3.3l v6 - VIN [r] Dodge Caravan II

ENGINE IDENTIFICATION

Note. For engine repair procedures not covered in this article, see ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION article in the GENERAL INFORMATION section.

Engine may be identified by eighth character of Vehicle Identification Number (VIN). The VIN is stamped on a plate on top of instrument panel, at lower left of windshield.

ENGINE IDENTIFICATION CODES

VALVE CLEARANCE ADJUSTMENT

Hydraulic valve lifters are used. No valve adjustment is required.

FUEL PRESSURE RELEASE

Note. For reassembly reference, label all electrical connectors, vacuum hoses and fuel lines before removal. Also place mating marks on engine hood and other major assemblies before removal.

1. Loosen fuel tank cap to release pressure. Disconnect injector wiring harness from engine wiring harness. Connect jumper wire from terminal No. 1 of injector harness to ground. (Scheme 45)
2. Connect another jumper wire to terminal No. 2 of injector harness. (Scheme 45) Touch jumper wire to positive battery terminal for no more than 5 seconds to release fuel pressure. Remove jumper wires, and reconnect wiring harness.

Scheme 45

COOLING SYSTEM BLEEDING

1. To bleed cooling system, remove engine temperature sending unit. Sending unit is located in front of cylinder head, near thermostat housing, just below spark plug wire holder.
2. Fill cooling system until coolant reaches sending unit level. Install sending unit, and tighten to 60 INCH lbs. (7 N.m). Finish filling cooling system.

ENGINE

Note. Remove engine with transaxle remaining in vehicle.

Removal

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(/dodge/caravan/ii-1990-1995/remont/mechanical/#33l-v6-vin-r__fuel-pressure-release) under REMOVAL & INSTALLATION. Disconnect negative battery cable. Scribe hood hinge location on hood for reassembly. Remove hood. Drain cooling system. Drain engine oil. Disconnect necessary coolant hoses, control cables, electrical connections and vacuum hoses.
2. Remove air cleaner and radiator/fan assembly. Wrap shop towel around fuel lines. Remove fuel lines from fuel rail by pushing inward on plastic ring, located at end of fuel line fitting, and pulling fuel line from fitting.
3. Raise and support vehicle. Remove A/C compressor and power steering pump with hoses attached, and secure aside.
4. Remove starter. Disconnect exhaust pipe at exhaust manifold. Remove torque converter cover. Mark flexplate to torque converter for reassembly reference.
5. Remove torque converter-to-flexplate bolts. Attach "C" clamp at bottom front edge of torque converter housing to secure converter.
6. Remove lower transaxle-to-cylinder block bolts. Lower vehicle. Support transaxle using floor jack. Attach lifting hoist to engine. Remove remaining transaxle-to-cylinder block bolts.
7. Place reference mark on side rail to indicate right insulator (timing chain side) position for reassembly reference. Remove right insulator-to-side rail bolts. CAUTION: Right insulator position on side rail must be marked for reassembly reference before removal to ensure proper positioning of engine. Insulator must be installed in original position.
8. Remove through bolt from left engine mount from inside fenderwell. Insulator bracket-to-transaxle bolts may be removed instead of through bolt. Remove front engine mount bolts, and lift engine from vehicle.

Scheme 46

1. To install, reverse removal procedure. DO NOT tighten engine mount bolts until all bolts are installed. If vertical bolts on right or left mount were loosened, axle shaft length must be checked.
2. To determine axle shaft length, measure distance between inner edge of outboard boot and inner edge of inboard boot at 6 o'clock position. (Scheme 46)
3. Axle shaft length must be within specification. See «AXLE SHAFT LENGTH SPECIFICATIONS»(/dodge/caravan/ii-1990-1995/remont/mechanical/#33l-v6-vin-r) table. AXLE SHAFT LENGTH SPECIFICATIONS Application In. (mm) AWD Models Right Axle Shaft 11.5-11.9 (292-302) Left Axle Shaft 9.0-9.4 (229-239) 2WD Models Right Axle Shaft 20.5-20.9 (521-531) Left Axle Shaft 9.0-9.4 (229-239)
4. Adjust axle shaft length to specification by sliding engine in slots on engine mounts. Tighten all engine mount bolts once correct axle shaft length is obtained. CAUTION: Tighten vertical bolt in right (timing chain side) mount bracket before tightening through bolt.
5. Ensure reference mark is aligned on torque converter and flexplate. Tighten bolts/nuts to specification. See «TORQUE SPECIFICATIONS»(/dodge/caravan/ii-1990-1995/remont/mechanical/#33l-v6-vin-r__torque-specifications) at end of article.
6. Lubricate fuel lines with 30W engine oil before reconnecting. Ensure fuel lines are installed by listening for a "click" sound. NOTE: Fuel supply line is a 5/16" diameter fitting and fuel return line is a 1/4" diameter fitting.
7. Fill and bleed cooling system. See «COOLING SYSTEM BLEEDING»(/dodge/caravan/ii-1990-1995/remont/mechanical/#33l-v6-vin-r__cooling-system-bleeding) under REMOVAL & INSTALLATION.

