2005 CHRYSLER CARAVAN oil dipstick

(9) Raise vehicle.
(10) Attach wiring harness support clip to the
engine oil dipstick tube.
(11) Connect oil pressure switch electrical connec-
tor.
(12) Install the A/C compressor.
(13) Install the water pump pulley.
(14) Connect the radiator lower hose.
(15) Install the accessory drive belt and splash
shield (Refer to 7 - COOLING/ACCESSORY DRIVE/
DRIVE BELTS - INSTALLATION).(16) Connect the engine block heater electrical con-
nector (if equipped).
(17) Connect the knock sensor electrical connector
(3.8L only).
(18) Install the torque converter to flex plate bolts.
(19) Install the transaxle case cover (Fig. 8).
(20) Install the powertrain struts (Fig. 8).
(21) Install the engine rear mount bracket.
(22) Install the engine front mount and bracket
assembly.
(23)AWD equipped;Install the power transfer
unit (PTU) (Refer to 21 - TRANSMISSION/TRANS-
AXLE/POWER TRANSFER UNIT - INSTALLA-
TION).
(24) Install the axle shafts (Refer to 3 - DIFFER-
ENTIAL & DRIVELINE/HALF SHAFT - INSTALLA-
TION).
(25) Connect exhaust pipe to manifold (Fig. 7).
(26) Install crossmember cradle plate (Fig. 6).
(27) Lower vehicle.
(28) Connect transaxle shift linkage.
(29) Connect transaxle electrical connectors.
(30) Remove plugs from transmission cooler hoses
and install transaxle oil cooler line service splice kit.
Refer to instructions included with kit.
(31) Install transaxle dipstick tube and attach
electrical harness clip.
(32) Connect the A/C lines to compressor.
(33) Connect the A/C compressor electrical connec-
tor.
(34) Evacuate and recharge A/C system.
(35) Connect crankshaft and camshaft position
sensors.
(36) Connect the fuel injector electrical harness
connector and engage clip to support bracket.
(37) Connect engine coolant temperature (ECT)
sensor and ignition coil electrical connectors.
(38) Connect the ground strap to rear of cylinder
head.
(39) Install power steering reservoir.
(40) Engage wire harness clip to engine right side
mount.
(41) Connect the brake booster and speed control
vacuum hoses.
(42) Connect the vacuum hoses to the throttle
body.
(43) Connect the EGR transducer electrical connec-
tor (if equipped).
(44) Connect the TPS, IAC, and MAP sensor elec-
trical connectors.
(45) Connect throttle cables to throttle body.
(46) Install the radiator fans (Refer to 7 - COOL-
ING/ENGINE/RADIATOR FAN - INSTALLATION).
(47) Connect the radiator upper hose.
(48) Connect the heater hoses. Remove pinch-off
pliers from the rear heater hoses (if equipped).
Fig. 13 Right Mount to Engine
1 - BOLT
2 - MOUNT BRACKET
3 - ENGINE RIGHT MOUNT ASSEMBLY
Fig. 14 LEFT MOUNT TO FRAME BRACKET
1 - FRAME BRACKET
2 - FRAME RAIL - LEFT
3 - BOLT
4 - TRANSAXLE MOUNT
9 - 92 ENGINE 3.3/3.8LRS
ENGINE 3.3/3.8L (Continued)

DESCRIPTION N´m Ft.
Lbs.In.
Lbs.
Engine Mounting (Refer to 9 - ENGINE/
ENGINE MOUNTING)
Exhaust ManifoldÐBolts 23 Ð 200
Exhaust Crossover
PipeÐBolts54 40 Ð
Intake Manifold -
LowerÐBolts23 Ð 200
Intake Manifold - Lower
Gasket RetainerÐBolts12 Ð 105
Intake Manifold
UpperÐBolts12 Ð 105
Lifter Yoke RetainerÐ
Bolts12 Ð 105
Oil Filter Attaching Fitting 54 40 Ð
Oil Cooler Attaching
Fitting27 20 Ð
Oil Filter 20 15 Ð
Oil Filter AdapterÐBolts 28 Ð 250
Oil Gallery Plug 27 20 Ð
Oil PanÐBolts 12 Ð 105
Oil Pan DrainÐPlug 27 20 Ð
Oil Pressure Switch 23 Ð 200
Oil Pump Cover
PlateÐScrews12 Ð 105
Oil Pump Pick-up
TubeÐBolt28 Ð 250
Oil Dipstick HousingÐ
Bolts48 35 Ð
Rocker Arm ShaftÐBolts 23 Ð 200
Spark Plug 16 12 Ð
Timing Chain Case Cover
ÐM8 Bolt 27 20 Ð
ÐM10 Bolt 54 40 Ð
Water PumpÐBolts 12 Ð 105
Water Pump PulleyÐ
Bolts28 Ð 250SPECIAL TOOLS
3.3/3.8L ENGINE
Dolly 6135
Cradle 6710A
Adapter 6909A
Adapter 8444
9 - 98 ENGINE 3.3/3.8LRS
ENGINE 3.3/3.8L (Continued)

