3.8l v6 Engine - VIN [l] Dodge Grand Caravan III

ENGINE IDENTIFICATION

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

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. See ENGINE IDENTIFICATION CODE table. Engine identification number and serial number are located on rear of cylinder block, just below the cylinder head.

ENGINE IDENTIFICATION CODE

GEARSHIFT CABLE ADJUSTMENT (A/T)

1. Place gear selector in Park position and remove ignition key from cylinder. If key is easily removed from cylinder, turn ignition switch to start position. If starter operates, Park position is correct. If starter does not operate, go to next step.
2. Move gear selector lever to Neutral position. Turn ignition switch to start position. If starter operates, linkage is adjusted properly. If starter does not operate, go to next step.
3. Park vehicle on a level surface and set parking brake. Place gear selector lever to Park position and remove key. Loosen cable adjustment screw at transaxle operating lever. Pull transaxle operating lever fully forward to park detent position.
4. Release park brake. Rock vehicle to assure it is in park lock. Reset park brake. Tighten cable adjustment screw. Verify gear selection indicator corresponds with gear position. If gear selection indicator does not correspond with gear position, repeat gearshift cable adjustment procedure.

VALVE CLEARANCE ADJUSTMENT

Hydraulic valve lifters 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

1. Disconnect negative battery cable. Remove fuel filler cap. Remove cap from pressure test port on fuel rail. (Scheme 34) Place shop towels around pressure test port to absorb spilled fuel.
2. Connect Fuel Pressure Gauge (5069) to pressure test port. Place other end of hose into an approved gasoline container. Release fuel pressure. Remove shop towels and dispose of properly. Install pressure test port cap.

Scheme 34

FUEL LINE & FITTING LEAK TEST

With fuel pressure on fuel line and fittings, apply a generous amount of liquid leak detector on fuel line and fitting. Watch for steady flow of bubbles at fuel line and fitting to indicate a leak. Repair fuel line or fitting as necessary if leak exists.

Removal

Note. Some fuel lines may contain a disconnect fitting. (Scheme 35) Proper procedure must be used for servicing fuel line.

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l__fuel-pressure-release). 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 35) It may be necessary to use a wrench to depress plastic ring. Separate fuel line from disconnect fitting.

Installation

1. Ensure plastic ring is in outward position (away from disconnect fitting). If plastic ring is in inward position (toward disconnect fitting), disconnect fitting must be replaced.
2. Lubricate end of fuel line with 30W engine oil. Insert fuel line into disconnect fitting until shoulder on fuel line locks in place.
3. 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.

Scheme 35

COOLING SYSTEM BLEEDING

1. To bleed cooling system, remove engine temperature sending unit. Engine temperature 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 engine temperature sending unit level. Install and tighten engine temperature sending unit to 60 INCH lbs. (6.8 N.m). Finish filling cooling system.

Note. Remove engine with transaxle remaining in vehicle.

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l__fuel-pressure-release).
2. Scribe hood hinge location on hood for reassembly. Remove hood. Remove windshield wiper unit. See «WIPER UNIT»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l). Remove battery and tray. Remove integral vacuum reservoir. Drain cooling system and engine oil. Disconnect necessary coolant hoses, control cables, electrical connections and vacuum hoses.
3. Remove air cleaner and radiator/fan assembly. Disconnect necessary fuel lines using proper procedure. See «FUEL LINE DISCONNECT FITTING»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l).
4. Raise and support vehicle. Remove A/C compressor and power steering pump with hoses attached and secure aside. Disconnect transmission shift linkages.
5. Remove starter. Disconnect exhaust pipe at exhaust manifold. Remove torque converter cover. Mark flexplate-to-torque converter location for reassembly reference.
6. Remove torque converter-to-flexplate bolts. Attach "C" clamp at bottom front edge of torque converter housing to secure torque converter.
7. 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.
8. Place reference mark on side rail to indicate right engine mount (timing chain side) position for reassembly reference. Remove right engine mount-to-side rail bolts. DO NOT remove large nut located on end of core from frame rail. (Scheme 36)
9. Remove front engine mount through-bolt. Remove through-bolt from left engine mount from inside fenderwell. Left engine mount bracket-to-transaxle bolts may be removed instead of through-bolt. Lift engine from vehicle.