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(/dodge/caravan/ii-1990-1995/remont/mechanical/#33l-v6-vin-r__fuel-pressure-release) under REMOVAL & INSTALLATION. Disconnect negative battery cable. Drain cooling system. Remove air cleaner-to-throttle body hose.
2. Disconnect control cables and linkages at throttle body. Disconnect Automatic Idle Speed (AIS) motor and Throttle Position Sensor (TPS) wiring harness connectors at throttle body. Remove vacuum hoses from throttle body and intake manifold.
3. Disconnect vacuum hoses and EGR tube flange from air intake plenum (upper intake manifold). Disconnect wiring connectors at charge temperature sensor, MAP sensor and O2 sensor heater. Remove cylinder head-to-air intake plenum support brace.
4. Wrap shop towel around fuel lines. Remove fuel lines from fuel rail by pushing inward on plastic ring, located at end of fuel line fitting, and pulling fuel line from fitting.
5. Remove ignition coils and alternator bracket from air intake plenum. Remove air intake plenum bolts. (Scheme 47) Rotate air intake plenum back over valve cover. Cover intake manifold ports using shop towels.
6. Disconnect vacuum hose at pressure regulator. Disconnect fuel injector wiring harness from engine wiring harness. Disconnect necessary sensor wiring connectors, near fuel rail and intake manifold.
7. Remove fuel rail retaining bolts and fuel rail. Disconnect coolant hoses at intake manifold. Remove intake manifold retaining bolts in sequence, and remove intake manifold. (Scheme 48) Remove intake manifold gasket end seal retaining screws, and remove gasket.

Scheme 47

Scheme 48

Installation

1. Ensure sealing surfaces are clean. Apply 1/4" (6.4 mm) diameter drop of silicone sealant in 4 corners where intake manifold contacts cylinder head.
2. Install intake manifold gasket. Tighten intake manifold gasket end seal retaining screws to 105 INCH lbs. (12 N.m). Install intake manifold. Tighten intake manifold bolts to specification in sequence. (Scheme 48) See «TORQUE SPECIFICATIONS»(/dodge/caravan/ii-1990-1995/remont/mechanical/#33l-v6-vin-r__torque-specifications) at end of article.
3. To install remaining components, reverse removal procedure. Ensure injector holes are clean. Lubricate injector "O" rings with engine oil before installing. Install injector until firmly seated in port.
4. Install air intake plenum with bolts finger tight. Loosely install alternator bracket-to-intake manifold bolt and cylinder head-to-intake manifold brace bolts.
5. Tighten air intake plenum bolts to specification in sequence. (Scheme 47) See «TORQUE SPECIFICATIONS»(/dodge/caravan/ii-1990-1995/remont/mechanical/#33l-v6-vin-r__torque-specifications). Tighten alternator bracket and intake manifold brace bolts.
6. Lubricate fuel lines with 30W engine oil before reconnecting. Ensure fuel lines are installed by listening for a "click" sound. NOTE: Fuel supply line is a 5/16" diameter fitting and fuel return line is a 1/4" diameter fitting.
7. Fill and bleed cooling system. See «COOLING SYSTEM BLEEDING»(/dodge/caravan/ii-1990-1995/remont/mechanical/#33l-v6-vin-r__cooling-system-bleeding) under REMOVAL & INSTALLATION.

