2005 CHRYSLER CARAVAN check oil

WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSES,
FITTINGS OR LINES, THE FUEL SYSTEM PRES-
SURE MUST BE RELEASED. REFER TO THE FUEL
PRESSURE RELEASE PROCEDURE IN THIS
GROUP. THIS MAY RESULT IN PERSONAL INJURY
OR DEATH.
DISCONNECTION/CONNECTION
(1) Perform fuel pressure release procedure. Refer
to Fuel Pressure Release Procedure in this group.
(2) Disconnect negative battery cable from battery
or auxiliary jumper terminal.
(3) Clean fitting of any foreign material before dis-
assembly.
(4) To disconnect quick-connect fitting, squeeze
plastic retainer tabs (Fig. 37) against sides of quick-
connect fitting with your fingers. Tool use is not
required for removal and may damage plastic
retainer. Pull fitting from fuel system component
being serviced. The plastic retainer will remain on
component being serviced after fitting is discon-
nected. The O-rings and spacer will remain in quick-
connect fitting connector body.
(5) Inspect quick-connect fitting body and compo-
nent for damage. Replace as necessary.
CAUTION: When the quick-connect fitting was dis-
connected, the plastic retainer will remain on the
component being serviced. If this retainer must be
removed, very carefully release the retainer from
the component with two small screwdrivers. After
removal, inspect the retainer for cracks or any dam-
age.
(6) Prior to connecting quick-connect fitting to
component being serviced, check condition of fitting
and component. Clean parts with a lint-free cloth.
Lubricate with clean engine oil.
(7) Insert quick-connect fitting to component being
serviced and into plastic retainer. When a connection
is made, a click will be heard.
(8) Verify a locked condition by firmly push-pull-
ing-push on fuel tube and fitting (15-30 lbs.).
(9) Connect negative cable to battery or auxiliary
jumper terminal.
(10) Use the DRB IIItscan tool ASD Fuel System
Test to pressurize the fuel system. Check for leaks.PLASTIC RETAINER RING TYPE FITTING
This type of fitting can be identified by the use of a
full-round plastic retainer ring (Fig. 38) usually black
in color.
CAUTION: The interior components (O-rings, spac-
ers, retainers) of this type of quick-connect fitting
are not serviced separately. Do not attempt to repair
damaged fittings or fuel lines/tubes. If repair is nec-
essary, replace the complete fuel tube assembly.
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSES,
FITTINGS OR LINES, THE FUEL SYSTEM PRES-
SURE MUST BE RELEASED. REFER TO THE FUEL
SYSTEM PRESSURE RELEASE PROCEDURE IN
THIS GROUP. THIS MAY RESULT IN PERSONAL
INJURY OR DEATH.
Fig. 38 Plastic Retainer Ring Type Fitting
1 - FUEL TUBE
2 - QUICK CONNECT FITTING
3 - PUSH
4 - PLASTIC RETAINER
5 - PUSH
6 - PUSH
7 - PUSH
8 - PUSH
RSFUEL DELIVERY14-19
QUICK CONNECT FITTING (Continued)

DISCONNECTION/CONNECTION
(1) Perform fuel pressure release procedure. Refer
to Fuel Pressure Release Procedure in this section.
(2) Disconnect negative battery cable from battery
or auxiliary jumper terminal.
(3) Clean fitting of any foreign material before dis-
assembly.
(4) To release fuel system component from quick-
connect fitting, firmly push fitting towards compo-
nent being serviced while firmly pushing plastic
retainer ring into fitting (Fig. 38). With plastic ring
depressed, pull fitting from component.The plastic
retainer ring must be pressed squarely into fit-
ting body. If this retainer is cocked during
removal, it may be difficult to disconnect fit-
ting. Use an open-end wrench on shoulder of
plastic retainer ring to aid in disconnection.(5) After disconnection, plastic retainer ring will
remain with quick-connect fitting connector body.
(6) Inspect fitting connector body, plastic retainer
ring and fuel system component for damage. Replace
as necessary.
(7) Prior to connecting quick-connect fitting to
component being serviced, check condition of fitting
and component. Clean parts with a lint-free cloth.
Lubricate with clean engine oil.
(8) Insert quick-connect fitting into component
being serviced until a click is felt.
(9) Verify a locked condition by firmly push-pull-
ing-push on fuel tube and fitting (15-30 lbs.).