Scheme 36

Scheme 37

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 determine axle shaft length, measure distance between inner edge of outboard boot and inner edge of inboard boot at 6 o'clock position. (Scheme 37)
3. Axle shaft length must be within specification. See «AXLE SHAFT LENGTH SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l) table. AXLE SHAFT LENGTH SPECIFICATIONS Application In. (mm) AWD Models Right Axle Shaft 11.5-11.9 (292-302) Left Axle Shaft 7.2-7.6 (183-193) 2WD Models 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.
5. Ensure reference mark is aligned on torque converter and flexplate. Tighten all bolts/nuts to specification. See «TORQUE SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l__torque-specifications).
6. Use proper procedure when installing fuel lines. See «FUEL LINE DISCONNECT FITTING»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l).
7. Fill and bleed cooling system. See «COOLING SYSTEM BLEEDING»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l__cooling-system-bleeding). After installation, start engine and run until operating temperature is reached. Adjust transmission linkage if necessary.

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l__fuel-pressure-release).
2. Disconnect negative battery cable. Remove windshield wiper unit. See «WIPER UNIT»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l). Drain cooling system. Remove air cleaner-to-throttle body hose.
3. Disconnect control cables and electrical connections from throttle body. Disconnect necessary vacuum hoses from throttle body and intake manifold.
4. Disconnect vacuum hoses and EGR tube flange from air intake plenum (upper intake manifold). Disconnect necessary electrical connections for intake manifold removal. Remove cylinder head-to-air intake plenum support brace.
5. Disconnect necessary fuel lines using proper procedure. See «FUEL LINE DISCONNECT FITTING»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l).
6. Remove ignition coils and generator bracket from air intake plenum. Remove air intake plenum bolts. (Scheme 38) Rotate air intake plenum back over valve cover. Cover intake manifold ports with shop towels.
7. Disconnect vacuum hose at fuel pressure regulator.
8. Disconnect fuel injector wiring harness from engine wiring harness. Disconnect necessary sensor wiring connectors, near fuel rail and intake manifold. Remove fuel rail bolts.
9. Remove fuel rail along with fuel injectors.
10. Gently rock and pull upward on rear section of fuel rail until fuel injectors clear the intake manifold. Gently rock and pull upward on front section of fuel rail until fuel injectors clear the intake manifold. Remove fuel rail along with fuel injectors.
11. Disconnect coolant hoses at intake manifold. Remove intake manifold bolts in sequence. (Scheme 39) Remove intake manifold. Remove intake manifold gasket end seal retaining screws, and remove gasket.

Scheme 38

Scheme 39

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 bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l__torque-specifications). Install intake manifold. Tighten intake manifold bolts to specification in sequence. (Scheme 39) See TORQUE SPECIFICATIONS table.
3. To install remaining components, reverse removal procedure. Lubricate fuel injector "O" rings with engine oil before installing.
4. Install fuel injector until firmly seated in port on intake manifold. Install and tighten fuel rail bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l__torque-specifications).
5. Install gasket and air intake plenum with bolts finger tight. Loosely install generator bracket-to-intake manifold bolt and cylinder head-to-intake manifold brace bolts.
6. Tighten air intake plenum bolts to specification in sequence. (Scheme 38) See «TORQUE SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l__torque-specifications). Tighten generator bracket and intake manifold brace bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l__torque-specifications).
7. Use proper procedure when installing fuel lines. See «FUEL LINE DISCONNECT FITTING»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l). Fill and bleed cooling system. See «COOLING SYSTEM BLEEDING»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l__cooling-system-bleeding).