1. Raise and support vehicle. Disconnect exhaust pipe from rear exhaust manifold flange. Disconnect EGR tube from rear exhaust manifold. Disconnect O2 sensor wiring.
2. Remove alternator assembly support brace at front of exhaust manifold. Remove crossover pipe mounting bolts. Remove retaining bolts and rear exhaust manifold.
3. Lower vehicle. Remove heat shield-to-front exhaust manifold bolts. Disconnect crossover pipe at front exhaust manifold. Remove retaining bolts and front exhaust manifold.

Inspection

Check exhaust manifolds for cracks and damage and mounting surfaces for warpage. Repair or replace exhaust manifold if warpage exceeds .008" (.20 mm).

To install, reverse removal procedure. Tighten mounting bolts/nuts to specification. See TORQUE SPECIFICATIONS at end of article.

1. Remove intake manifold and exhaust manifold. See «INTAKE MANIFOLD»(/dodge/caravan/ii-1990-1995/remont/mechanical/#33l-v6-vin-r) and «EXHAUST MANIFOLD»(/dodge/caravan/ii-1990-1995/remont/mechanical/#33l-v6-vin-r) under REMOVAL & INSTALLATION. Disconnect necessary wiring and coolant hoses.
2. Remove rocker arm assembly. See «ROCKER ARMS & PUSH RODS»(/dodge/caravan/ii-1990-1995/remont/mechanical/#33l-v6-vin-r) under REMOVAL & INSTALLATION. Mark push rod location for reassembly reference. Remove push rods. Remove cylinder head bolts in sequence. (Scheme 49) Remove cylinder head.

Scheme 49

1. Check cylinder head warpage. Resurface head if warpage exceeds specification. See «CYLINDER HEAD»(/dodge/caravan/ii-1990-1995/remont/mechanical/#33l-v6-vin-r) table under ENGINE SPECIFICATIONS at end of article. CAUTION: DO NOT grind more than .008" (.20 mm) total from cylinder head surface and cylinder block deck surface.
2. Hold a straightedge across cylinder head bolt threads. If threads fail to contact straightedge in all areas, cylinder head bolts are stretched and must be replaced.

1. To install, reverse removal procedure. Ensure cylinder head gasket is installed with identification number facing away from cylinder block. Tighten cylinder head bolts to specification in sequence using 4 steps. (Scheme 49) See «TORQUE SPECIFICATIONS»(/dodge/caravan/ii-1990-1995/remont/mechanical/#33l-v6-vin-r__torque-specifications) at end of article. CAUTION: No. 9 cylinder head bolt is an 8-mm bolt and must be tightened to specification after 11-mm bolts are tightened in sequence to specification.
2. When tightening cylinder head bolts required additional 1/4 turn, torque should exceed 90 ft. lbs. (122 N.m). Replace cylinder head bolt if torque does not exceed specification.
3. To install remaining components, reverse removal procedure. Ensure proper procedure is followed when installing rocker arm assembly and push rods. See «ROCKER ARMS & PUSH RODS»(/dodge/caravan/ii-1990-1995/remont/mechanical/#33l-v6-vin-r) under REMOVAL & INSTALLATION.
4. Fill and bleed cooling system. See «COOLING SYSTEM BLEEDING»(/dodge/caravan/ii-1990-1995/remont/mechanical/#33l-v6-vin-r__cooling-system-bleeding) under REMOVAL & INSTALLATION.

Raise and support vehicle. Remove right wheel inner splash shield. Remove drive belt. Remove retaining bolt and vibration damper. Using Seal Remover (C-4991), remove seal from timing chain cover. (Scheme 50)

Using Seal Installer (C-4992), install seal until seal is even with timing chain cover surface. Using Plate (L-4524), thrust bearing/washer and bolt, install vibration damper. Tighten bolt to specification. See TORQUE SPECIFICATIONS at end of article. To install remaining components, reverse removal procedure.

