speed* (Minimum with engine at operating temperature)34.47 kPa5 psi
At 3000 RPM205-551 kPa30-80 psi
Oil Filter By-Pass Valve Setting62-103 kPa9-15 psi
Oil Pressure Switch Actuating Pressure14-28 Kpa2-4 psi
CAUTION: *If pressure is ZERO at curb idle, DO NOT run engine at 3000 rpm.
CAUTION
*If pressure is ZERO at curb idle, DO NOT run engine at 3000 rpm.

LUBRICATION

ENGINE OIL PUMP SPECIFICATIONS

DESCRIPTIONSPECIFICATION
MetricStandard
Clearance Over rotors-Inner and Outer0.10 mm0.004 in.
Cover Out-Of-Flat (Max.)0.025 mm0.001 in.
Inner Rotor Thickness7.64 mm0.301 in.
Outer Rotor Thickness (Min)7.64 mm0.301 in.
Outer Rotor Clearance (Max)0.039 mm0.015 in.
Outer Rotor Diameter (Min)79.95 mm3.148 in.
Tip Clearance Between Rotors (Max)0.20 mm0.008 in.

OIL PUMP

SPECIFICATIONS - TORQUE

DESCRIPTIONN.mFt. Lbs.In. Lbs.
Camshaft Sprocket-Bolt5440
Camshaft Thrust Plate-Bolts12105
Forged Connecting Rod Cap-Nuts54 +1/4 turn40 +1/4 turn
Cracked Connecting Rod Cap-BoltsRefer to PISTON & CONNECTING ROD
Crankshaft Main Bearing Cap-Bolts41 +1/4 turn30 +1/4 turn
Crankshaft Main Bearing Cap Cross Bolts (3.8L)6145
Crankshaft Oil Seal Retainer Rear-Bolts12105
Crankshaft Damper-Bolt5440
Cylinder Block Drain Plugs2015
Cylinder Head-BoltsRefer to CYLINDER HEAD .
Cylinder Head Cover-Bolts12105
Flex Plate to Crankshaft8865
Engine Mounting(Refer to ENGINE MOUNTING
Powertrain Torque Strut5440
Exhaust Manifold-Bolts23200
Exhaust Crossover Pipe-Bolts5440
Intake Manifold - Lower-Bolts23200
Intake Manifold - Lower Gasket Retainer-Bolts12105
Intake Manifold Upper-Bolts12105
Lifter Yoke Retainer-Bolts12105
Oil Filter Attaching Fitting5440
Oil Cooler Attaching Fitting2720
Oil Filter2015
Oil Filter Adapter-Bolts28250
Oil Gallery Plug2720
Oil Pan-Bolts12105
Oil Pan Drain-Plug2720
Oil Pressure Switch23200
Oil Pump Cover Plate-Screws12105
Oil Pump Pick-up Tube-Bolt28250
Oil Dipstick Housing-Bolts4835
Rocker Arm Shaft-Bolts23200
Spark Plug1612
Thermostat Housing12105
Timing Chain Case Cover...
M8 Bolt2720
M10 Bolt5440
Water Pump-Bolts12105
Water Pump Pulley-Bolts28250

Scheme 178

Scheme 178: 3.8L ENGINE
Scheme 178: 3.8L ENGINE

Scheme 179

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Scheme 180

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Scheme 200

Scheme 200
Scheme 200

Scheme 201

Scheme 201: REMOVAL
Scheme 201: REMOVAL
1 - INTAKE AIR TEMPERATURE SENSOR
2 - CRANK CASE VENTILATION HOSE
3 - BOLT

Scheme 202

Scheme 202
Scheme 202
  1. Disconnect the IAT sensor. (Scheme 201)
  2. Disconnect the CCV hose. (Scheme 201)
  3. Separate the air inlet tube from the throttle body. (Scheme 201)
  4. Remove the air cleaner cover bolts. (Scheme 201) 1 - AIR CLEANER COVER 2 - AIR CLEANER ELEMENT 3 - AIR CLEANER HOUSING
  5. Lift cover and pull toward the engine and remove cover tabs from air cleaner housing.
  6. Lift cover and remove the filter. (Scheme 202)

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