2005 CHRYSLER CARAVAN belt

(2) Position new seal over the guide with the seal
spring in the direction of the engine front cover (Fig.
80).
(3) Install seal using Special Tool C-4992-1 until
seal is flush with cover. (Fig. 80).
(4) Install crankshaft damper. (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
INSTALLATION)
(5) Install accessory drive belt. (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION)
(6) Install inner splash shield and right front
wheel.
(7) Lower vehicle and connect negative cable to
battery.
CRANKSHAFT OIL SEAL -
REAR
REMOVAL
(1) Remove the transaxle. Refer to TRANSAXLE
AND POWER TRANSFER UNIT for procedure.
(2) Remove the flex plate. (Refer to 9 - ENGINE/
ENGINE BLOCK/FLEX PLATE - REMOVAL)
(3) Insert a 3/16 flat bladed pry tool between the
dust lip and the metal case of the crankshaft seal.
Angle the pry tool (Fig. 81) through the dust lip
against metal case of the seal. Pry out seal.CAUTION: Do not permit the pry tool blade to con-
tact crankshaft seal surface. Contact of the pry tool
blade against crankshaft edge (chamfer) is permit-
ted.
INSTALLATION
CAUTION: If burr or scratch is present on the
crankshaft edge (chamfer), cleanup with 400 grit
sand paper to prevent seal damage during installa-
tion of new seal.
(1) Place Special Tool 6926-1 magnetic pilot tool on
crankshaft (Fig. 82).
(2) Place seal over Special Tool 6926-1 Pilot. Using
Special Tool 6926-2 Installer with C-4171 Handle,
drive seal into the retainer housing (Fig. 82).
(3) Install the flex plate. (Refer to 9 - ENGINE/
ENGINE BLOCK/FLEX PLATE - INSTALLATION)
(4) Install transaxle. Refer to TRANSAXLE AND
POWER TRANSFER UNIT for procedure.
Fig. 80 CRANKSHAFT FRONT SEAL INSTALLATION
1 - SPECIAL TOOL C-4992-1
2 - SEAL
3 - SPECIAL TOOL C-4992-2
4 - CRANKSHAFT
Fig. 81 Crankshaft Rear Oil Seal - Removal
1 - REAR CRANKSHAFT SEAL
2 - ENGINE BLOCK
3 - ENGINE BLOCK
4 - REAR CRANKSHAFT SEAL METAL CASE
5 - PRY IN THIS DIRECTION
6 - CRANKSHAFT
7 - SCREWDRIVER
8 - REAR CRANKSHAFT SEAL DUST LIP
9 - SCREWDRIVER
RSENGINE 3.3/3.8L9 - 131
CRANKSHAFT OIL SEAL - FRONT (Continued)

CRANKSHAFT REAR OIL SEAL
RETAINER
REMOVAL
(1) Remove crankshaft rear oil seal (Refer to 9 -
ENGINE/ENGINE BLOCK/CRANKSHAFT OIL
SEAL - REAR - REMOVAL).
(2) Remove oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - REMOVAL).
(3) Remove oil seal retainer screws (Fig. 83).
(4) Remove oil seal retainer (Fig. 83).
(5) Clean engine block and retainer of oil and gas-
ket material. Make sure surfaces are clean and free
of oil.
INSTALLATION
(1) Position new gasket and install retainer on
block (Fig. 83). Tighten attaching screws to 12 N´m
(105 in. lbs.).
(2) Install oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION).
(3) Install oil seal (Refer to 9 - ENGINE/ENGINE
BLOCK/CRANKSHAFT OIL SEAL - REAR -
INSTALLATION).
VIBRATION DAMPER
REMOVAL
(1) Disconnect negative cable from battery.
(2) Raise vehicle on hoist.
(3) Remove the right front wheel and inner splash
shield.
(4) Remove the accessory drive belt. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)
(5) Remove vibration damper bolt.
(6) Insert Special Tool 8450 into crankshaft nose
(Fig. 84).
(7) Position 3-jaw puller Special Tool 1026 on
damper as shown in (Fig. 84). Turn puller forcing
screw until damper releases from crankshaft.
(8) Remove the crankshaft vibration damper.
INSTALLATION
(1) Install crankshaft vibration damper using the
forcing screw, nut, and thrust bearing/washer from
Special Tool 8452 (Fig. 85).
NOTE: To minimize friction and prolong tool life,
lubricate the threads on the forcing screw of Spe-
cial Tool 8452.
(2) Position vibration damper on crankshaft.
(3) Screw Special Tool 8452 into crankshaft until
the bolt seats. Turn the nut to install damper until it
seats fully.
(4) Remove Special Tool 8452.
(5) Install vibration damper bolt. Torque bolt to 54
N´m (40 ft. lbs.).
Fig. 82 Rear Crankshaft Oil SealÐInstallation
1 - SPECIAL TOOLS:
2 - C-4171 HANDLE
3 - 6926±2 INSTALLER
4 - 6926±1 GUIDE
5 - SEAL
Fig. 83 CRANKSHAFT REAR OIL SEAL
1 - OIL SEAL
2 - BOLT
3 - RETAINER - OIL SEAL
4 - GASKET
9 - 132 ENGINE 3.3/3.8LRS
CRANKSHAFT OIL SEAL - REAR (Continued)