Scheme 50

1. Disconnect battery cables. Drain cooling system. Disconnect coolant hoses from timing chain cover. Support engine, and remove right engine mount at timing chain cover. Remove oil pan. See «OIL PAN»(/dodge/caravan/ii-1990-1995/remont/mechanical/#33l-v6-vin-r) under REMOVAL & INSTALLATION.
2. Remove oil pump pick-up tube. Remove transaxle inspection cover (if necessary). Raise and support vehicle. Remove right wheel and inner splash shield. Remove drive belt.
3. Remove A/C compressor with hoses attached, and secure it aside. Remove A/C compressor mounting bracket. Remove retaining bolt and vibration damper. Remove idler pulley from front engine bracket on front of cylinder block. Remove engine bracket from cylinder block.
4. Note location of cam sensor, located in top of timing chain cover. Disconnect electrical connector at cam sensor. Loosen cam sensor retaining bolt enough for slot in cam sensor to slide past bolt. Pull cam sensor from timing chain cover. Remove timing chain cover retaining bolts, cover, gasket and "O" rings.

Note. Tap lightly on top of cam sensor to loosen it (if necessary). DO NOT pull on wiring harness during cam sensor removal.

Note. Install front crankshaft oil seal after installing timing chain cover to ensure oil pump engages properly.

1. Install new gasket and "O" rings on cylinder block. Rotate crankshaft so oil pump drive areas (flat areas) of crankshaft are positioned vertically.
2. Align flat areas of oil pump in timing chain cover with flat areas on crankshaft. Install timing chain cover. Ensure oil pump engages with crankshaft. Install timing chain cover retaining bolts, and tighten to specification. See «TORQUE SPECIFICATIONS»(/dodge/caravan/ii-1990-1995/remont/mechanical/#33l-v6-vin-r__torque-specifications) at end of article.
3. Using Seal Installer (C-4992), install front crankshaft oil seal until seal is even with timing chain cover surface. Using Plate (L-4524), thrust bearing/washer and bolt, install vibration damper. Tighten retaining bolt to specification. See «TORQUE SPECIFICATIONS»(/dodge/caravan/ii-1990-1995/remont/mechanical/#33l-v6-vin-r__torque-specifications) .
4. When installing cam sensor, ensure cam sensor and mounting surface is clean. If original cam sensor is installed, use NEW spacer and "O" ring. If replacement cam sensor is installed, ensure paper spacer and "O" ring are installed on cam sensor.
5. Apply engine oil to cam sensor "O" ring, and install cam sensor in timing chain cover. Hold cam sensor downward until cam sensor contacts camshaft timing gear. Tighten retaining bolt to specification while cam sensor is held downward. See «TORQUE SPECIFICATIONS»(/dodge/caravan/ii-1990-1995/remont/mechanical/#33l-v6-vin-r__torque-specifications) . Reconnect electrical connector at cam sensor.
6. To install remaining components, reverse removal procedure. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/caravan/ii-1990-1995/remont/mechanical/#33l-v6-vin-r__torque-specifications) .
7. Fill and bleed cooling system. See «COOLING SYSTEM BLEEDING»(/dodge/caravan/ii-1990-1995/remont/mechanical/#33l-v6-vin-r__cooling-system-bleeding) under REMOVAL & INSTALLATION.

1. Remove timing chain cover. See «TIMING CHAIN COVER»(/dodge/caravan/ii-1990-1995/remont/mechanical/#33l-v6-vin-r) under REMOVAL & INSTALLATION. Check timing chain stretch to determine if chain requires replacement.
2. Position measuring scale near link on timing chain at camshaft sprocket so movement can be measured. Place torque wrench on camshaft sprocket bolt. Apply 30 ft. lbs. (41 N.m) torque with cylinder heads installed or 15 ft. lbs. (20 N.m) with cylinder heads removed on camshaft sprocket bolt in direction of engine rotation. Note reading on measuring scale. NOTE: When applying torque to camshaft sprocket bolt, DO NOT allow crankshaft to move. If necessary, hold crankshaft.
3. Apply same amount of torque in opposite direction, and note amount of timing chain movement on measuring scale. If movement exceeds 1/8" (3.17 mm), replace timing chain.
4. To remove timing chain, rotate crankshaft so timing marks are aligned. (Scheme 51) Remove camshaft sprocket retaining bolt, washer, camshaft sprocket, timing chain and crankshaft sprocket.

