3.0l v6 Engine - VIN [3] Dodge Grand Caravan III

ENGINE IDENTIFICATION

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 corner of windshield. Engine identification number and serial number are located on rear of cylinder block, just below the cylinder head.

ENGINE IDENTIFICATION CODE

VALVE CLEARANCE ADJUSTMENT

Hydraulic valve lash adjusters are used. No valve clearance adjustment is required.

TROUBLE SHOOTING

Note. To trouble shoot mechanical engine components, see appropriate table in TROUBLE SHOOTING article in GENERAL INFORMATION.

REMOVAL & INSTALLATION

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.

FUEL PRESSURE RELEASE

Note. Diagnostic Trouble Codes (DTC) may be set when fuel pump relay is removed. Using Diagnostic Readout Box (DRB) scan tool, erase DTC.

1. Remove fuel pump relay from Power Distribution Center (PDC). PDC is located in engine compartment near battery. Start and run engine until it stalls. Attempt restarting engine until it will no longer start. Turn ignition off. Unplug connector from any injector.
2. Connect an 18-gauge (or smaller) jumper, between either injection terminal and positive battery terminal. Connect one end of a second jumper to remaining injector terminal.
3. Momentarily touch other end of second jumper to negative battery terminal (no more then 4 seconds). Place a rag or towel around quick connect fitting located at fuel rail.
4. Disconnect quick connect fitting to rail. See «FUEL LINE DISCONNECT FITTINGS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#30l-v6-engine-vin-3__fuel-line-disconnect-fittings) . Return fuel pump relay to PDC.

FUEL LINE DISCONNECT FITTINGS

Note. Some fuel lines may contain a quick disconnect fitting. (Scheme 1) Proper procedure must be used for servicing fuel line.

Removal & Installation (Plastic Retainer Type Fitting)

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#30l-v6-engine-vin-3__fuel-pressure-release). Disconnect negative battery cable. Ensure area around fuel line and disconnect fitting is clean. Place shop towel around fuel line.
2. Pull backward on disconnect fitting while depressing plastic ring into disconnect fitting. (Scheme 1) It may be necessary to use a wrench to depress plastic ring. Separate fuel line from disconnect fitting.
3. To install, ensure plastic ring is in the outward position (away from disconnect fitting). If plastic ring is in the inward position (toward disconnect fitting), disconnect fitting must be replaced.
4. Lubricate end of fuel line with 30W engine oil. Insert fuel line into disconnect fitting until shoulder on fuel line locks in place.
5. Pull on fuel line and disconnect fitting to ensure fuel line is locked in place. If fuel line is not locked in place, ensure plastic ring is not causing locking retainer to remain in the released position. Reconnect negative battery cable. Start engine and check for leaks.

Removal & Installation (Tab Type Fitting)

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#30l-v6-engine-vin-3__fuel-pressure-release) . Disconnect negative battery cable. Ensure area around fuel line and disconnect fitting is clean. Place shop towel around fuel line.
2. Squeeze retainer tabs together and pull fuel tube/quick-connect fitting assembly off of fuel tube nipple.
3. To install, coat fuel tube nipple with clean 30 weight engine oil. Push quick-connect fitting over fuel tube until retainer seats and a click is heard.

Scheme 1

Note. Remove engine with transaxle remaining in vehicle.

Removal

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#30l-v6-engine-vin-3__fuel-pressure-release). Disconnect battery. Scribe hood hinge location on hood for installation reference. Remove hood. Drain cooling system and engine oil. Disconnect necessary coolant hoses, control cables, electrical connections and vacuum hoses.
2. Disconnect necessary fuel lines using proper procedure. See «FUEL LINE DISCONNECT FITTING»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#30l-v6-engine-vin-3__fuel-line-disconnect-fittings). Remove air cleaner and radiator/fan assembly. Raise and support vehicle.
3. Remove A/C compressor and power steering pump with hoses attached and secure aside (if equipped). Remove starter. Disconnect exhaust pipe at exhaust manifold.
4. Remove torque converter cover. Place reference mark on flexplate and torque converter for installation reference. Remove torque converter-to-flexplate bolts. Attach "C" clamp to bottom front edge of torque converter housing to secure torque converter.
5. Remove lower transaxle-to-cylinder block bolts. Lower vehicle. Support transaxle with transmission jack. Attach lifting hoist to engine. Remove remaining transaxle-to-cylinder block bolts.
6. Place reference mark on frame rail to indicate right (timing belt side) engine mount position for installation reference. Remove right engine mount-to-frame rail bolts. DO NOT remove large nut on end of right engine mount core from frame rail. (Scheme 2)
7. Remove through bolt from left (flexplate side) engine mount from inside fenderwell. Remove front engine mount through bolt. Lift engine from vehicle.