1. Disconnect negative battery cable. Remove accessory drive belt and generator. 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 generator assembly support brace at front of exhaust manifold. Remove exhaust crossover pipe mounting bolts. Remove bolts and rear exhaust manifold. Remove heat shield from rear engine mount. Remove generator/power steering support strut.
3. Lower vehicle. Remove heat shield-to-front exhaust manifold bolts. Disconnect exhaust crossover pipe at front exhaust manifold. Remove bolts and front exhaust manifold.

Inspection

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

To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS .

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l__fuel-pressure-release) .
2. Disconnect negative battery cable. Remove air cleaner cover and hose. Remove plenum chamber. See «INTAKE MANIFOLD»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l) . Remove valve cover and spark plugs. Remove ignition coil connector. Using breaker bar, turn crankshaft pulley retaining bolt. Place No. 1 piston to TDC. Remove rocker arms with rocker shaft and install a dummy shaft.
3. Install spark plug adapter into No. 1 cylinder spark plug hole. Attach air hose to spark plug adapter. Apply 90-100 psi (621-689 kPa) of air pressure to hose. Air pressure will hold valves in place while servicing components. Using Valve Spring Compressor (C-4682), compress valve springs. Remove valve retainer locks. Remove valve springs and seals. Follow same procedure on remaining 5 cylinders using firing sequence of 1-2-3-4-5-6.

To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS .

1. Drain engine coolant. Remove intake manifold and exhaust manifold. See «INTAKE MANIFOLD»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l) and «EXHAUST MANIFOLD»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l). Disconnect necessary wiring and coolant hoses. Remove PCV hoses and evaporation control system hose.
2. Remove rocker arm assembly. See «ROCKER ARMS & PUSH RODS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l). Mark push rod location for reassembly reference. Remove push rods. Remove cylinder head bolts in sequence. (Scheme 40) Remove cylinder head.

Scheme 40

1. Check cylinder head warpage. Resurface or replace cylinder head if warpage exceeds specification. See «CYLINDER HEAD SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l) table under ENGINE SPECIFICATIONS.
2. Hold a straightedge across threads of cylinder head bolt. 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.
2. Install and tighten cylinder head bolts to specification in sequence using 4 steps. (Scheme 40) See «TORQUE SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l__torque-specifications).
3. When tightening cylinder head bolts that require an additional 1/4 turn, torque should exceed 90 ft. lbs. (122 N.m). Replace cylinder head bolt if torque does not exceed specification.
4. 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/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l).
5. Fill and bleed cooling system. See «COOLING SYSTEM BLEEDING»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l__cooling-system-bleeding).

Raise and support vehicle. Remove right wheel and inner splash shield. Remove drive belt. Remove bolt and vibration damper. Using Seal Remover (C-4991), remove front cover oil seal from timing chain cover. (Scheme 41)

1. Install front cover oil seal on crankshaft with spring side of oil seal toward the engine. Using Oil Seal Installer (C-4992), install front cover oil seal until oil seal is even with surface of timing chain cover.
2. Using Plate (L-4524), thrust bearing/washer and bolt, install vibration damper. Remove plate, thrust bearing/washer and bolt. Install and tighten vibration damper bolt to specification. See «TORQUE SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l__torque-specifications) . To install remaining components, reverse removal procedure.

Scheme 41

1. Disconnect battery cables. Drain cooling system. Disconnect coolant hoses from timing chain cover. Support engine. Remove right engine mount at timing chain cover. Remove oil pan. See «OIL PAN»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l) .
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 aside. Remove A/C compressor mounting bracket. Remove bolt and vibration damper. Remove idler pulley from engine bracket on front of cylinder block. Remove engine bracket from cylinder block.
4. Note location of camshaft position sensor, located in top of timing chain cover. Disconnect electrical connector at camshaft position sensor. Loosen camshaft position sensor bolt enough for slot in camshaft position sensor to slide past bolt.
5. Pull camshaft position sensor from timing chain cover. Remove bolts, timing chain cover, gasket and "O" rings. Remove front cover oil seal from timing chain cover.