(6) Install the accessory drive belt. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION)
(7) Install inner splash shield and right front
wheel.
(8) Connect negative cable to battery.
FLEX PLATE
REMOVAL
(1) Remove the transaxle (Refer to 21 - TRANS-
MISSION/TRANSAXLE/AUTOMATIC - 41TE -
REMOVAL).
(2) Remove flex plate attaching bolts.
(3) Remove the flex plate (Fig. 86).
INSTALLATION
(1) Position flex plate with backing plate on the
crankshaft (Fig. 86).
(2) Apply MopartLock & Seal Adhesive to the flex
plate bolts.
(3) Install flex plate bolts (Fig. 86). Tighten bolts
to 95 N´m (70 ft. lbs.).
(4) Install the transaxle (Refer to 21 - TRANSMIS-
SION/TRANSAXLE/AUTOMATIC - 41TE - INSTAL-
LATION).
Fig. 84 Vibration Damper - Removal
1 - SPECIAL TOOL 8450 - INSERT
2 - SPECIAL TOOL 1026-3JAWPULLER
Fig. 85 Vibration Damper - Installation
1 - FORCING SCREW / NUT FROM SPECIAL TOOL 8452
2 - VIBRATION DAMPER
3 - THRUST BEARING / WASHER
Fig. 86 FLEX PLATE
1 - FLEX PLATE
2 - BOLT (QTY. 8)
3 - BACKING PLATE
RSENGINE 3.3/3.8L9 - 133
VIBRATION DAMPER (Continued)

OIL FILTER ADAPTER
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove the oil filter.
(3) Disconnect oil pressure switch electrical con-
nector.
(4) Remove oil filter adapter attaching bolts (Fig.
100).
(5) Remove oil filter adapter and seal (Fig. 100).
INSTALLATION
(1) Clean oil filter adapter and install new seal.
(2) Position adapter on engine block and install
bolts (Fig. 100).
(3) Tighten adapter bolts to 28 N´m (250 in. lbs.).
(4) Connect oil pressure switch electrical connector
(Fig. 100).
(5) Install the oil filter.
(6) Lower vehicle on hoist.
(7) Start engine and allow to run approximately 2
minutes.
(8) Turn off engine and check oil level. Adjust oil
level as necessary.
OIL PAN
REMOVAL
(1) Disconnect negative cable from battery and
remove engine oil dipstick.
(2) Raise vehicle on hoist and drain engine oil.
(3) Remove drive belt splash shield.
(4) Remove strut to transaxle attaching bolt (Fig.
101). Loosen strut to engine block attaching bolts.
(5) Remove transaxle case cover (Fig. 101).
(6) Remove oil pan fasteners (Fig. 102).
(7) Remove the oil pan and gasket (Fig. 102).
CLEANING
(1) Clean oil pan with solvent and wipe dry with a
clean cloth.
(2) Clean all gasket material from mounting sur-
faces of pan and block.
(3) Clean oil screen and pick-up tube in clean sol-
vent.
Fig. 100 OIL FILTER ADAPTER
1 - SEAL
2 - OIL FILTER ADAPTER
3 - OIL FILTER
4 - BOLT
5 - OIL PRESSURE SWITCH
6 - BOLT
Fig. 101 Powertrain Struts and Transaxle Case
Cover
1 - BRACKET - ENGINE REAR MOUNT
2 - BOLT - TRANSAXLE CASE COVER
3 - STRUT - TRANSAXLE TO ENGINE HORIZONTAL
4 - BOLT - HORIZONTAL STRUT
5 - BOLT - STRUT TO TRANSAXLE
6 - COVER - TRANSAXLE CASE LOWER
7 - STRUT - TRANSAXLE TO ENGINE
8 - BOLT - STRUT TO ENGINE
9 - BOLT - ENGINE REAR MOUNT BRACKET
9 - 142 ENGINE 3.3/3.8LRS