Installation

1. To install, reverse removal procedure. DO NOT tighten engine mount bolts until all bolts are installed. If vertical bolts on right or left engine mount were loosened, axle shaft length must be checked.
2. To check axle shaft length, measure distance between inner edge of outboard boot and inner edge of inboard boot at 6 o'clock position. (Scheme 3)
3. Axle shaft length must be within specification. See «AXLE SHAFT LENGTH SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#30l-v6-engine-vin-3) table. AXLE SHAFT LENGTH SPECIFICATIONS Application In. (mm) Right Axle Shaft 18.7-19.1 (475-485) Left Axle Shaft 7.2-7.6 (183-193)
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. Ensure vertical bolt in right (timing belt side) engine mount is tightened before tightening through-bolt.
5. Ensure reference mark is aligned on torque converter and flexplate. Tighten bolts/nuts to specification. See «TORQUE SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#30l-v6-engine-vin-3) table. Ensure proper procedure is used when installing fuel lines. See «FUEL LINE DISCONNECT FITTINGS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#30l-v6-engine-vin-3__fuel-line-disconnect-fittings).

Scheme 2

Scheme 3

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#30l-v6-engine-vin-3__fuel-pressure-release) under REMOVAL & INSTALLATION. Disconnect negative battery cable. Drain cooling system. Remove air cleaner hose from throttle body.
2. Remove throttle cable and transaxle kickdown linkage. Disconnect necessary electrical connections and vacuum hoses at throttle body and intake manifold.
3. Remove ignition coil from upper intake manifold. Disconnect fuel lines from fuel rail using proper procedure if fuel line uses a disconnect fitting. See «FUEL LINE DISCONNECT FITTINGS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#30l-v6-engine-vin-3__fuel-line-disconnect-fittings) under REMOVAL & INSTALLATION.
4. Remove bolts, upper air intake and gaskets. (Scheme 4) Cover intake manifold openings with shop towel.
5. Disconnect vacuum hoses from fuel rail and fuel pressure regulator. Disconnect fuel injector wiring harness connector from engine wiring harness. Remove bolts/nuts and fuel pressure regulator from fuel rail.
6. Remove bolts and fuel rail with fuel injectors from intake manifold. Disconnect coolant hoses from intake manifold. Remove nuts, washers, intake manifold and gaskets. (Scheme 4)

Scheme 4

Inspection

Inspect for clogged coolant passages in end crossovers. Check intake manifold mounting surfaces for warpage. Ensure warpage does not exceed specification. See INTAKE MANIFOLD WARPAGE table.

INTAKE MANIFOLD WARPAGE

1. Install gaskets and intake manifold. Install and tighten intake manifold nuts to specification in sequence. (Scheme 5) See «TORQUE SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#30l-v6-engine-vin-3) table.
2. Ensure fuel injector holes are clean. Lubricate fuel injector "O" rings with engine oil before installing. Install fuel rail with fuel injectors until fuel injectors are fully seated in intake manifold.
3. Install and tighten fuel rail bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#30l-v6-engine-vin-3) table. Install fuel pressure regulator on fuel rail. Install and tighten pressure regulator bolts/nuts to specification.
4. Install fuel lines on fuel rail. Reinstall vacuum hoses on fuel rail and fuel pressure regulator. Reconnect fuel injector wiring harness connector on engine wiring harness.
5. Install upper air intake gaskets on intake manifold with beaded sealant side facing upward, away from intake manifold. Install upper air intake. Install and tighten upper air intake bolts to specification in sequence. (Scheme 6)
6. To install remaining components, reverse removal procedure. Fill cooling system.

