2005 CHRYSLER CARAVAN Service Manual

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Page 2289 of 2339

CHRYSLER CARAVAN 2005 Service Manual Fig. 9 ORVR System Schematic
1 - FUEL TANK (PLASTIC) 11 - NATURAL VACUUM LEAD DETECTION (NVLD)
2 - FUEL FILLER TUBE 12 - LIQUID SEPARATOR (IF EQUIPPED)
3 - FUEL CAP (PRESSURE/RELIEF) 13 - ENGINE WIRIN

Page 2290 of 2339

CHRYSLER CARAVAN 2005 Service Manual DIAGNOSIS AND TESTING - VEHICLE DOES
NOT FILL
CONDITION POSSIBLE CAUSES CORRECTION
Pre-Mature Nozzle Shut-Off Defective fuel tank assembly
components.Fill tube improperly installed
(sump)
Fill tube ho

Page 2291 of 2339

CHRYSLER CARAVAN 2005 Service Manual PCV VALVE
DESCRIPTION
The PCV valve contains a spring loaded plunger.
The plunger meters the amount of crankcase vapors
routed into the combustion chamber based on intake
manifold vacuum (Fig. 10) or

Page 2292 of 2339

CHRYSLER CARAVAN 2005 Service Manual (2) Install hose on PCV valve. Remove the
make-up air hose from the air plenum at the rear of
the engine. Hold a piece of stiff paper (parts tag)
loosely over the end of the make-up air hose.
(3) Afte

(2) Install hose on PCV valve. Remove the
make-up air hose from the air plenum at the rear of
the engine. Hold a piece of stiff paper (parts tag)
loosely over the end of the make-up air hose.
(3) After allowing approximately one minute for
crankcase pressure to reduce, the paper should draw
up against the hose with noticeable force. If the
engine does not draw the paper against the grommet
after installing a new valve, replace the PCV valve
hose.
(4) Turn the engine off. Remove the PCV valve
from intake manifold. The valve should rattle when
shaken.
(5) Replace the PCV valve and retest the system if
it does not operate as described in the preceding
tests.Do not attempt to clean the old PCV valve.
If the valve rattles, apply a light coating of Loctitet
Pipe Sealant With Teflon to the threads. Thread the
PCV valve into the manifold plenum and tighten to 7
N´m (60 in. lbs.) torque.
VAPOR CANISTER
DESCRIPTION
There are 2 EVAP canisters on the vehicle. The
vacuum and vapor tubes connect to the top of the
canister. It is a charcoal canister (Fig. 15) or (Fig.
16).OPERATION
All vehicles use a maintenance free, evaporative
(EVAP) canister. Fuel tank vapors vent into the can-
ister. The canister temporarily holds the fuel vapors
until intake manifold vacuum draws them into the
combustion chamber. The Powertrain Control Module
(PCM) purges the canister through the proportional
purge solenoid. The PCM purges the canister at pre-
determined intervals and engine conditions.
Purge Free Cells
Purge-free memory cells are used to identify the
fuel vapor content of the evaporative canister. Since
the evaporative canister is not purged 100% of the
time, the PCM stores information about the evapora-
tive canister's vapor content in a memory cell.
The purge-free cells are constructed similar to cer-
tain purge-normal cells. The purge-free cells can be
monitored by the DRB IIItScan Tool. The only dif-
ference between the purge-free cells and normal
adaptive cells is that in purge-free, the purge is com-
pletely turned off. This gives the PCM the ability to
compare purge and purge-free operation.
REMOVAL
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the 2 hoses (Fig. 15).
(3) Remove bolt.
(4) Pull canister rearward to remove.
Fig. 15 FRONT EVAP CANISTER
1 - Front EVAP Canister
2 - Vent Valve
Fig. 16 REAR EVAP CANISTER
1 - Rear EVAP Canister
2 - Front EVAP Canister
3 - Vent Valve
RSEVAPORATIVE EMISSIONS25-19
PCV VALVE (Continued)

