Chrysler Town, Dodge Caravan. Manual — part 320
AIR CLEANER ELEMENT
REMOVAL
(1) Unsnap 2 clips.
(2) Lift cover and pull toward the engine and
remove cover tabs from air box.
(3) Lift cover and remove the element (Fig. 15).
INSTALLATION
(1) Install the air filter element into air box (Fig.
15).
(2) Move cover so that the tabs insert into the air
box.
(3) Push cover down and snap the 2 clips.
Adapter 8406
Cooling System Tester 7700
Combustion Leak Tester C-3685-A
Pressure Transducer CH7059
Compression Test Adapter 8116
DRB III
T
with PEP Module OT-CH6010A
Fig. 15 AIR BOX COVER
9 - 98
ENGINE 3.3/3.8L
RS
ENGINE 3.3/3.8L (Continued)
AIR CLEANER HOUSING
REMOVAL
(1) Disconnect the negative battery cable.
(2) Disconnect the inlet air temperature sensor
(Fig. 16).
(3) Remove the inlet hose to throttle body.
(4) Remove the bolt for air box at upper radiator
cross member.
(5) Pull air box up and off over the single locating
pin.
(6) Remove air box from vehicle
INSTALLATION
(1) Install air box into vehicle and onto the locat-
ing pin.
(2) Install bolt to hold air box to the upper radia-
tor cross member.
(3) Install the inlet hose to the throttle body.
(4) Connect the inlet air temperature sensor (Fig.
16).
(5) Connect the negative battery cable.
CYLINDER HEAD
DESCRIPTION
The
aluminum
cylinder
heads
(Fig.
17)
are
designed to create high flow combustion chambers to
improve performance, while minimizing the change
to the burn rate in the chamber. The cylinder head
incorporates the combustion chamber. Two valves
per-cylinder are used with inserted valve seats and
guides. A multi-layer steel (MLS) type gasket is used
between the cylinder head and engine block.
DIAGNOSIS AND TESTING—CYLINDER HEAD
GASKET
A cylinder head gasket leak can be located between
adjacent cylinders or between a cylinder and the
adjacent water jacket.
Possible indications of the cylinder head gasket
leaking between adjacent cylinders are:
• Loss of engine power
• Engine misfiring
• Poor fuel economy
Possible indications of the cylinder head gasket
leaking between a cylinder and an adjacent water
jacket are:
• Engine overheating
• Loss of coolant
• Excessive steam (white smoke) emitting from
exhaust
• Coolant foaming
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determine if an engine cylinder head gasket is
leaking between adjacent cylinders, follow the proce-
dures in Cylinder Compression Pressure Test (Refer
to 9 - ENGINE - DIAGNOSIS AND TESTING). An
engine cylinder head gasket leaking between adja-
cent cylinders will result in approximately a 50–70%
reduction in compression pressure.
CYLINDER-TO-WATER JACKET LEAKAGE TEST
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING WITH COOLANT PRES-
SURE CAP REMOVED.
VISUAL TEST METHOD
With the engine cool, remove the coolant pressure
cap. Start the engine and allow it to warm up until
thermostat opens.
If a large combustion/compression pressure leak
exists, bubbles will be visible in the coolant.
COOLING SYSTEM TESTER METHOD
WARNING: WITH COOLING SYSTEM TESTER IN
PLACE, PRESSURE WILL BUILD UP FAST. EXCES-
SIVE
PRESSURE
BUILT
UP,
BY
CONTINUOUS
ENGINE OPERATION, MUST BE RELEASED TO A
SAFE PRESSURE POINT. NEVER PERMIT PRES-
SURE TO EXCEED 138 kPa (20 psi).
Install Cooling System Tester 7700 or equivalent to
pressure cap neck. Start the engine and observe the
tester’s pressure gauge. If gauge pulsates with every
power stroke of a cylinder a combustion pressure
leak is evident.
Fig. 16 Inlet Air Temperature Sensor
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ENGINE 3.3/3.8L
9 - 99
CHEMICAL TEST METHOD
Combustion leaks into the cooling system can also
be checked by using Bloc-Chek Kit C-3685-A or
equivalent. Perform test following the procedures
supplied with the tool kit.
REMOVAL - CYLINDER HEAD
(1) Drain the cooling system. (Refer to 7 - COOL-
ING - STANDARD PROCEDURE)
(2) Disconnect negative cable from battery.