Scheme 5

Scheme 6

1. Raise and support vehicle. Disconnect exhaust pipe from rear exhaust manifold flange. Disconnect oxygen sensor wiring. Remove exhaust crossover pipe mounting bolts. (Scheme 4) Remove nuts, rear exhaust manifold and gasket.
2. Lower vehicle. Remove exhaust manifold heat shield from front exhaust manifold. Disconnect exhaust crossover pipe at front exhaust manifold. Remove nuts, front exhaust manifold and gasket.

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

To install, reverse removal procedure. Install NEW gasket with numbers 1-3-5 embossed toward the top, on rear exhaust manifold. Install NEW gasket with numbers 2-4-6 embossed toward the top, on front exhaust manifold. Tighten bolts/nuts to specification. See TORQUE SPECIFICATIONS table.

1. Disconnect negative cable from battery.
2. When removing left cylinder head cover: Remove air inlet resonator. Remove dipstick tube.
3. When removing right cylinder head cover: Remove wiper unit. Remove accessory drive belt. Disconnect generator wiring. Remove generator.
4. Relocate spark plug wires.
5. Remove vacuum connections.
6. Remove rocker cover screws and remove cover.

1. Clean cylinder head and cover mating surfaces.
2. Install new gasket.
3. Apply sealant such as Mopar Silicone Rubber Adhesive Sealant to cover ends.
4. Install cover and tighten cover bolt washer and gasket assembly. See «TORQUE SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#30l-v6-engine-vin-3__torque-specifications) .
5. Reverse removal procedures to complete installation.

1. Remove intake and exhaust manifolds. See «INTAKE MANIFOLD»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#30l-v6-engine-vin-3) and «EXHAUST MANIFOLD»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#30l-v6-engine-vin-3). Remove timing belt and camshaft sprockets. See «TIMING BELT»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#30l-v6-engine-vin-3). Remove distributor and adapter housing from cylinder head.
2. Remove rocker arm shaft assembly. See «ROCKER ARM & VALVE LASH ADJUSTER»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#30l-v6-engine-vin-3). Remove camshaft.
3. Remove cylinder head bolts in sequence. (Scheme 7) Remove cylinder head and gasket.

Scheme 7

Check cylinder head for warpage. Resurface head if warpage exceeds specification. See CYLINDER HEAD table under ENGINE SPECIFICATIONS.

1. To install, reverse removal procedure. Ensure the 10-mm Allen hex cylinder head bolts and washers are installed in correct location. (Scheme 7)
2. Install and tighten cylinder head bolts to specification in sequence, using 3 steps. See «TORQUE SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#30l-v6-engine-vin-3) table. (Scheme 7)
3. To install remaining components, reverse removal procedure. Tighten bolts/nuts to specification. See «TORQUE SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#30l-v6-engine-vin-3) table.

1. Crankshaft front seal is located in oil pump case. Timing belt and crankshaft sprocket must be removed for access to crankshaft front seal. Crankshaft front seal removal procedure not available from manufacturer.
2. To install, apply engine oil to lip on crankshaft front seal. Use Seal Installer (MB998306) to install NEW seal.

1. Disconnect negative battery cable. Remove accessory drive belts. Remove A/C compressor and power steering pump with hoses attached and secure aside (if equipped). Remove A/C compressor mounting bracket and drive belt tensioner. Remove power steering/alternator belt tensioner.
2. Raise and support vehicle. Remove right inner fender shield. Remove crankshaft pulleys and vibration damper. Lower vehicle. Support engine with floor jack. Separate right (timing belt side) engine mount from engine mount bracket located in front of timing belt cover.
3. Slightly raise engine. Remove engine mount bracket. Remove timing belt covers, noting bolt length for installation reference. Rotate engine and align timing marks on camshaft sprockets and crankshaft sprocket. (Scheme 8) If reusing timing belt, mark direction of timing belt rotation for installation reference.
4. Loosen timing belt tensioner bolt. Move timing belt tensioner away from timing belt. Remove timing belt. Note direction of flange installation on front of crankshaft, in front of crankshaft sprocket. Remove flange and crankshaft sprocket from crankshaft (if necessary).
5. If removing camshaft sprocket, hold camshaft by engaging Camshaft Sprocket Holder (MB990775) in the holes on front of camshaft sprocket. Remove camshaft sprocket bolt and washer. Remove camshaft sprocket.