INSPECTION
(1) Inspect oil drain plug and plug hole for
stripped or damaged threads and repair as necessary.
Install a new drain plug gasket. Tighten to 27 N´m
(20 ft. lbs.).
(2) Inspect oil pan mounting flange for bends or
distortion. Straighten flange if necessary.
(3) Inspect condition of oil screen and pick-up tube.
INSTALLATION
(1) Clean sealing surfaces and apply a 1/8 inch
bead of MopartEngine RTV GEN II at the parting
line of the chain case cover and the rear seal retainer
(Fig. 103).
(2) Position a new pan gasket on oil pan (Fig. 102).
(3) Install oil pan and tighten fasteners to 12 N´m
(105 in. lbs.) (Fig. 102).
(4) Install cover to transaxle case (Fig. 101).
(5) Install the strut bolt to transaxle housing (Fig.
101). Tighten all bending brace bolts.
(6) Install the drive belt splash shield.
(7) Lower vehicle and install oil dipstick.
(8) Connect negative cable to battery.
(9) Fill crankcase with oil to proper level.
OIL PRESSURE RELIEF VALVE
REMOVAL
(1) Remove oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - REMOVAL).
(2) Drill a 3.175 mm (1/8 in.) hole in the center of
the retainer cap (Fig. 104). Insert a self-threading
sheet metal screw into the cap.
(3) Using suitable pliers, remove cap and discard.
(4) Remove spring and relief valve (Fig. 104).
Fig. 102 OIL PAN
1 - GASKET
2 - BOLT
3 - OIL PAN
4 - NUT
Fig. 103 Oil Pan Sealing
1 - SEALER LOCATIONS
Fig. 104 Oil Pressure Relief Valve
1 - RELIEF VALVE
2 - SPRING
3 - RETAINER CAP
RSENGINE 3.3/3.8L9 - 143
OIL PAN (Continued)

INSTALLATION
(1) Clean relief valve, spring and bore.
NOTE: Lubricate relief valve with clean engine oil
before installing.
(2) Install relief valve and spring into housing.
(3) Install new retainer cap until flush with seal-
ing surface.
(4) Install oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION).
(5) Fill crankcase with proper oil to correct level.
OIL PRESSURE SWITCH
DESCRIPTION
The engine oil pressure switch is located on the
lower left front side of the engine. It screws into the
oil filter adapter. The normally closed switch provides
an input through a single wire to the low pressure
indicator light on the instrument cluster.
OPERATION
The oil pressure switch provides a ground for the
instrument cluster low oil pressure indicator light.
The switch receives oil pressure input from the
engine main oil gallery. When engine oil pressure is
greater than 27.5 Kpa (4 psi), the switch contacts
open, providing a open circuit to the low pressure
indicator light. For wiring circuits and diagnostic
information, (Refer to Appropriate Wiring/Diagnostic
Information).
REMOVAL
(1) Raise vehicle on hoist.
(2) Disconnect electrical connector from switch.
(3) Remove oil pressure switch (Fig. 105).
INSTALLATION
(1) Install oil pressure switch. Torque oil pressure
switch to 23 N´m (200 in. lbs.) (Fig. 105).
(2) Connect electrical connector to switch.
(3) Lower the vehicle.
(4) Start engine and check for leaks.
(5) Check engine oil level. Adjust as necessary.
OIL PUMP
DESCRIPTION
The oil pump is located in the timing chain cover.
It is driven by the crankshaft.
REMOVAL
The oil pump is contained within the timing chain
cover housing (Fig. 106).
(1) Remove oil pan. (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - REMOVAL)
(2) Remove the timing chain cover. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL)
(3) Disassemble oil pump from timing chain cover.
(Refer to 9 - ENGINE/LUBRICATION/OIL PUMP -
DISASSEMBLY)
(4) Clean and Inspect oil pump components. (Refer
to 9 - ENGINE/LUBRICATION/OIL PUMP - CLEAN-
ING) (Refer to 9 - ENGINE/LUBRICATION/OIL
PUMP - INSPECTION)
Fig. 105 OIL FILTER ADAPTER
1 - SEAL
2 - OIL FILTER ADAPTER
3 - OIL FILTER
4 - BOLT
5 - OIL PRESSURE SWITCH
6 - BOLT
9 - 144 ENGINE 3.3/3.8LRS
OIL PRESSURE RELIEF VALVE (Continued)