Remove all gasket material from cylinder head and
block (Refer to 9 - ENGINE - STANDARD PROCE-
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:
²Standard dimension = less than 0.05 mm (0.002
inch.)
²Service Limit = 0.2 mm (0.008 inch.)
²Grinding 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 ªLº
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 ªRº 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).
Fig. 18 DIPSTICK & TUBE
1 - DIPSTICK
2 - BOLT
3 - TUBE
Fig. 19 Checking Cylinder Head FlatnessÐTypical
Fig. 20 Head Gasket Installation
1 - CYLINDER HEAD GASKET
2 - LOCATION IDENTIFICATION (L = LEFT BANK, R = RIGHT
BANK)
9 - 104 ENGINE 3.3/3.8LRS
CYLINDER HEAD (Continued)

(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 val-
ues:
²Step 1: Bolts1±8to61N´m(45ft.lbs.)
²Step 2: Bolts1±8to88N´m(65ft.lbs.)
²Step 3: Bolts1±8(again) to 88 N´m (65 ft. lbs.)
²Step 4: Bolts1±8turn an additional 1/4 Turn.
(Do not use a torque wrench for this step.)
NOTE: Bolt torque after 1/4 turn should be over 122
N´m (90 ft. lbs.). If not, replace the bolt.
(6) Inspect push rods and replace worn or bent
rods.
(7) Install the push rods.
(8) Install the rocker arm and shaft assemblies.
(Refer to 9 - ENGINE/CYLINDER HEAD/ROCKER
ARMS - INSTALLATION)
(9) Install the cylinder head covers. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION)
(10) Install the exhaust manifolds. (Refer to 9 -
ENGINE/MANIFOLDS/EXHAUST MANIFOLD -
INSTALLATION)(11) Install new O-ring on dipstick tube. Install
dipstick tube assembly (Fig. 18).
(12) Install the spark plugs.
(13) Install upper and lower intake manifolds.
(Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANI-
FOLD - INSTALLATION)
(14) Fill the cooling system. (Refer to 7 - COOL-
ING - STANDARD PROCEDURE)
(15) Connect negative cable to battery.
CYLINDER HEAD COVER(S)
DESCRIPTION
The cylinder head covers are made of stamped
steel. The covers are sealed with steel reinforced sil-
icon rubber gaskets. The cylinder head cover uses
rubber isolators at each fastener location (Fig. 23).
NOTE: Due to the tight packaging near the cylinder
head covers, which makes spill clean-up difficult, a
spill during an engine oil change may be misinter-
preted as an oil leak. When investigating an oil leak
in the location of the cylinder head covers and
intake manifold, follow the procedure found in Oil
Leak Diagnosis (Refer to 9 - ENGINE - DIAGNOSIS
AND TESTING) for determining the source of a leak.Fig. 21 Checking Bolts for Stretching (Necking)
1 - STRETCHED BOLT
2 - THREADS ARE NOT STRAIGHT ON LINE
3 - THREADS ARE STRAIGHT ON LINE
4 - UNSTRETCHED BOLT
Fig. 22 CYLINDER HEAD TIGHTENING SEQUENCE
Fig. 23 Cylinder Head Cover
1 - CYLINDER HEAD COVER
2 - BOLT
RSENGINE 3.3/3.8L9 - 105
CYLINDER HEAD (Continued)