1. Install NEW gasket and "O" rings on timing chain cover. Ensure gasket is even with lower edge of timing chain cover. 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 and tighten timing chain cover bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l__torque-specifications) .
3. Install front cover oil seal on crankshaft with spring side of oil seal toward the engine. Using Oil Seal Installer (C-4992), install front cover oil seal until oil seal is even with surface of timing chain cover.
4. Using Plate (L-4524), thrust bearing/washer and bolt, install vibration damper. Remove plate, thrust bearing/washer and bolt. Install and tighten vibration damper bolt to specification. See «TORQUE SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l__torque-specifications) .
5. Install engine bracket. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l__torque-specifications) . Install idler pulley.
6. Ensure camshaft position sensor and mounting surface is clean. If installing original camshaft position sensor, use NEW paper spacer on end of camshaft position sensor. Install NEW "O" ring on camshaft position sensor. If installing replacement camshaft position sensor, ensure paper spacer is located on end of camshaft position sensor and "O" ring is installed on camshaft position sensor.
7. Apply engine oil to "O" ring on camshaft position sensor. Install camshaft position sensor in timing chain cover. Hold camshaft position sensor downward until camshaft position sensor contacts camshaft sprocket.
8. Install and tighten bolt to specification while holding camshaft position sensor downward. See «TORQUE SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l__torque-specifications) . Reconnect electrical connector at camshaft position sensor. Ensure electrical connector is positioned away from drive belt.
9. To install remaining components, reverse removal procedure. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l__torque-specifications) . Fill and bleed cooling system. See «COOLING SYSTEM BLEEDING»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l__cooling-system-bleeding) .

1. Remove timing chain cover. See «TIMING CHAIN COVER»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l). Check timing chain stretch to determine if timing chain replacement is required.
2. Position measuring scale near link on timing chain at camshaft sprocket so movement can be measured. Place torque wrench on camshaft sprocket bolt. The proper amount of torque must be applied on camshaft sprocket bolt in normal direction of engine rotation. Apply 30 ft. lbs. (41 N.m) torque with cylinder heads installed or 15 ft. lbs. (20 N.m) torque with cylinder heads removed. Note reading on measuring scale.
3. Apply same amount of torque in opposite direction. Note amount of timing chain movement on measuring scale. Replace timing chain if movement exceeds 1/8" (3.17 mm).
4. To remove timing chain, rotate crankshaft so timing arrows are aligned. (Scheme 42) Remove camshaft sprocket bolt, washer, camshaft sprocket and timing chain. Using puller, remove crankshaft sprocket from crankshaft (if necessary).

1. Install crankshaft sprocket on crankshaft with timing arrow facing outward (if removed). Ensure crankshaft sprocket is fully seated on crankshaft. Rotate crankshaft so timing arrow on crankshaft sprocket is at 12 o'clock position.
2. Install timing chain on camshaft sprocket so colored link on timing chain aligns with dot on camshaft sprocket. (Scheme 42) Position camshaft sprocket so timing arrow is at 6 o'clock position.
3. Install timing chain on crankshaft sprocket so colored link on timing chain aligns with dot on crankshaft sprocket. (Scheme 42)
4. Install camshaft sprocket on camshaft. Ensure timing arrows, dots and colored links are properly positioned. (Scheme 42) Install washer and camshaft sprocket bolt. Tighten camshaft sprocket bolt to specification. See «TORQUE SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l__torque-specifications).
5. Rotate crankshaft 2 full revolutions. Ensure timing arrows, dots and colored links are properly positioned. Ensure camshaft end play is within specification. See «CAMSHAFT SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l) table under ENGINE SPECIFICATIONS.
6. If camshaft end play is not within specification, replace camshaft thrust plate, located between camshaft sprocket and camshaft. To install remaining components, reverse removal procedure.