(10) Connect negative battery cable to battery or
auxiliary jumper terminal.
(11) Use the DRB IIItscan tool ASD Fuel System
Test to pressurize the fuel system. Check for leaks.
14 - 20 FUEL DELIVERYRS
QUICK CONNECT FITTING (Continued)

1 second. Therefore, battery voltage is not supplied to
the fuel pump, ignition coil, fuel injectors and heated
oxygen sensors.
ENGINE START-UP MODE
This is an OPEN LOOP mode. If the vehicle is in
park or neutral (automatic transaxles) or the clutch
pedal is depressed (manual transaxles) the ignition
switch energizes the starter relay when the engine is
not running. The following actions occur when the
starter motor is engaged.
²If the PCM receives the camshaft position sensor
and crankshaft position sensor signals, it energizes
the Auto Shutdown (ASD) relay and fuel pump relay.
If the PCM does not receive both signals within
approximately one second, it will not energize the
ASD relay and fuel pump relay. The ASD and fuel
pump relays supply battery voltage to the fuel pump,
fuel injectors, ignition coil, (EGR solenoid and PCV
heater if equipped) and heated oxygen sensors.
²The PCM energizes the injectors (on the 69É
degree falling edge) for a calculated pulse width until
it determines crankshaft position from the camshaft
position sensor and crankshaft position sensor sig-
nals. The PCM determines crankshaft position within
1 engine revolution.
²After determining crankshaft position, the PCM
begins energizing the injectors in sequence. It adjusts
injector pulse width and controls injector synchroni-
zation by turning the individual ground paths to the
injectors On and Off.
²When the engine idles within  64 RPM of its
target RPM, the PCM compares current MAP sensor
value with the atmospheric pressure value received
during the Ignition Switch On (zero RPM) mode.
Once the ASD and fuel pump relays have been
energized, the PCM determines injector pulse width
based on the following:
²MAP
²Engine RPM
²Battery voltage
²Engine coolant temperature
²Inlet/Intake air temperature (IAT)
²Throttle position
²The number of engine revolutions since cranking
was initiated
During Start-up the PCM maintains ignition tim-
ing at 9É BTDC.
ENGINE WARM-UP MODE
This is an OPEN LOOP mode. The following inputs
are received by the PCM:
²Manifold Absolute Pressure (MAP)
²Crankshaft position (engine speed)
²Engine coolant temperature
²Inlet/Intake air temperature (IAT)²Camshaft position
²Knock sensor
²Throttle position
²A/C switch status
²Battery voltage
²Vehicle speed
²Speed control
²O2 sensors
The PCM adjusts injector pulse width and controls
injector synchronization by turning the individual
ground paths to the injectors On and Off.
The PCM adjusts ignition timing and engine idle
speed. Engine idle speed is adjusted through the idle
air control motor.
CRUISE OR IDLE MODE
When the engine is at operating temperature this
is a CLOSED LOOP mode. During cruising or idle
the following inputs are received by the PCM:
²Manifold absolute pressure
²Crankshaft position (engine speed)
²Inlet/Intake air temperature
²Engine coolant temperature
²Camshaft position
²Knock sensor
²Throttle position
²Exhaust gas oxygen content (O2 sensors)
²A/C switch status
²Battery voltage
²Vehicle speed
The PCM adjusts injector pulse width and controls
injector synchronization by turning the individual
ground paths to the injectors On and Off.
The PCM adjusts engine idle speed and ignition
timing. The PCM adjusts the air/fuel ratio according
to the oxygen content in the exhaust gas (measured
by the upstream and downstream heated oxygen sen-
sor).
The PCM monitors for engine misfire. During
active misfire and depending on the severity, the
PCM either continuously illuminates or flashes the
malfunction indicator lamp (Check Engine light on
instrument panel). Also, the PCM stores an engine
misfire DTC in memory, if 2nd trip with fault.
The PCM performs several diagnostic routines.
They include:
²Oxygen sensor monitor
²Downstream heated oxygen sensor diagnostics
during open loop operation (except for shorted)
²Fuel system monitor
²EGR monitor (if equipped)
²Purge system monitor
²Catalyst efficiency monitor
²All inputs monitored for proper voltage range,
rationality.
RSFUEL INJECTION14-23
FUEL INJECTION (Continued)

(5) Rotate injector and pull injector out of fuel rail.
The clip will stay on the injector.