Scheme 51

1. Install crankshaft sprocket on crankshaft. Rotate crankshaft so timing mark on crankshaft sprocket is at 12 o'clock position.
2. Install timing chain on camshaft sprocket. Position camshaft sprocket so timing mark is at 6 o'clock position. Install timing chain on crankshaft sprocket.
3. Install camshaft sprocket on camshaft. Ensure timing marks are aligned. (Scheme 51) Install washer and camshaft sprocket bolt. Tighten camshaft sprocket bolt to specification. See «TORQUE SPECIFICATIONS»(/dodge/caravan/ii-1990-1995/remont/mechanical/#33l-v6-vin-r__torque-specifications) at end of article.
4. Ensure camshaft end play is within specification. See «CAMSHAFT»(/dodge/caravan/ii-1990-1995/remont/mechanical/#33l-v6-vin-r) table under ENGINE SPECIFICATIONS at end of article. If camshaft end play is not within specification, replace thrust plate, located between camshaft sprocket and camshaft. To install remaining components, reverse removal procedure.

1. Remove air intake plenum (upper intake manifold). See «INTAKE MANIFOLD»(/dodge/caravan/ii-1990-1995/remont/mechanical/#33l-v6-vin-r) under REMOVAL & INSTALLATION. Disconnect spark plug wires. Disconnect closed ventilation system and evaporation control system components from valve cover (if necessary).
2. Remove valve cover. Remove rocker arm and shaft assembly retaining bolts. Remove rocker arm assembly. If removing push rods, mark component location for reassembly reference.

Note. If disassembling rocker arm assemblies, mark component location for reassembly reference. Components must be installed in original locations.

1. Ensure push rods are seated in valve lifters. Install rocker arm assembly in original location. Ensure steel retainers are located on retaining bolt area of rocker arm shafts.
2. Slowly tighten rocker arm shaft bolts to specification, starting at center and working out. See «TORQUE SPECIFICATIONS»(/dodge/caravan/ii-1990-1995/remont/mechanical/#33l-v6-vin-r__torque-specifications) at end of article. To install remaining components, reverse removal procedure.

1. Remove cylinder head. See «CYLINDER HEAD»(/dodge/caravan/ii-1990-1995/remont/mechanical/#33l-v6-vin-r) under REMOVAL & INSTALLATION. Remove retaining bolts, yoke retainer and aligning yoke. (Scheme 52)
2. Using Valve Lifter Remover (C-4129), remove valve lifter. Mark component location for reassembly reference.

Scheme 52

1. Inspect valve lifter roller for damage. Ensure valve lifter O.D. and oil clearance are to specification. See «VALVE LIFTERS»(/dodge/caravan/ii-1990-1995/remont/mechanical/#33l-v6-vin-r) table under ENGINE SPECIFICATIONS at end of article. Inspect valve lifter bore in cylinder block and outside surface of lifter for scoring.
2. If scoring exists, ream cylinder block bore for next oversize valve lifter. Oversize valve lifters are available in .001" (.02 mm), .008"(.20 mm) and .030" (.76 mm) sizes.

To install, reverse removal procedure. Ensure components are installed in original locations. Lubricate valve lifters with engine oil before installing. Tighten bolts to specification. See TORQUE SPECIFICATIONS at end of article.

CAMSHAFT

Note. Manufacturer lists camshaft service procedure with engine removed only.

Remove engine. See ENGINE under REMOVAL & INSTALLATION. Remove valve lifters and timing chain. See VALVE LIFTERS and TIMING CHAIN under REMOVAL & INSTALLATION. Remove camshaft thrust plate retaining bolts. Remove camshaft.

Inspect camshaft for wear. Measure camshaft journal diameter. Replace camshaft if it is not within specification. See CAMSHAFT table under ENGINE SPECIFICATIONS at end of article.

1. Lubricate camshaft with camshaft lubricant. Install camshaft. Tighten thrust plate bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/caravan/ii-1990-1995/remont/mechanical/#33l-v6-vin-r__torque-specifications) at end of article. Ensure camshaft end play is within specification. If camshaft end play is not within specification, replace thrust plate. See «CAMSHAFT»(/dodge/caravan/ii-1990-1995/remont/mechanical/#33l-v6-vin-r) table under ENGINE SPECIFICATIONS at end of article.
2. To install remaining components, reverse removal procedure. Ensure components are installed in original locations.