Scheme 8

1. Install crankshaft sprocket (if removed). Ensure timing mark on crankshaft sprocket is facing outward. Install camshaft sprockets (if removed). Using camshaft sprocket holder, tighten camshaft sprocket bolt to specification. See «TORQUE SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#30l-v6-engine-vin-3) table.
2. Rotate timing belt tensioner counterclockwise and temporarily tighten bolt. Ensure all timing marks are aligned. (Scheme 8) Install timing belt on crankshaft sprocket while holding timing belt tight on tension side. If reusing timing belt, ensure timing belt is installed in original direction of rotation.
3. Install timing belt on front (radiator side) camshaft sprocket, water pump pulley, rear camshaft sprocket and then on timing belt tensioner. Ensure timing belt is installed in this order.
4. Apply rotating force on front (radiator side) camshaft sprocket in opposite direction to apply pressure on tension side of timing belt. Ensure all timing marks align. (Scheme 8)
5. Install flange on front of crankshaft sprocket (if removed) with flat side against timing belt and offset side toward front of crankshaft. Loosen timing belt tensioner bolt, allowing spring tension to be applied on timing belt tensioner and timing belt.
6. Rotate crankshaft clockwise 2 full revolutions. DO NOT rotate crankshaft counterclockwise. Realign all timing marks. Tighten timing belt tensioner bolt to specification. See «TORQUE SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#30l-v6-engine-vin-3) table.
7. To install remaining components, reverse removal procedure. Ensure timing belt cover bolts are installed in original location. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#30l-v6-engine-vin-3) table.

Note. Valve lash adjuster operation should be checked before removing rocker arm.

1. Remove air cleaner assembly. Disconnect negative battery cable. Disconnect spark plug wires. Remove valve covers and gaskets.
2. To check valve lash adjuster operation, insert a small wire through air bleed hole at top of rocker arm, directly above valve lash adjuster. Lightly push valve lash adjuster check ball downward.
3. With check ball held downward, move rocker arm up and down to check for rocker arm free play. Replace valve lash adjuster if no rocker arm free play exists.
4. To remove rocker arms and valve lash adjusters, install valve lash adjuster retainers on rocker arms. (Scheme 9) Remove distributor drive adapter.
5. Loosen, but DO NOT remove, camshaft bearing cap bolts. Mark location of rocker arms for installation reference. Camshaft bearing caps are numbered for location. (Scheme 11) Remove rocker arms, shafts and camshaft bearing caps as an assembly.

Scheme 9

Scheme 10

1. Ensure intake valve rocker arm shaft has a.12" (3.0 mm) oil hole in bottom of shaft. (Scheme 10) Exhaust valve rocker arm shaft does not have oil hole.
2. Ensure camshaft bearing cap No. 1 installed with machined portion of rocker arm shaft facing downward, toward cylinder head. This positions notch areas of rocker arm shafts upward, pointing toward outside of camshaft bearing cap. (Scheme 11)
3. Apply sealant on camshaft bearing cap-to-cylinder head mating surfaces at both ends of cylinder head. (Scheme 12) Install rocker arm shaft assembly.
4. Tighten camshaft bearing cap bolts to 85 INCH lbs. (9.6 N.m) in the following order: No. 3, No. 2, No. 1 and then No. 4 camshaft bearing cap. Repeat procedure and tighten bolts to 15 ft. lbs. (20 N.m).
5. Install distributor drive adapter. Coat lip of NEW camshaft oil seal lip with grease. Install camshaft oil seal by threading Seal Installer (MD998713) into camshaft. Remove seal installer.
6. Apply silicone sealant on outer diameter of NEW camshaft plug. Using Plug Installer (MD998306), install camshaft plug in cylinder head and camshaft bearing cap. Ensure camshaft plug is positioned.020" (.50 mm) below surface of cylinder head.
7. Apply silicone sealant at front and rear camshaft bearing cap-to-valve cover gasket contact areas before installing valve cover. To install remaining components, reverse removal procedure. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#30l-v6-engine-vin-3) table.

