1991 3.3 Rebuild

My 91 Grand Caravan spun a rod bearing at 235,000 miles and 31 years. As luck would have it, I was 200 miles from home. I rented a UHaul Truck and Tow Dolley and towed the wounded vehicle home.
I began disassembling the engine in preparation for removal immediately. I found that the #4 rod bearing had spun and the#4 piston was hitting the cylinder head. All the other main and rod bearings looked fine.
The engine block had very little cylinder wall wear, about .003" - .004". There were no perceptible ridges at the tops of the cylinder walls. I decided to rebuild the engine myself except for machine shop operations.
Once the engine was out of the vehicle, I finished stripping the block of all parts and removed all the freeze and oil plugs. The camshaft and roller lifters were visibly worn. The pistons showed some skirt wear and the oil rings were fairly caked with oil deposits.
I pressure-washed the block and once all the oily grime was gone, I prepared it for an Electrolysis bath (see youtube) to clean the water passages. It did a great job of cleaning up all the invisible parts of the block. After about 48 hours of Electrolysis, I pulled the block out of the bath, pressure washed it again and treated it with WD40 Blast. I cleaned all the block threads with Taps and prepared to send it to a machine shop for cylinder boring and main bearing line boring (if needed).
Since there was only one 1991 block used for both 3.3 L and 3.8 L engines in 1991, I decided to have the block bored to 96 mm (3.780"). I found a set of 2007 3.8 L 96 mm bore flat top EUM Silvalite pistons that would work with my 3.3 L crankshaft and stock 6.18" rods. These pistons have 1.261" compression distance, the same as stock 3.3 L dished pistons. This engine will now be a 3.5 Liter engine with 9.7:1 compression.
I purchased a reground 3.3 crankshaft and matching main/rod bearings from Crankshaft Supply in Minneapolis, MN for $175. They provided fast shipping and excellent customer support. I recommend them highly. They provided a return shipping tag and refunded the $75 core charge quickly.
I found a reconditioned rod on ebay that was an exact replacement for my #4 Rod. It weighs almost exactly the same as the rest of the rods and has same forging number. I will weigh both ends of the rods and adjust weights as needed after the rods are reconditioned and fitted with new rod bolts. The new pistons will weigh more than the original ones, so the crank will need balancing.
I originally planned to use Hastings Moly Rings, but they could not ship before Christmas. Summit Racing customer support was excellent and arranged to cancel order from Hastinngs and refund my purchase price quickly. I found similar 1.2mm/1.5mm/3.0mm Moly Rings from Mahle on Amazon.
I ordered a new 3.8 L 4th Gen Cam, new lifters, valves, valve guides, valve seals, push rods, and rocker arms. I have not found new valve springs and will continue looking for a suitable replacement.
I will recondition the cylinder heads myself after the machine shop cleans and surfaces them. I also drilled and retapped the rocker shaft bosses for larger, longer bolts in order to help prevent rocker shat boss breakage. In the future, I may get later model cylinder heads, Intake and exhaust manifolds, and larger throttle body and air filter box.