Removal & Installation

1. Inspect camshaft bearing for damage. Replace camshaft bearing if damaged or if I.D. is not within specification. See «CAMSHAFT»(/dodge/caravan/ii-1990-1995/remont/mechanical/#33l-v6-vin-r) table under ENGINE SPECIFICATIONS at end of article. CAUTION: Ensure No. 2 camshaft bearing aligns with oil passage to left cylinder head and No. 3 camshaft bearing aligns with oil passage to right cylinder head.
2. Use Camshaft Bearing Remover/Installer (C-3132-A) for camshaft bearing replacement. Ensure all oil holes are aligned.

1. Remove transaxle and flexplate. Using screwdriver, pry oil seal from seal retainer.
2. To install, place Oil Seal Installer (C-4681) on crankshaft. Coat oil seal O.D. with Loctite. Install oil seal over oil seal installer. Tap oil seal into seal retainer. Install flexplate and transaxle. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/caravan/ii-1990-1995/remont/mechanical/#33l-v6-vin-r__torque-specifications) at end of article.

1. Drain cooling system. Remove drive belt. Remove right front lower fender shield. Remove water pump pulley. Remove retaining bolts, water pump and "O" ring.
2. To install, reverse removal procedure using new "O" ring. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/caravan/ii-1990-1995/remont/mechanical/#33l-v6-vin-r__torque-specifications) at end of article.
3. Fill and bleed cooling system. See «COOLING SYSTEM BLEEDING»(/dodge/caravan/ii-1990-1995/remont/mechanical/#33l-v6-vin-r__cooling-system-bleeding) under REMOVAL & INSTALLATION.

1. Disconnect negative battery cable. Remove engine oil dipstick. Raise and support vehicle. Drain engine oil. Remove retaining bolts, oil pan and gasket.
2. To install, reverse removal procedure. Apply silicone sealant at timing chain cover and rear crankshaft seal retainer-to-cylinder block junction areas before installing gasket. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/caravan/ii-1990-1995/remont/mechanical/#33l-v6-vin-r__torque-specifications) at end of article.

Cylinder Head

Inspect cylinder head for cracks and warpage. Repair or replace cylinder head if warpage exceeds specification. See CYLINDER HEAD table under ENGINE SPECIFICATIONS at end of article.

Valve Springs

1. Check valve spring free length and pressure. Replace valve spring if it is not within specification. See «VALVES & VALVE SPRINGS»(/dodge/caravan/ii-1990-1995/remont/mechanical/#33l-v6-vin-r) table under ENGINE SPECIFICATIONS at end of article.
2. Measure valve spring installed height from spring seat to bottom of spring retainer. If spacers are installed, measure from top of spacer. If height exceeds 1.594" (40.50 mm), install a .031" (.80 mm) thick spacer in cylinder head counterbore to obtain correct installed height. See «VALVES & VALVE SPRINGS»(/dodge/caravan/ii-1990-1995/remont/mechanical/#33l-v6-vin-r) table.

Valve Stem Oil Seals

Ensure oversize valve stem seals are used when oversize valves are installed.

Valve Guides

1. Check valve stem oil clearance. Ensure valve stem diameter is within specification. Valve guide must be reamed for valve with oversize valve stem if oil clearance exceeds specification. See «CYLINDER HEAD»(/dodge/caravan/ii-1990-1995/remont/mechanical/#33l-v6-vin-r) table under ENGINE SPECIFICATIONS at end of article. NOTE: DO NOT ream valve guides from standard to maximum oversize in one step. Ream valve guides to oversize in gradual steps so guides are reamed true in relation to valve seat. After reaming valve guides, valve seat runout must be checked.
2. Valves are available with oversize valve stems of .006" (.15 mm), .016" (.40 mm) and .031" (.80 mm). Cylinder head must be replaced if guide cannot be cleaned using a .031" (.80 mm) reamer.

Valve Seat

Check valve seat width and runout. Grind valve seat if it is not within specification. See CYLINDER HEAD table under ENGINE SPECIFICATIONS at end of article. Cylinder head must be replaced if valve seat cannot be corrected.