Scheme 42

1. Remove wiper arms. Remove cowl cover. Release hood latch and open good. Disconnect wiper unit wire connector from engine compartment wire harness. Disconnect windshield washer hose from coupling inside unit.
2. Disconnect drain tubes. Remove nuts holding wiper unit to lower windshield fence. Remove bolts holding wiper unit to dash panel. Lift wiper unit from weld-studs on lower windshield fence.

To install, reverse removal procedure. Ensure components are installed in original location. Tighten bolts to specification. See TORQUE SPECIFICATIONS .

1. Remove air intake plenum (upper intake manifold). See «INTAKE MANIFOLD»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l) . 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 shaft bolts. Remove rocker arm assembly. If removing push rods, mark push rod location for reassembly reference.

1. Ensure push rods are seated in valve lifters. Install rocker arm assembly in original location. Ensure steel retainers are located on bolt area of rocker arm shafts.
2. Slowly tighten rocker arm shaft bolts to specification, starting at center and working outward. See «TORQUE SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l__torque-specifications) . To install remaining components, reverse removal procedure.

1. Remove cylinder head. See «CYLINDER HEAD»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l__cylinder-head). Remove bolts, yoke retainer and aligning yoke. (Scheme 43)
2. Using Valve Lifter Remover (C-4129), remove valve lifter. Mark valve lifter location for reassembly reference.

1. Inspect valve lifter roller for damage. Ensure valve lifter O.D., oil clearance and cylinder block bore diameter is within specification. See «VALVE LIFTERS SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l) table under ENGINE SPECIFICATIONS. Inspect valve lifter bore in cylinder block and outside surface of valve lifter for scoring.
2. If scoring exists or bore diameter is not within specification, 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 location. Lubricate valve lifters with engine oil before installing. Tighten bolts to specification. See TORQUE SPECIFICATIONS .

Scheme 43

1. Remove engine. See «ENGINE»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l) . Remove valve lifters and timing chain. See «VALVE LIFTERS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l__valve-lifters) and «TIMING CHAIN»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l) .
2. Remove camshaft thrust plate from front of camshaft. Remove camshaft, using care not to damage camshaft lobes and camshaft bearings.

Inspect camshaft for wear. Replace camshaft if journal diameter is not within specification. See CAMSHAFT SPECIFICATIONS table under ENGINE SPECIFICATIONS.

1. Lubricate camshaft with camshaft lubricant. Install camshaft. Install and tighten camshaft thrust plate bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l__torque-specifications) .
2. Ensure camshaft end play is within specification. Replace camshaft thrust plate if camshaft end play is not within specification. See «CAMSHAFT SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l) table under ENGINE SPECIFICATIONS.
3. To install remaining components, reverse removal procedure. Ensure components are installed in original location.

1. Inspect camshaft bearing for damage. Replace camshaft bearing if damaged or if I.D. is not within specification. See «CAMSHAFT SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l) table under ENGINE SPECIFICATIONS.
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 crankshaft rear oil seal retainer.
2. To install, place Oil Seal Installer (C-4681) on crankshaft. Coat outside diameter of oil seal with Loctite. Install oil seal over oil seal installer. Tap oil seal into crankshaft rear oil seal retainer. Remove oil seal installer. Install flexplate and transaxle.

1. Disconnect negative battery cable from battery.
2. Drain cooling system.
3. Remove air intake resonator.
4. Remove coolant reserve system tank to filler neck tube hose.
5. Disconnect fans from the connector located on the left side of the fan module.
6. Remove the Coolant Recovery System (CRS) tank retaining screw from the upper radiator closure panel crossmember.
7. Disconnect the upper radiator mounting screws from the crossmember. Disconnect the engine block heater wire if equipped.
8. Remove the upper radiator closure panel crossmember.
9. Remove air cleaner assembly.
10. Disconnect automatic transmission lines from the transmission and plug lines.
11. Disconnect inlet and outlet hoses from the radiator. Remove the lower hose clip from the fan module.
12. Remove A/C condenser fasteners and separate the condenser from the radiator. Verify the condenser is supported in position.
13. Remove A/C filter/dryer mounting bracket, 2 bolts to the fan module and 2 nuts to the filter/dryer, and remove bracket.
14. Radiator can now be lifted free from engine compartment. Care should be taken not to damage radiator cooling fins or water tubes during removal.