(3) Remove upper and lower intake manifolds.
(Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANI-
FOLD - REMOVAL)
WARNING: INTAKE MANIFOLD GASKET IS MADE
OF VERY THIN METAL AND MAY CAUSE PER-
SONAL INJURY, HANDLE WITH CARE.
(4) Remove the cylinder head covers. (Refer to 9 -
ENGINE/CYLINDER
HEAD/CYLINDER
HEAD
COVER(S) - REMOVAL)
(5) Remove the spark plugs from cylinder head.
(6) Remove the dipstick and tube (Fig. 18).
(7) Remove exhaust manifold(s). (Refer to 9 -
ENGINE/MANIFOLDS/EXHAUST
MANIFOLD
-
REMOVAL)
(8) Remove rocker arm and shaft assemblies.(Refer
to 9 - ENGINE/CYLINDER HEAD/ROCKER ARMS -
REMOVAL) Remove push rods and mark positions
to ensure installation in original locations.
(9) Remove the eight head bolts from each cylinder
head and remove cylinder heads (Fig. 22).
CLEANING
To ensure engine gasket sealing, proper surface
preparation must be performed, especially with the
use of aluminum engine components and multi-layer
steel cylinder head gaskets.
NOTE: Multi-Layer Steel (MLS) head gaskets require
a scratch free sealing surface.
Remove all gasket material from cylinder head and
block (Refer to 9 - ENGINE - STANDARD PROCE-
Fig. 17 Cylinder Head and Components
1 - VALVE LOCKS
5 - SPRING SEATS
2 - RETAINERS
6 - CYLINDER HEAD
3 - VALVE SPRINGS
7 - VALVE - EXHAUST
4 - VALVE STEM SEALS
8 - VALVE - INTAKE
9 - 100
ENGINE 3.3/3.8L
RS
CYLINDER HEAD (Continued)
DURE). Be careful not to gouge or scratch the alumi-
num head sealing surface.
Clean all engine oil passages.
INSPECTION
(1) Before cleaning, check for leaks, damage and
cracks.
(2) Clean cylinder head and oil passages.
(3) Check cylinder head for flatness (Fig. 19).
(4) Cylinder head must be flat within:
• Standard dimension = less than 0.05 mm (0.002
inch.)
• Service Limit = 0.2 mm (0.008 inch.)
• Grinding Limit = Maximum of 0.2 mm (0.008
inch.) is permitted.
CAUTION: 0.20 mm (0.008 in.) MAX is a combined
total dimension of the stock removal limit from cyl-
inder head and block top surface (Deck) together.
INSTALLATION - CYLINDER HEAD
(1) Clean all sealing surfaces of engine block and
cylinder heads. (Refer to 9 - ENGINE - STANDARD
PROCEDURE)
(2) Position new gasket(s) on engine block (Fig.
20). The left bank gasket is identified with the “L”
stamped in the exposed area of the gasket located at
front of engine (shown in (Fig. 20)). The right bank
gasket is identified with a “R” stamped in the
exposed area of the gasket also, but is located at the
rear of the engine.
(3) The cylinder head bolts are torqued using
the torque yield method, they should be exam-
ined BEFORE reuse. If the threads are necked
down, the bolts must be replaced (Fig. 21).
(4) Necking can be checked by holding a scale or
straight edge against the threads. If all the threads
do not contact the scale the bolt should be replaced.
(5) Tighten the cylinder head bolts 1–8 in the
sequence shown in (Fig. 22). Using the 4 step torque
turn method, tighten according to the following values:
• Step 1: Bolts 1 – 8 to 61 N·m (45 ft. lbs.)
• Step 2: Bolts 1 – 8 to 88 N·m (65 ft. lbs.)
• Step 3: Bolts 1 – 8 (again) to 88 N·m (65 ft. lbs.)
• Step 4: Bolts 1 – 8 turn an additional 1/4 Turn.
(Do not use a torque wrench for this step.)
Fig. 18 DIPSTICK & TUBE
1 - DIPSTICK
2 - BOLT
3 - TUBE
Fig. 19 Checking Cylinder Head Flatness—Typical
Fig. 20 Head Gasket Installation
1 - CYLINDER HEAD GASKET
2 - LOCATION IDENTIFICATION (L = LEFT BANK, R = RIGHT
BANK)
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ENGINE 3.3/3.8L
9 - 101
CYLINDER HEAD (Continued)
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