Scheme 11

Remove timing belt. See TIMING BELT . Remove rocker arm and valve lash adjuster. See ROCKER ARM & VALVE LASH ADJUSTER . Remove camshaft and oil seals.

1. Ensure all oil holes in cylinder head are not restricted. Inspect camshaft and cylinder head journal areas for damage. Inspect distributor drive gear for damage.
2. Measure camshaft lobe height. Replace camshaft if damaged or camshaft lobe height is not within specification. See «CAMSHAFT»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#30l-v6-engine-vin-3) table under ENGINE SPECIFICATIONS.

To install, reverse removal procedure. Lubricate camshaft with engine oil before installing. Ensure proper procedure is used when installing rocker arms, as camshaft bearing caps must be properly installed. See ROCKER ARM & VALVE LASH ADJUSTER .

1. Crankshaft rear oil seal is a one-piece oil seal mounted in crankshaft rear oil seal retainer. Manufacturer lists procedure with crankshaft rear oil seal retainer removed from cylinder block.
2. Remove transaxle and flexplate for access to crankshaft rear oil seal retainer. Remove bolts and crankshaft rear oil seal retainer. It may be necessary to remove oil pan, as oil pan seals against crankshaft rear oil seal retainer. Remove oil seal from crankshaft rear oil seal retainer.

1. Using Oil Seal Installer (MD998718), install oil seal into crankshaft rear oil seal retainer. Apply engine oil to lip of oil seal.
2. Apply silicone sealant on crankshaft rear oil seal retainer-to-cylinder block surface. Install crankshaft rear oil seal retainer on cylinder block. Install and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#30l-v6-engine-vin-3) table. To install remaining components, reverse removal procedure.

1. Drain cooling system down below the thermostat level.
2. Remove thermostat housing bolts and housing (Scheme 13)
3. Remove thermostat, discard gasket and clean both gasket sealing surfaces.

Installation - 3.0L Engine

1. Center thermostat in water box pocket. check that the flange is seated correctly in the countersunk portion of the intake manifold water box (Scheme 13) and (Scheme 14)
2. Install new gasket on water box.
3. Install housing over gasket and thermostat and tighten bolts to 12 N.m (108 in. lbs.).
4. Refill the cooling system to the proper level.

Scheme 12

1. Remove timing belt. See «TIMING BELT»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#30l-v6-engine-vin-3) . Drain cooling system. Remove bolts, water pump, gasket and "O" ring on coolant inlet pipe.
2. To install, reverse removal procedure using NEW "O" ring and NEW gasket. Apply water to "O" ring before installing water pump. DO NOT apply grease to "O" ring. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#30l-v6-engine-vin-3) table.
3. To install remaining components, reverse removal procedure. Fill cooling system.

1. Oil pan removal procedure not available from manufacturer. To install, apply a.12" (3.0 mm) diameter bead of silicone sealant around edge of oil pan before installing.
2. Ensure sealant is applied in sealing surface groove and on inside of oil pan bolt holes. DO NOT allow sealant to be forced from flange area toward the flexplate. Install oil pan. Tighten bolts to specification in sequence. (Scheme 15)

Scheme 13

Cylinder Head

Check cylinder head warpage. Resurface cylinder head if warpage exceeds specification. See CYLINDER HEAD table under ENGINE SPECIFICATIONS.

Valve Springs

Check valve spring free length, out-of-square and pressure. Replace valve spring if not within specifications. See VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS.

Valve Stem Oil Seals

Valve stem oil seals must be replaced if removed for any reason. When reinstalling valves, DO NOT overcompress valve springs or valve stem oil seal may be damaged.

Valve Guides

1. Check valve guide I.D. and valve stem-to-valve guide oil clearance. Clearance must be within specification. See «CYLINDER HEAD»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#30l-v6-engine-vin-3) table under ENGINE SPECIFICATIONS.
2. Measure valve guide protrusion from top of valve guide to spring seat area on cylinder head. Valve guide protrusion should be within specification. See «CYLINDER HEAD»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#30l-v6-engine-vin-3) table under ENGINE SPECIFICATIONS. No service procedure is available from manufacturer.