Valves

Ensure valve margin, head diameter, refinish length and stem diameter are within specification. See VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS at end of article. Valves are available with oversize valve stems of .006" (.15 mm), .016" (.40 mm) and .031" (.80 mm).

Seat Correction Angles

Use a 15-degree stone to lower valve seat and a 65-degree stone to raise valve seat.

Piston & Rod Assembly

Install piston with notch or groove on top of piston toward front (timing chain end) of engine. Note direction of connecting rod installation on piston before removal. Connecting rod must be installed in original direction. No other information for connecting rod-to-piston installation is available.

Fitting Pistons

1. Measure piston diameter at 1.65" (41.9 mm) from top of piston at 90-degree angle to piston pin. Measure cylinder bore diameter at .50" (12.7 mm) below top surface of cylinder bore, middle of bore and .50" (12.7 mm) from bottom of cylinder bore. NOTE: Piston diameter and cylinder bore should be measured at room temperature of approximately 70°F (21°C).
2. Ensure piston diameter and clearance are within specification. See «PISTONS, PINS & RINGS»(/dodge/caravan/ii-1990-1995/remont/mechanical/#33l-v6-vin-r) table under ENGINE SPECIFICATIONS at end of article.

Piston Rings

Ensure ring end gap and side clearances are within specification. See PISTONS, PINS & RINGS table under ENGINE SPECIFICATIONS at end of article. Ensure piston ring end gaps are properly positioned. (Scheme 53)

Scheme 53

Rod Bearings

1. Before installing rod bearings, hold a straightedge across threads of connecting rod bolts. If threads fail to contact straightedge in all areas, bolts are stretched and must be replaced.
2. Apply light coat of engine oil to connecting rod bolt threads before tightening nut to specification. See «TORQUE SPECIFICATIONS»(/dodge/caravan/ii-1990-1995/remont/mechanical/#33l-v6-vin-r__torque-specifications) at end of article. Ensure oil clearance and side play are within specification. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(/dodge/caravan/ii-1990-1995/remont/mechanical/#33l-v6-vin-r) and «CONNECTING RODS SPECIFICATIONS»(/dodge/caravan/ii-1990-1995/remont/mechanical/#33l-v6-vin-r) tables under ENGINE SPECIFICATIONS at end of article.

Crankshaft & Main Bearings

1. Before installing main bearings, hold a straightedge across threads of main bearing cap bolts. If threads fail to contact straightedge in all areas, bolts are stretched and must be replaced. CAUTION: Crankshaft journal grinding should not exceed .012"(.30 mm) undersize. DO NOT grind thrust surfaces of No. 2 main bearing. With cast iron crankshafts, final paper or cloth polishing after regrind must be done in same direction as engine rotation.
2. Apply light coat of engine oil to threads before tightening bolt to specification. See «TORQUE SPECIFICATIONS»(/dodge/caravan/ii-1990-1995/remont/mechanical/#33l-v6-vin-r__torque-specifications) at end of article. Ensure oil clearance and end play are within specification. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(/dodge/caravan/ii-1990-1995/remont/mechanical/#33l-v6-vin-r) and «CONNECTING RODS SPECIFICATIONS»(/dodge/caravan/ii-1990-1995/remont/mechanical/#33l-v6-vin-r) tables under ENGINE SPECIFICATIONS at end of article.

Thrust Bearing

Thrust bearing is located on No. 2 main bearing. Replace thrust bearing if crankshaft end play is not within specification. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS and CONNECTING RODS SPECIFICATIONS tables under ENGINE SPECIFICATIONS at end of article.

Cylinder Block

1. Check cylinder bore, out-of-round and taper. Measurements should be taken at .50" (12.7 mm) below top surface of cylinder bore, middle of bore and .50" (12.7 mm) from bottom of cylinder bore. NOTE: Cylinder bore should be measured at room temperature of approximately 70°F (21°C).
2. Bore cylinder block if it is not within specification. See «CYLINDER BLOCK»(/dodge/caravan/ii-1990-1995/remont/mechanical/#33l-v6-vin-r) table under ENGINE SPECIFICATIONS at end of article. Cylinder block warpage information is not available from manufacturer.
3. Check valve lifter bore diameter and for signs of scoring. If scoring exists or lifter bore diameter is not within specification, ream cylinder block bore for next oversize valve lifter. See «VALVE LIFTERS»(/dodge/caravan/ii-1990-1995/remont/mechanical/#33l-v6-vin-r) table under ENGINE SPECIFICATIONS at end of article.
4. Oversize valve lifters are available in .001" (.02 mm), .008" (.20 mm) and .030" (.76 mm) sizes.