1. Be sure the air seals are in position before radiator is installed. Slide radiator down into position behind closure panel. Seat the radiator with the rubber isolators into the mount holes provided, with a 10 lbs. force.
2. Install filter/dryer and mounting bracket onto fan module.
3. Install Air Conditioning Condenser onto the radiator.
4. Unplug lines and connect automatic transmission lines to transmission.
5. Install inlet and outlet radiator hoses (including coolant reserve hose) and connect the fan motor electrical connection.
6. Install air cleaner assembly.
7. Install the upper radiator closure panel crossmember.
8. Install the upper radiator mounting screws. Tighten radiator mounting bolts to 12 N.m (105 in. lbs.). Connect the engine block heater wire if equipped.
9. Install the Coolant Recovery System (CRS) tank retaining screw to the upper radiator closure panel crossmember.
10. Install air intake resonator.
11. Fill cooling system. Refer to «COOLING SYSTEM SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/cooling-system-mechanical/#engine-cooling-system-specifications) .
12. Connect negative battery cable

Turn the draincock stem counterclockwise to unscrew the stem. When the stem is unscrewed to the end of the threads turn back 1/8 turn and, pull the stem from the radiator tank.

Push the draincock assembly body into the tank opening until it snaps into place. Tighten the draincock stem by turning clockwise until it stops.

1. Drain cooling system down below the thermostat level.
2. Remove thermostathousing bolts and housing (Scheme 44)
3. Remove thermostat, discard gasket and clean both gasket sealing surfaces.

1. Place a new gasket (dipped in water) on the water box surface, center thermostat into opening in the intake manifold.
2. Place housing over gasket and thermostat, making sure thermostat is in recess provided (Scheme 44)
3. Bolt housing to intake manifold, tighten bolts to 28 N.m (250 in. lbs.).
4. Refill the cooling system to the proper level.

1. Drain cooling system. Remove drive belt. Remove right front lower fender shield. Remove water pump pulley. Remove bolts, water pump and "O" ring.
2. To install, reverse removal procedure. Use NEW "O" ring. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l__torque-specifications) . Fill and bleed cooling system. See «COOLING SYSTEM BLEEDING»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l__cooling-system-bleeding) under REMOVAL & INSTALLATION.

1. Disconnect negative battery cable. Remove engine oil dipstick. Raise and support vehicle. Drain engine oil. Remove bolts, oil pan and gasket.
2. To install, reverse removal procedure. Use a NEW gasket. Apply silicone sealant at timing chain cover and rear crankshaft oil seal retainer-to-cylinder block junction areas before installing NEW gasket. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l__torque-specifications) .

Cylinder Head

Inspect cylinder head for cracks and warpage. Resurface or replace cylinder head if warpage exceeds specification. See CYLINDER HEAD SPECIFICATIONS table under ENGINE SPECIFICATIONS.

Valve Springs

1. Check valve spring free length and pressure. Replace valve spring if not within specification. See «VALVES & VALVE SPRINGS SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l) table under ENGINE SPECIFICATIONS.
2. Measure valve spring installed height from top of spring seat to bottom of spring retainer. If valve spring installed height exceeds 1.681" (42.70 mm), install a .031" (.79 mm) thick spacer in cylinder head counterbore to obtain correct installed height. See «VALVES & VALVE SPRINGS SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l) table under ENGINE SPECIFICATIONS.