Valve Seat

Check valve seat width. Grind valve seat if valve seat width is not within specification. See CYLINDER HEAD table under ENGINE SPECIFICATIONS.

Valves

Check valve margin, length and stem diameter. Replace valve if not within specifications. See VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS.

Valve Seat Correction Angles

Use 15-degree stone to lower valve seat or 65-degree stone to raise valve seat. (Scheme 16)

Scheme 14

Rocker Arm Shaft Assembly

1. Note location and direction of rocker arm components and camshaft bearing caps. Remove camshaft bearing cap bolts. Disassemble rocker arm shaft assembly. (Scheme 10)
2. Ensure intake valve rocker arm shaft has a.12" (3.0 mm) oil hole in bottom of shaft. (Scheme 10) Exhaust valve rocker arm shaft does not have oil hole.
3. Inspect components for damage. Ensure all oil holes are not clogged. Replace components if damaged. Reassemble rocker arm shaft assembly.

Valve Lash Adjuster

Valve lash adjuster is located in rocker arm. Valve lash adjuster must not be disassembled.

Piston & Rod Assembly

1. Pistons are not interchangeable from side-to-side. Piston must be installed on connecting rod so front mark "R" or "L" on top of piston mark is on the same side as front mark "72" on connecting rod. (Scheme 17)
2. Ensure connecting rod center-to-center length, bend and twist are within specification. See «CONNECTING RODS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#30l-v6-engine-vin-3) table under ENGINE SPECIFICATIONS.
3. For cylinders No. 1, 3 and 5, install pistons with front mark "R" and arrow on top of piston facing toward front (timing belt side) of engine. (Scheme 17)
4. For cylinders No. 2, 4 and 6, install piston with front mark "L" and arrow on top of piston facing toward front (timing belt side) of engine. On all cylinders, ensure front mark "72" mark on connecting rod is facing toward front of engine. (Scheme 17)

Scheme 15

Fitting Pistons

1. Measure cylinder bore diameter at .50" (12.7 mm) below top surface of cylinder bore, middle of cylinder bore and .50" (12.7 mm) from bottom of cylinder bore. Measure piston diameter .08" (2.0 mm) from bottom of piston skirt at 90 degree angle to piston pin.
2. Ensure piston diameter and clearance are within specification. See «PISTONS, PINS & RINGS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#30l-v6-engine-vin-3) table under ENGINE SPECIFICATIONS. Cylinder block can be bored for oversize pistons if not within specification. Oversize pistons are available in .010" (.25 mm), .020" (.50 mm), .030" (.75 mm) and .039" (1.00 mm) sizes.

Piston Rings

Ensure ring end gap and side clearances are within specification. See PISTONS, PINS & RINGS table under ENGINE SPECIFICATIONS. Ensure piston ring end gaps are properly positioned. (Scheme 18)

Scheme 16

Rod Bearings

1. Place cylinder number reference mark on connecting rod and cap before removing. When replacing rod bearings, ensure front mark "72" on connecting rod faces toward front (timing belt side) of engine. (Scheme 19)
2. Tighten connecting rod nuts to specification. See «TORQUE SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#30l-v6-engine-vin-3) table. Ensure bearing oil clearance and side play are within specifications. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#30l-v6-engine-vin-3) and «CONNECTING RODS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#30l-v6-engine-vin-3) tables under ENGINE SPECIFICATIONS.

Crankshaft & Main Bearings

1. Ensure main bearing cap assembly is marked with arrow facing toward the front (timing belt side) of engine for reassembly reference before removing. (Scheme 19)
2. Ensure crankshaft journal diameter, taper and out-of-round are within specification. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#30l-v6-engine-vin-3) table under ENGINE SPECIFICATIONS.
3. Upper main bearings contain oil grooves, while lower main bearings installed in main bearing cap assembly do not. Install main bearing cap assembly with arrow toward front (timing belt side) of engine.
4. Coat main bearing cap assembly bolts with oil before installing. Tighten main bearing cap assembly bolts to specification in sequence. (Scheme 19) See «TORQUE SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#30l-v6-engine-vin-3) table.
5. Ensure main bearing oil clearance and crankshaft end play are within specification. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#30l-v6-engine-vin-3) table under ENGINE SPECIFICATIONS. Replace thrust bearing if crankshaft end play is not within specification.