(6) Check injector O-ring for damage. If O-ring is
damaged, it must be replaced. If injector is reused, a
protective cap must be installed on the injector tip to
prevent damage. Replace the injector clip if it is dam-
aged.
(7) Repeat for remaining injectors.
INSTALLATION
INSTALLATION - 2.4L
The fuel rail must be removed first. Refer to Fuel
Injector Rail Removal in this section.
(1) Before installing an injector the rubber O-ring
must be lubricated with a drop of clean engine oil to
aid in installation.
(2) Install injector clip by sliding open end into the
top slot of the injector. The edge of the receiver cup
will slide into the side slots of clip.
(3) Install injector top end into fuel rail receiver
cap. Be careful not to damage O-ring during installa-
tion (Fig. 14).
(4) Repeat steps for remaining injectors.
(5) Connect fuel injector wiring.
INSTALLATION - 3.3/3.8L
(1) Before installing an injector the rubber O-ring
must be lubricated with a drop of clean engine oil to
aid in installation.
(2) Install injector clip by sliding open end into the
top slot of the injector. The edge of the receiver cup
will slide into the side slots of clip (Fig. 13).
(3) Install injector top end into fuel rail receiver
cap. Be careful not to damage O-ring during installa-
tion (Fig. 13).
(4) Repeat steps for remaining injectors.
(5) Install fuel rail, refer to Fuel Rail in the Fuel
Delivery section.
(6) Connect fuel injector wiring.
(7) Install the Intake Manifold, (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSTALLATION)
(8) Connect the negative battery cable.
FUEL PUMP RELAY
DESCRIPTION
The fuel pump relay is located in the PDC. The
inside top of the PDC cover has a label showing relay
and fuse location.
OPERATION
The fuel pump relay supplies battery voltage to the
fuel pump. A buss bar in the Power Distribution Cen-
ter (PDC) supplies voltage to the solenoid side and
contact side of the relay. The fuel pump relay power
circuit contains a fuse between the buss bar in the
PDC and the relay. The fuse is located in the PDC.
Refer to the Wiring Diagrams for circuit information.
The PCM controls the fuel pump relay by switch-
ing the ground path for the solenoid side of the relay
on and off. The PCM turns the ground path off when
the ignition switch is in the Off position. When the
ignition switch is in the On position, the PCM ener-
gizes the fuel pump. If the crankshaft position sensor
does not detect engine rotation, the PCM de-ener-
gizes the relay after approximately one second.
Fig. 14 SERVICING FUEL INJECTOR TYPICAL
1 - FUEL INJECTOR
2 - LOCKING SLOT
3 - FUEL RAIL RECEIVER CUP
14 - 32 FUEL INJECTIONRS
FUEL INJECTOR (Continued)

GEAR
TABLE OF CONTENTS
page page
GEAR
DESCRIPTION.........................26
OPERATION...........................26
WARNING
WARNINGS AND CAUTIONS.............26
REMOVAL
REMOVAL - LHD GEAR.................26
REMOVAL - RHD GEAR................29INSTALLATION
INSTALLATION - LHD GEAR.............31
INSTALLATION - RHD GEAR.............33
SPECIAL TOOLS
POWER STEERING GEAR..............34
OUTER TIE ROD
REMOVAL.............................34
INSTALLATION.........................35
GEAR
DESCRIPTION
This vehicle is equipped with a rack and pinion
power steering gear (Fig. 1). It is mounted to the
underside of the front suspension cradle/crossmem-
ber.
The steering column is attached to the gear
through the use of an intermediate shaft and cou-
plers. The outer ends of the power steering gear's
outer tie rods connect to the steering knuckles.
NOTE: The power steering gear should NOT be ser-
viced or adjusted unless DaimlerChrysler Corpora-
tion authorizes. If a malfunction or oil leak occurs,
the complete steering gear should be replaced.
Only the outer tie rods may be replaced separately
from the rest of the gear.
OPERATION
Turning of the steering wheel is converted into lin-
ear (side-to-side) travel through the meshing of the
helical pinion teeth with the rack teeth in the steer-
ing gear. This travel pushes and pulls the tie rods to
change the direction of the vehicle's front wheels.
Power assist steering provided by the power steer-
ing pump is controlled by an open center, rotary type
control valve which directs oil from the pump to
either side of the integral rack piston upon demand.