46) (Refer to 9 - ENGINE - SPECIFICATIONS). If
the cylinder walls are badly scuffed or scored, the
cylinder block should be replaced, and new pistons
and rings fitted.
Measure the cylinder bore at three levels in direc-
tions A and B (Fig. 46). Top measurement should be
10 mm (3/8 in.) down and bottom measurement
should be 10 mm (3/8 in.) up from bottom of bore.
(Refer to 9 - ENGINE - SPECIFICATIONS).
HYDRAULIC LIFTERS (CAM IN
BLOCK)
DESCRIPTION
The hydraulic lifters are a roller type design and
are positioned in the cylinder block. The lifters are
aligned and retained by a yoke and a retainer (Fig.
48).
Lifter alignment is maintained by machined flats
on lifter body. Lifters are fitted in pairs into six
aligning yokes. The aligning yokes are secured by a
yoke retainer (Fig. 48).
DIAGNOSIS AND TESTING - HYDRAULIC
LIFTERS
HYDRAULIC LIFTERS DIAGNOSIS - PRELIMINARY
STEP
Before disassembling any part of the engine to cor-
rect lifter noise, check the engine oil pressure. (Referto 9 - ENGINE/LUBRICATION - DIAGNOSIS AND
TESTING)
Check engine oil level. The oil level in the pan
should never be above the MAX mark on dipstick, or
below the MIN mark. Either of these two conditions
could cause noisy lifters.
OIL LEVEL TOO HIGH
If oil level is above the MAX mark on dipstick, it is
possible for the connecting rods to dip into the oil
while engine is running and create foaming. Foam in
oil pan would be fed to the hydraulic lifters by the oil
pump causing them to become soft and allow valves
to seat noisily.
OIL LEVEL TOO LOW
Low oil level may allow pump to take in air which
when fed to the lifters it causes them to become soft
and allows valves to seat noisily. Any leaks on intake
side of pump, through which air can be drawn, will
create the same lifter noise. Check the lubrication
system from the intake strainer to the oil pump
cover, including the relief valve retainer cap. When
lifter noise is due to aeration, it may be intermittent
or constant, and usually more than one lifter will be
noisy. When oil level and leaks have been corrected,
the engine should be operated at fast idle to allow all
of the air inside of the lifters to be bled out.
VALVE TRAIN NOISE
To determine source of valve train noise, operate
engine at idle with cylinder head covers removed and
listen for source of the noise.
NOTE: Worn valve guides or cocked springs are
sometimes mistaken for noisy lifters. If such is the
case, noise may be dampened by applying side
thrust on the valve spring. If noise is not apprecia-
bly reduced, it can be assumed the noise is in the
tappet. Inspect the rocker arm push rod sockets
and push rod ends for wear.
Valve lifter noise ranges from light noise to a
heavy click. A light noise is usually caused by exces-
sive leak-down around the unit plunger which will
necessitate replacing the lifter, or by the plunger par-
tially sticking in the lifter body cylinder. A heavy
click is caused either by a lifter check valve not seat-
ing, or by foreign particles becoming wedged between
the plunger and the lifter body causing the plunger
to stick in the down position. This heavy click will be
accompanied by excessive clearance between the
valve stem and rocker arm as valve closes. In either
case, lifter assembly should be removed for inspec-
tion.
Fig. 46 Checking Cylinder Bore Size
9 - 116 ENGINE 3.3/3.8LRS
ENGINE BLOCK (Continued)

(11) Start engine and inspect for leaks.
(12) Stop engine and inspect oil level.
NOTE: Care should be exercised when disposing
used engine oil after it has been drained from a
vehicle engine. Refer to the WARNING listed above.
STANDARD PROCEDURE - ENGINE OIL LEVEL
CHECK
The best time to check engine oil level is after it
has sat overnight, or if the engine has been running,
allow the engine to be shut off for at least 5 minutes
before checking oil level.
Checking the oil while the vehicle is on level
ground will improve the accuracy of the oil level
reading (Fig. 97). Add only when the level is at or
below the ADD mark.
Fig. 97 Engine Oil Level Dipstick and Fill Locations
1 - COOLANT RECOVERY CONTAINER 3 - ENGINE OIL LEVEL DIPSTICK
2 - ENGINE OIL FILL CAP 4 - RADIATOR PRESSURE CAP
Fig. 96 Engine Oil Drain Plug and Oil Filter
1 - DRAIN PLUG
2 - OIL FILTER
9 - 140 ENGINE 3.3/3.8LRS
OIL (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)