Scheme 17

Thrust Bearing

1. Two types of thrust bearings are used, one with positioning tabs and another without. One set of thrust bearings (one with positioning tab and one without tab) fit in cylinder block, and another set in main bearing cap assembly at No. 3 main bearing.
2. Thrust bearing without positioning tab fits on front (timing belt side) of cylinder block and rear (flexplate side) of main bearing cap assembly. Thrust bearing with positioning tab fits on rear (flexplate side) of cylinder block and on front (timing belt side) of main bearing cap assembly. Groove side on thrust bearing goes toward crankshaft.
3. Replace thrust bearing if crankshaft end play is not within specification. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#30l-v6-engine-vin-3) table under ENGINE SPECIFICATIONS.

Cylinder Block

1. Using a feeler gauge and straightedge, check cylinder block deck surface for warpage. Resurface cylinder block if warpage exceeds specification. See «CYLINDER BLOCK»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#30l-v6-engine-vin-3) table under ENGINE SPECIFICATIONS.
2. Check cylinder bore, taper and out-of-round. 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.
3. Ensure bore diameter, taper and out-of-round are within specification. See «CYLINDER BLOCK»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#30l-v6-engine-vin-3) table under ENGINE SPECIFICATIONS. Cylinder block can be bored for oversize pistons if not within specification. Oversize pistons are available in .010" (.25 mm), .020" (.50 mm), .030" (.75 mm) and .039" (1.00 mm) sizes.

ENGINE LUBRICATION SYSTEM

Crankshaft-driven oil pump provides pressurized lubrication to main oil gallery. see scheme 20

Scheme 18

Crankcase Capacity

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

Oil Pressure Specifications

Oil pressure should be 6 psi (41 kPa) at idle and 35-75 psi (241-517 kPa) at 3000 RPM with engine at normal operating temperature.

Removal & Disassembly

1. Remove timing belt and crankshaft sprocket. See «TIMING BELT»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#30l-v6-engine-vin-3). Remove oil pan and pick-up tube.
2. Remove oil pump-to-cylinder block bolts. Note bolt location and length for installation reference. Remove oil pump and gasket. Disassemble oil pump. see scheme 21 Remove crankshaft front seal from oil pump case.

1. Inspect components for damage. Measure clearance between small area of inner rotor and oil pump case. Measure outer rotor-to-oil pump case clearance between outer rotor and oil pump case.
2. With inner and outer rotors installed in oil pump case, place straightedge across oil pump case, above both rotors. Using feeler gauge, measure rotor end clearance between rotors and straightedge.
3. Ensure relief plunger slides freely in bore of oil pump case. Replace oil pump assembly if any clearance exceeds specification. See «OIL PUMP SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#30l-v6-engine-vin-3) table.

OIL PUMP SPECIFICATIONS

Reassembly & Installation

1. To reassemble, reverse disassembly procedure. Ensure components are installed in original location. Tighten screws for pump cover and plug for relief plunger to specification. See «TORQUE SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#30l-v6-engine-vin-3) table.
2. If crankshaft front seal was removed from oil pump case, use Seal Installer (MB998306) to install NEW seal. Lubricate lip of seal with oil before installing oil pump.
3. To install, reverse removal procedure using NEW gasket. Ensure proper length bolts are installed in correct locations. see scheme 21 Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#30l-v6-engine-vin-3).

Scheme 19

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

ENGINE SPECIFICATIONS

GENERAL SPECIFICATIONS

CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS

CONNECTING RODS

PISTONS, PINS & RINGS

CYLINDER BLOCK

VALVES & VALVE SPRINGS

CYLINDER HEAD

CAMSHAFT

See also:
• FUEL LINE DISCONNECT FITTINGS
• FUEL PRESSURE RELEASE
• AXLE SHAFT LENGTH SPECIFICATIONS
• TORQUE SPECIFICATIONS