Road feel is controlled by the diameter of a torsion
bar which initially steers the vehicle. As required
steering effort increases, as in a turn, the torsion bar
twists, causing relative rotary motion between the
rotary valve body and the valve spool. This move-
ment directs oil behind the integral rack piston
which, in turn, builds hydraulic pressure and assists
in the turning effort.Manual steering control of the vehicle can be main-
tained if power steering assist is lost. However,
under this condition, steering effort is significantly
increased.
WARNING
WARNINGS AND CAUTIONS
WARNING: POWER STEERING FLUID, ENGINE
PARTS AND EXHAUST SYSTEM MAY BE
EXTREMELY HOT IF ENGINE HAS BEEN RUNNING.
DO NOT START ENGINE WITH ANY LOOSE OR DIS-
CONNECTED HOSES. DO NOT ALLOW HOSES TO
TOUCH HOT EXHAUST MANIFOLD OR CATALYST.
WARNING: FLUID LEVEL SHOULD BE CHECKED
WITH THE ENGINE OFF TO PREVENT PERSONAL
INJURY FROM MOVING PARTS.
CAUTION: When the system is open, cap all open
ends of the hoses, power steering pump fittings or
power steering gear ports to prevent entry of for-
eign material into the components.
REMOVAL
REMOVAL - LHD GEAR
(1) Remove cap from power steering fluid reser-
voir.
(2) Using a siphon pump, remove as much fluid as
possible from the power steering fluid reservoir.Use
care not to damage the filter mesh below the
fluid surface.
19 - 26 GEARRS

TRANSMISSION/TRANSAXLE
TABLE OF CONTENTS
page page
40TE AUTOMATIC TRANSAXLE..............141TE AUTOMATIC TRANSAXLE............146
40TE AUTOMATIC TRANSAXLE
TABLE OF CONTENTS
page page
40TE AUTOMATIC TRANSAXLE
DESCRIPTION..........................2
OPERATION............................4
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - 4XTE
TRANSAXLE GENERAL DIAGNOSIS........5
DIAGNOSIS AND TESTING - ROAD TEST....5
DIAGNOSIS AND TESTING - HYDRAULIC
PRESSURE TESTS.....................6
DIAGNOSIS AND TESTING - CLUTCH AIR
PRESSURE TESTS.....................8
DIAGNOSIS AND TESTING - TORQUE
CONVERTER HOUSING FLUID LEAKAGE....9
REMOVAL.............................9
DISASSEMBLY.........................12
ASSEMBLY............................29
INSTALLATION.........................51
SCHEMATICS AND DIAGRAMS
4XTE TRANSAXLE HYDRAULIC
SCHEMATICS........................54
SPECIFICATIONS - 41TE TRANSAXLE.......66
SPECIAL TOOLS.......................68
ACCUMULATOR
DESCRIPTION.........................73
OPERATION...........................73
DRIVING CLUTCHES
DESCRIPTION.........................74
OPERATION...........................74
FINAL DRIVE
DESCRIPTION.........................74
OPERATION...........................75
DISASSEMBLY.........................75
ASSEMBLY............................78
ADJUSTMENTS
DIFFERENTIAL BEARING PRELOAD
MEASUREMENT AND ADJUSTMENT......79FLUID
STANDARD PROCEDURE
FLUID LEVEL AND CONDITION CHECK....82
STANDARD PROCEDURE - FLUID AND
FILTER SERVICE......................82
GEAR SHIFT CABLE
REMOVAL.............................84
HOLDING CLUTCHES
DESCRIPTION.........................86
OPERATION...........................86
INPUT CLUTCH ASSEMBLY
DISASSEMBLY.........................86
ASSEMBLY............................95
OIL PUMP
DESCRIPTION........................110
OPERATION..........................110
DISASSEMBLY........................110
ASSEMBLY...........................112
PLANETARY GEARTRAIN
DESCRIPTION........................112
OPERATION..........................112
SEAL - OIL PUMP
REMOVAL............................113
INSTALLATION........................113
SHIFT INTERLOCK SOLENOID
DESCRIPTION........................113
OPERATION..........................114
DIAGNOSIS AND TESTING - BRAKE/
TRANSMISSION SHIFT INTERLOCK
SOLENOID..........................115
REMOVAL............................115
INSTALLATION........................116
SOLENOID/PRESSURE SWITCH ASSY
DESCRIPTION........................117
OPERATION..........................118
REMOVAL............................118
INSTALLATION........................119
RSTRANSMISSION/TRANSAXLE21-1

DIAGNOSIS AND TESTING - CLUTCH AIR
PRESSURE TESTS
Inoperative clutches can be located using a series
of tests by substituting air pressure for fluid pressure
(Fig. 5) (Fig. 6). The clutches may be tested by apply-
ing air pressure to their respective passages. The
valve body must be removed and Tool 6056 installed.