ENGINE OILING SYSTEM

Crankshaft-driven oil pump provides lubrication to main gallery. (Scheme 54)

Crankcase Capacity

Crankcase capacity with oil filter is 4.5 qts. (4.3L).

Oil Pressure

Oil pressure should be 5 psi (.35 kg/cm 2 ) at curb idle and 30-80 psi (2.1-5.6 kg/cm 2 ) at 3000 RPM.

Scheme 54

OIL PUMP

Note. Oil pan and timing chain cover must be removed to service oil pump. Pressure relief valve can be serviced by removing oil pan and pick-up tube only.

Removal & Disassembly

1. If servicing oil pump, remove oil pan. See «OIL PAN»(/dodge/caravan/ii-1990-1995/remont/mechanical/#33l-v6-vin-r) under REMOVAL & INSTALLATION. Remove pick-up tube. Remove timing chain cover. See «TIMING CHAIN COVER»(/dodge/caravan/ii-1990-1995/remont/mechanical/#33l-v6-vin-r) under REMOVAL & INSTALLATION.
2. To service pressure relief valve, drill a 1/8" (3.175 mm) hole in relief valve retainer cap. Retainer cap is located at oil pan surface of timing chain cover, near oil pan stud.
3. Install a self-tapping screw into hole. If timing chain cover is installed, pull self-tapping screw to remove retainer cap.
4. If timing chain cover is removed, clamp self-tapping screw in a vise. Support timing chain cover while lightly tapping on timing chain cover using soft-faced hammer until retainer cap is removed.
5. Remove spring and pressure relief valve. Remove retaining bolts and pump cover. Note direction of rotor installation for reassembly reference. Remove inner and outer rotors. (Scheme 55)

Scheme 55

1. Inspect components for damage. Using straightedge and feeler gauge, check pump cover warpage. Replace pump cover if clearance equals or exceeds specification. See «OIL PUMP SPECIFICATIONS»(/dodge/caravan/ii-1990-1995/remont/mechanical/#33l-v6-vin-r) table.
2. Measure thickness of both rotors and outer rotor O.D. Replace rotors if not within specification.
3. Install outer rotor in timing chain cover. Measure clearance between outer rotor and timing chain cover. If clearance equals or exceeds specification but outer rotor O.D. is within specification, replace timing chain cover.
4. Install inner rotor, and measure clearance between inner and outer rotors. Replace pump assembly if clearance is equal to or exceeds specification.
5. Place straightedge across timing chain cover surface. Using feeler gauge, check rotor end clearance between rotors and straightedge. Replace pump if clearance is equal to or exceeds specification.
6. Ensure pressure relief valve slides freely in bore. Check pressure relief valve spring free length and pressure. Replace spring if not within specification.

OIL PUMP SPECIFICATIONS

Reassembly & Installation

To reassemble, reverse disassembly procedure. Install new retainer cap. Tighten pump cover bolts to specification. See TORQUE SPECIFICATIONS at end of article. Fill rotor cavity with engine oil before installing. To install, reverse removal procedure.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

ENGINE SPECIFICATIONS

GENERAL SPECIFICATIONS

CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS SPECIFICATIONS

CONNECTING RODS SPECIFICATIONS

PISTONS, PINS & RINGS SPECIFICATIONS

CYLINDER BLOCK SPECIFICATIONS

VALVES & VALVE SPRINGS SPECIFICATIONS

CYLINDER HEAD SPECIFICATIONS

CAMSHAFT SPECIFICATIONS

VALVE LIFTERS SPECIFICATIONS

See also:
• ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION
• FUEL PRESSURE RELEASE
• AXLE SHAFT LENGTH SPECIFICATIONS
• TORQUE SPECIFICATIONS
• COOLING SYSTEM BLEEDING
• ENGINE