(2) Install timing chain cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION) and oil pan (Refer to 9
- ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
INTAKE MANIFOLD
DESCRIPTION
The intake system is made up of an upper and
lower intake manifold. The upper intake manifold is
made of a composite for both the 3.3L engine and for
the 3.8L engine (Fig. 118). The lower intake manifold
is common between the two engines (Fig. 122). It also
provides coolant crossover between cylinder heads
and houses the coolant thermostat (Fig. 122).
The intake manifold utilizes a compact design with
very low restriction and outstanding flow balance.
This design allows the engine to perform with a wide
torque curve while increasing higher rpm horse-
power.
If, for some reason, the molded-in vacuum ports
break, the composite manifold can be salvaged. The
vacuum ports are designed to break at the shoulder,
if overloaded. Additional material in the shoulder
area provides sufficient stock to repair. For more
information and procedure, (Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD - STANDARD
PROCEDURE). Also, if the special screws that attach
the MAP sensor, power steering reservoir, throttle
cable bracket, and the EGR tube become stripped, an
oversized screw is available to repair the stripped-out
condition. For more information and procedure,
(Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANI-
FOLD - STANDARD PROCEDURE)
DIAGNOSIS AND TESTING - INTAKE
MANIFOLD LEAKS
An intake manifold air leak is characterized by
lower than normal manifold vacuum. Also, one or
more cylinders may not be functioning.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
(1) Start the engine.
(2) Spray a small stream of water (Spray Bottle) at
the suspected leak area.
(3) If engine RPM'S change, the area of the sus-
pected leak has been found.
(4) Repair as required.
INTAKE MANIFOLD - UPPER
STANDARD PROCEDURE
STANDARD PROCEDURE - MANIFOLD
STRIPPED THREAD REPAIR
The composite upper intake manifold thread
bosses, if stripped out, can be repaired by utilizing a
repair screw available through Mopartparts. Repair
screws are available for the following manifold
attached components:
²MAP sensor
²Power steering reservoir
²EGR tube
²Throttle cable bracket
The repair screws require a unique tightening
torque specification from the original screw. Refer to
the following chart for specification.
DESCRIPTION TORQUE*
STRIP-OUT REPAIR SCREWS ONLY
MAP Sensor Repair
Screw4 N´m (35 in. lbs.)
Power Steering Reservoir
Repair Screw9 N´m (80 in. lbs.)
EGR Tube Attaching
Repair Screw9 N´m (80 in. lbs.)
Throttle Cable Bracket
Repair Screw9 N´m (80 in. lbs.)
*Install Slowly Using Hand Tools Only
Fig. 113 Oil Pressure Relief Valve
1 - RELIEF VALVE
2 - SPRING
3 - RETAINER CAP
RSENGINE 3.3/3.8L9 - 147
OIL PUMP (Continued)

(6) Remove the heat shield attaching screws (Fig.
128).
(7) Remove the upper heat shield (Fig. 128).
(8) Raise vehicle on hoist and remove drive belt
shield.
(9) Loosen the power steering pump support strut
lower bolt (Fig. 126).
(10) Disconnect downstream oxygen sensor connec-
tor.
(11) Disconnect catalytic converter pipe from
exhaust manifold (Fig. 127).(12) Lower vehicle and remove the power steering
pump support strut upper bolt (Fig. 126).
(13) Remove bolts attaching exhaust manifold to
cylinder head and remove manifold (Fig. 128).
(14) Inspect and clean manifold. (Refer to 9 -
ENGINE/MANIFOLDS/EXHAUST MANIFOLD -
CLEANING) (Refer to 9 - ENGINE/MANIFOLDS/
EXHAUST MANIFOLD - INSPECTION)
CLEANING
(1) Discard gasket (if equipped) and clean all sur-
faces of manifold and cylinder head.
INSPECTION
Inspect exhaust manifolds for damage or cracks
and check distortion of the cylinder head mounting
surface and exhaust crossover mounting surface with
a straightedge and thickness gauge (Fig. 129).
Manifold surface flatness limits should not exceed
1.0 mm (0.039 in.).
INSTALLATION
(1) Position exhaust manifold on cylinder head and
install bolts to center runner (cylinder #3) and initial
tighten to 2.8 N´m (25 in. lbs.) (Fig. 128)
(2) Using a new gasket, attach crossover pipe to
exhaust manifold and tighten bolts to 41 N´m (30 ft.
lbs.) (Fig. 125).
Fig. 126 P/S PUMP STRUT
1 - BOLT - LOWER
2 - STRUT - P/S PUMP
3 - BOLT - UPPER
Fig. 127 Catalytic Converter to Exhaust Manifold
1 - FLAG NUT
2 - GASKET
3 - BOLT
4 - CATALYTIC CONVERTER
Fig. 128 EXHAUST MANIFOLD - RIGHT
1 - SCREW - HEAT SHIELD
2 - HEAT SHIELD - UPPER
3 - BOLT - EXHAUST MANIFOLD
4 - HEAT SHIELD - LOWER
5 - EXHAUST MANIFOLD - RIGHT
6 - OXYGEN SENSOR - UPSTREAM
RSENGINE 3.3/3.8L9 - 153
EXHAUST MANIFOLD - RIGHT (Continued)