To make air pressure tests, proceed as follows:
NOTE: The compressed air supply must be free of
all dirt and moisture. Use a pressure of 30 psi.
Remove oil pan and valve body. See Valve body
removal.
OVERDRIVE CLUTCH
Apply air pressure to the overdrive clutch apply
passage and watch for the push/pull piston to move
forward. The piston should return to its starting
position when the air pressure is removed.
REVERSE CLUTCH
Apply air pressure to the reverse clutch apply pas-
sage and watch for the push/pull piston to move rear-
ward. The piston should return to its starting
position when the air pressure is removed.
2/4 CLUTCH
Apply air pressure to the feed hole located on the
2/4 clutch retainer. Look in the area where the 2/4
piston contacts the first separator plate and watch
carefully for the 2/4 piston to move rearward. The
piston should return to its original position after the
air pressure is removed.
LOW/REVERSE CLUTCH
Apply air pressure to the low/reverse clutch feed
hole (rear of case, between 2 bolt holes). Then, look
in the area where the low/reverse piston contacts the
first separator plate. Watch carefully for the piston to
move forward. The piston should return to its origi-
nal position after the air pressure is removed.
UNDERDRIVE CLUTCH
Because this clutch piston cannot be seen, its oper-
ation is checked by function. Air pressure is applied
to the low/reverse and the 2/4 clutches. This locks the
output shaft. Use a piece of rubber hose wrapped
around the input shaft and a pair of clamp-on pliers
to turn the input shaft. Next apply air pressure to
the underdrive clutch. The input shaft should not
rotate with hand torque. Release the air pressure
and confirm that the input shaft will rotate.
Fig. 5 Air Pressure Test Plate
1 - TOOL 6056
2 - ACCUMULATORS
Fig. 6 Testing Reverse Clutch
1 - TOOL 6056
2 - AIR NOZZLE
21 - 8 40TE AUTOMATIC TRANSAXLERS
40TE AUTOMATIC TRANSAXLE (Continued)

(3) Rotate the differential at least one full revolu-
tion to ensure the tapered roller bearings are fully
seated.
(4) Using Tool L-4436A and an inch-pound torque
wrench, check the turning torque of the differential
(Fig. 186).The turning torque should be
between 5 and 18 inch-pounds.
(5) If the turning torque is within specifications,
remove tools. Setup is complete.
(6) If turning torque is not within specifications
proceed with the following steps.
(a) Remove differential bearing retainer from
the transaxle case.(b) Remove the bearing cup from the differential
bearing retainer using Tool 6062A.
(c) Remove the existing shim from under the
cup.
(d) Measure the existing shim.
(e) If the turning torque was too high when mea-
sured, install a 0.05 mm (0.002 inch) thinner shim.
If the turning torque is was too low, install a 0.05
mm (0.002 inch) thicker shim. Repeat until 5 to 18
inch-pounds turning torque is obtained. Oil Baffle
is not required to be installed when making shim
selection.
(f) Install the proper shim under the bearing
cup. Make sure the oil baffle is installed properly
in the bearing retainer, below the bearing shim
and cup.
(g) Install the differential bearing retainer using
Tool 5052 and C-4171. Seal the retainer to the
housing with MOPARtAdhesive Sealant and
torque bolts to 28 N´m (250 in. lbs.).
(7) Using Tool L-4436A and an inch-pound torque
wrench, recheck the turning torque of the differential
(Fig. 186).The turning torque should be
between 5 and 18 inch-pounds.
Shim thickness need be determined only if any of
the following parts are replaced:
²Transaxle case
²Differential carrier
²Differential bearing retainer
²Extension housing
²Differential bearing cups and cones
Fig. 186 Checking Differential Bearings Turning
Torque
1 - SPECIAL TOOL L-4436±A
2 - TORQUE WRENCH
21 - 80 40TE AUTOMATIC TRANSAXLERS
FINAL DRIVE (Continued)