Valve Stem Oil Seals

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

Valve Guides

1. Check valve stem-to-guide oil clearance. Ensure valve stem diameter is within specification. Ensure valve guide I.D. and oil clearance is within specification.
2. Valve guide must be reamed for valve with oversize valve stem if oil clearance or valve guide I.D. exceeds specification. See «CYLINDER HEAD SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l) table under ENGINE SPECIFICATIONS.
3. Valves are available with oversize valve stems of .005" (.13 mm), .015" (.38 mm) and .030" (.76 mm). Cylinder head must be replaced if valve guide cannot be repaired using a .030" (.76 mm) reamer.

Valve Seat

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

Valves

1. Ensure valve margin, head diameter, refinish length and stem diameter are within specification. See «VALVES & VALVE SPRINGS SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l) table under ENGINE SPECIFICATIONS. Valves are available with oversize valve stems of .005" (.13 mm), .015" (.38 mm) and .030" (.76 mm).
2. Once valve and valve spring is installed in cylinder head, valve tip height must be checked. Measure distance from tip of valve stem to surface on cylinder head, just below the spring seat.
3. Valve tip height should be within specification. See «VALVES & VALVE SPRINGS SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l) table under ENGINE SPECIFICATIONS. Grind end of valve stem to obtain correct valve tip height (if necessary).

Valve Seat Correction Angles

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

Valve Lifters

1. Inspect valve lifter roller for damage. Ensure valve lifter O.D., oil clearance and cylinder block bore diameter is within specification. See «VALVE LIFTERS SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l) table under ENGINE SPECIFICATIONS. Inspect valve lifter bore in cylinder block and outside surface of valve lifter for scoring.
2. If scoring exists or bore diameter is not within specification, 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.

Piston & Rod Assembly

1. 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.
2. Before installing piston and rod assembly, 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. Install piston with notch or groove on top of piston toward front (timing chain end) of engine.

Fitting Pistons

1. Measure piston diameter, at 90-degree angle to piston pin, at 1.42" (36.0 mm) from top of piston. 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.
2. Ensure piston diameter and clearance are within specification. See «PISTONS, PINS & RINGS SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l) table under ENGINE SPECIFICATIONS.

Piston Rings

Ensure ring end gap and side clearances are within specification. Using feeler gauge, measure ring gap with ring in position at least.50" (12.7 mm) from bottom of cylinder bore. See PISTONS, PINS & RINGS SPECIFICATIONS table under ENGINE SPECIFICATIONS. Install piston rings on piston with identification mark on ring toward top of piston. Ensure piston ring end gaps are properly positioned. (Scheme 45)

Scheme 44

Rod Bearings

Note. Install bearings halves in pairs. DO NOT use a new bearing half with old bearing half. DO NOT file rods or bearing caps.

1. Place reference mark on connecting rod and rod cap for reassembly reference if no mark exists. 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. Install bearing shells with tangs inserted into machined grooves in rods and caps. Install cap with tangs on same side as rod.
2. Apply light coat of engine oil to connecting rod bolt threads before tightening nut to specification. See «TORQUE SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l__torque-specifications) . Ensure oil clearance and side play are within specification. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l) and «CONNECTING RODS SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l) tables under ENGINE SPECIFICATIONS.

Crankshaft & Main Bearings

1. Ensure main bearing caps are marked for location in cylinder block for reassembly reference before removing. Ensure crankshaft journal diameter, taper and out-of-round are within specification. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l) table under ENGINE SPECIFICATIONS. CAUTION: Crankshaft main bearing journal grinding should not exceed .012" (.30 mm) undersize. DO NOT grind thrust surfaces of No. 2 main bearing journal. With cast iron crankshafts, final paper or cloth polishing after regrind must be done in same direction as engine rotation.
2. 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.
3. Apply light coat of engine oil to main bearing cap bolt threads before tightening bolt to specification. See «TORQUE SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l__torque-specifications) . Ensure oil clearance and crankshaft end play are within specification. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l) table under ENGINE SPECIFICATIONS.
4. During final reassembly, ensure proper procedure is used for thrust bearing alignment. See «THRUST BEARING»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l__thrust-bearing) .