Page 2293 of 2339

CHRYSLER CARAVAN 2005 Service Manual REMOVAL - WITH NVLD - FOLD-IN-FLOOR
(1) Raise and support the vehicle.
(2) Remove the 3 hoses.
(3) Remove bolt (Fig. 17).
(4) Pull canister rearward to remove.
REMOVAL - REAR EVAP CANISTER
(1) Raise a

Page 2294 of 2339

CHRYSLER CARAVAN 2005 Service Manual INSTALLATION - REAR EVAP CANISTER
(1) Install canister arrow heads into the rubber
gromments (Fig. 20).
(2) Install bolt and tighten.
(3) Install hoses.
(4) Lower vehicle.
Fig. 20 REAR EVAP CANISTER B

Page 2295 of 2339

CHRYSLER CARAVAN 2005 Service Manual EXHAUST GAS RECIRCULATION
TABLE OF CONTENTS
page page
EXHAUST GAS RECIRCULATION
SPECIFICATIONS
TORQUE............................22
TUBE
REMOVAL - 2.4L........................22
INSTALLATION - 2.4L...

Page 2296 of 2339

CHRYSLER CARAVAN 2005 Service Manual VA LV E
DESCRIPTION
The EGR system consists of:
²EGR tube (connects a passage in the intake
manifold to the exhaust port in the cylinder head)
²EGR valve
²Electronic EGR Transducer
²Connecting hos

VA LV E
DESCRIPTION
The EGR system consists of:
²EGR tube (connects a passage in the intake
manifold to the exhaust port in the cylinder head)
²EGR valve
²Electronic EGR Transducer
²Connecting hoses
OPERATION
Refer to Monitored Systems - EGR Monitor in this
group for more information.
The engines use Exhaust Gas Recirculation (EGR)
systems. The EGR system reduces oxides of nitrogen
(NOx) in engine exhaust and helps prevent detona-
tion (engine knock). Under normal operating condi-
tions, engine cylinder temperature can reach more
than 3000ÉF. Formation of NOx increases proportion-
ally with combustion temperature. To reduce the
emission of these oxides, the cylinder temperature
must be lowered. The system allows a predetermined
amount of hot exhaust gas to recirculate and dilute
the incoming air/fuel mixture. The diluted air/fuel
mixture reduces peak flame temperature during com-
bustion.
The electric EGR transducer contains an electri-
cally operated solenoid and a back-pressure trans-
ducer (Fig. 2). The Powertrain Control Module (PCM)
operates the solenoid. The PCM determines when toenergize the solenoid. Exhaust system back-pressure
controls the transducer.
When the PCM energizes the solenoid, vacuum
does not reach the transducer. Vacuum flows to the
transducer when the PCM de-energizes the solenoid.
When exhaust system back-pressure becomes high
enough, it fully closes a bleed valve in the trans-
ducer. When the PCM de-energizes the solenoid and
back-pressure closes the transducer bleed valve, vac-
uum flows through the transducer to operate the
EGR valve.
Fig. 1 EGR VALVE AND TUBE 2.4L
1 - EGR Tube
2 - EGR Valve
Fig. 2 EGR Valve and Transducer - Typical
1 - DIAPHRAGM
2 - PISTON
3 - SPRING
4 - EGR VALVE ASSEMBLY
5 - VACUUM MOTOR
6 - VACUUM MOTOR FITTING
7 - VACUUM OUTLET FITTING TO EGR VALVE
8 - EGR VALVE CONTROL ASSEMBLY
9 - ELECTRIC SOLENOID PORTION OF VALVE CONTROL
10 - VACUUM INLET FITTING FROM ENGINE
11 - BACK-PRESSURE HOSE
12 - TRANSDUCER PORTION OF VALVE CONTROL
13 - ELECTRICAL CONNECTION POINT
14 - EGR VALVE BACK-PRESSURE FITTING
15 - EXHAUST GAS INLET
16 - STEM PROTECTOR AND BUSHING
17 - BASE
18 - MOVEMENT INDICATOR
19 - POPPET VALVE
20 - SEAT
21 - EXHAUST GAS OUTLET
RSEXHAUST GAS RECIRCULATION25-23

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