Thrust Bearing

1. 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 SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l) table under ENGINE SPECIFICATIONS.
2. To obtain correct thrust bearing alignment, install all main bearing cap bolts finger tight. Tighten main bearing cap bolts to specification on No. 1, 3 and 4 main bearing caps. See «TORQUE SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l__torque-specifications) .
3. Pry crankshaft toward rear of cylinder block, and then back toward front of cylinder block. Hold crankshaft in forward position. Tighten main bearing cap bolts to specification on No. 2 main bearing cap.

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.
2. Replace cylinder block if not within specification. See «CYLINDER BLOCK SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l) table under ENGINE SPECIFICATIONS. Cylinder block deck surface 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 SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l) table under ENGINE SPECIFICATIONS. Oversize valve lifters are available in .001" (.02 mm), .008" (.20 mm) and .030" (.76 mm) sizes.

ENGINE LUBRICATION SYSTEM

Crankshaft-driven oil pump provides lubrication to main gallery. (Scheme 46)

Crankcase Capacity

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

Oil Pressure

Oil pressure should be 5 psi (34 kPa) at idle and 30-80 psi (205-551 kPa) at 3000 RPM with engine at normal operating temperature.

Scheme 45

Removal & Disassembly

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.

1. If servicing oil pump, remove oil pan. See «OIL PAN»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l). Remove oil pump pick-up tube. Remove timing chain cover. See «TIMING CHAIN COVER»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l).
2. To service pressure relief valve, drill a 1/8" (3.175 mm) hole in pressure relief valve retainer cap. Pressure relief valve 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 bolts and pump cover. Note direction of rotor installation for reassembly reference. Remove inner and outer rotors. see scheme 14

Scheme 46

1. Inspect components for damage. Using straightedge and feeler gauge, check pump cover warpage. Replace pump cover if clearance is equal to or exceeds specification. See «OIL PUMP SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l) table.
2. Measure thickness of both rotors and outer rotor O.D. Replace rotors if measurement is equal to or exceeds specification.
3. Install outer rotor in timing chain cover. Press outer rotor against one side of timing chain cover. Measure outer rotor-to-timing chain cover clearance. If clearance is equal to or exceeds specification but outer rotor O.D. is within specification, replace timing chain cover.
4. Install inner rotor in timing chain cover. Measure clearance between inner and outer rotors. Replace both rotors if clearance is equal to or exceeds specification.
5. Place straightedge across timing chain cover surface, above both rotors. Using feeler gauge, measure rotor end clearance between rotors and straightedge. Replace both rotors if clearance is equal to or exceeds specification and rotor thickness is within 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

1. To reassemble, reverse disassembly procedure. Ensure inner rotor is installed with chamfered side of rotor facing the pump cover. Tighten pump cover bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/grand-caravan/iii-1995-2000/remont/mechanical/#38l-v6-engine-vin-l__torque-specifications) .
2. Install NEW pressure relief valve retainer cap. Fill rotor cavity with engine oil before installing. To install, reverse removal procedure.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

ENGINE SPECIFICATIONS

GENERAL ENGINE SPECIFICATIONS

CYLINDER BLOCK SPECIFICATIONS

VALVES & VALVE SPRINGS SPECIFICATIONS

CYLINDER HEAD SPECIFICATIONS

VALVE LIFTERS SPECIFICATIONS

CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS SPECIFICATIONS

CAMSHAFT SPECIFICATIONS

PISTONS, PINS & RINGS SPECIFICATIONS

CONNECTING RODS SPECIFICATIONS

See also:
• COOLING SYSTEM SPECIFICATIONS
• ENGINE IDENTIFICATION CODE
• FUEL PRESSURE RELEASE
• TORQUE SPECIFICATIONS
• COOLING SYSTEM BLEEDING
• CYLINDER HEAD
• VALVE LIFTERS
• THRUST BEARING