2005 CHRYSLER CARAVAN length

VALVE SPRINGS
DESCRIPTION SPECIFICATION
Metric Standard
Free Length
(Approx.)48.4 mm 1.905 in.
Nominal Force
(Valve Closed)338 N @ 38.0
mm75.98 lbs. @
1.496 in.
Nominal Force
(Valve Open)607 N @ 29.75
mm136 lbs. @
1.172 in.
Installed Height 38.00 mm 1.496 in.
Number of Coils 7.82
Wire Diameter 3.86 mm 1.496 in
OIL PUMP
DESCRIPTION SPECIFICATION
Metric Standard
Clearance Over
Rotors (Max.)0.10 mm 0.004 in.
Cover
Out-of-Flat
(Max.)0.025 mm 0.001 in.
Inner Rotor
Thickness (Min.)9.40 mm 0.370 in.
Outer Rotor
Thickness (Min.)9.40 mm 0.370 in.
Outer Rotor
Clearance
(Max.)0.039 mm 0.015 in.
Outer Rotor
Diameter (Min.)79.95 mm 3.148 in.
Tip Clearance
Between Rotors
(Max.)0.20 mm 0.008 in.
OIL PRESSURE
DESCRIPTION SPECIFICATION
Metric Standard
At Curb Idle
Speed*25 kPa 4 psi
At 3000 rpm 170 - 550 kPa 25 - 80 psi
CAUTION:
*If pressure is ZERO at curb idle, DO NOT run engine
at 3000 rpm.
SPECIFICATIONS - TORQUE
DESCRIPTION N´m Ft.
Lbs.In.
Lbs.
Balance Shaft Carrier to
BlockÐBolts54 40 Ð
Balance Shaft Gear
CoverÐDouble Ended
Fastener12 Ð 105
Balance Shaft SprocketÐ
Bolt28 Ð 250
Balance Shaft Chain
TensionerÐBolts12 Ð 105
Balance Shaft Carrier
CoverÐBolts12 Ð 105
Camshaft SprocketÐBolt 101 75 Ð
Connecting Rod
CapÐBolts27 +
1¤4
turn20
+1¤4
turnÐ
Crankshaft Main Bearing
Cap/Bedplate
ÐM8 Bolts 28 250
ÐM11 Bolts 41 +
1¤4
Turn30
+1¤4
TurnÐ
Crankshaft Damper 136 100 Ð
Cylinder HeadÐBolts (Refer to 9 - ENGINE/
CYLINDER HEAD -
INSTALLATION)
Cylinder Head CoverÐ
Bolts12 Ð 105
Flex Plate to Crankshaft 95 70 Ð
Engine Mount Bracket
RightÐBolts61 45 Ð
Engine MountingÐBolts (Refer to 9 ENGINE/
ENGINE MOUNTING)
Exhaust Manifold to
Cylinder HeadÐBolts19 Ð 170
Exhaust Manifold Heat
ShieldÐBolts12 Ð 105
Intake Manifold - Lower
ÐBolts28 Ð 250
Intake Manifold -
UpperÐBolts28 Ð 250
Oil Filter 12 Ð 105
Oil PanÐBolts 12 Ð 105
Oil Pan DrainÐPlug 28 20 Ð
Oil Pressure Switch 21 Ð 190
9 - 20 ENGINE 2.4LRS
ENGINE 2.4L (Continued)

LUBRICATION
DESCRIPTION
The lubrication system is a full-flow filtration,
pressure feed type. The oil pump is mounted in the
front engine cover and driven by the crankshaft.
OPERATION
Engine oil drawn up through the pickup tube and
is pressurized by the oil pump and routed through
the full-flow filter to the main oil gallery running the
length of the cylinder block. A diagonal hole in each
bulkhead feeds oil to each main bearing. Drilled pas-
sages within the crankshaft route oil from main bear-
ing journals to connecting rod journals. Balance shaft
lubrication is provided through an oil passage from
the number one main bearing cap through the bal-
ance shaft carrier support leg. This passage directly
supplies oil to the front bearings and internal
machined passages in the shafts that routes oil from
front to the rear shaft bearing journals. A vertical
hole at the number five bulkhead routes pressurized
oil through a restrictor (integral to the cylinder head
gasket) up past a cylinder head bolt to an oil gallery
running the length of the cylinder head. The cam-shaft journals are partially slotted to allow a prede-
termined amount of pressurized oil to pass into the
bearing cap cavities. Lubrication of the camshaft
lobes are provided by small holes in the camshaft
bearing caps that are directed towards each lobe. Oil
returning to the pan from pressurized components
supplies lubrication to the valve stems. Cylinder
bores and wrist pins are splash lubricated from
directed slots on the connecting rod thrust collars
(Fig. 86).
DIAGNOSIS AND TESTING - CHECKING
ENGINE OIL PRESSURE
(1) Disconnect and remove oil pressure switch.
(Refer to 9 - ENGINE/LUBRICATION/OIL PRES-
SURE SENSOR/SWITCH - REMOVAL)
(2) Install Special Tools C-3292 Gauge with 8406
Adaptor fitting.
(3) Start engine and record oil pressure. Refer to
Specifications for correct oil pressure requirements.
(Refer to 9 - ENGINE - SPECIFICATIONS)
CAUTION: If oil pressure is 0 at idle, do not perform
the 3000 RPM test
(4) If oil pressure is 0 at idle. Shut off engine,
check for pressure relief valve stuck open, a clogged
oil pick-up screen or a damaged oil pick-up tube
O-ring.
(5) After test is complete, remove test gauge and
fitting.
Fig. 85 Right Mount to Rail and Engine
1 - BOLT - MOUNT TO RAIL 68 N´m (50 ft. lbs.)
2 - BOLT - MOUNT TO ENGINE 54 N´m (40 ft. lbs.)
3 - BOLT - MOUNT TO RAIL (HORIZONTAL) 68 N´m (50 ft. lbs.)
4 - RIGHT ENGINE MOUNT
5 - RIGHT FRAME RAIL
Fig. 86 Engine Lubrication System
RSENGINE 2.4L9-53
RIGHT MOUNT (Continued)

(9) Disconnect throttle and speed control (if
equipped) cables from throttle lever and bracket.
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
THROTTLE CONTROL CABLE - REMOVAL)
(10) Remove the EGR tube. (Refer to 25 - EMIS-
SIONS CONTROL/EXHAUST GAS RECIRCULA-
TION/TUBE - REMOVAL)
(11) Remove the upper manifold support bracket
bolt to manifold (Fig. 109).
(12) Remove engine oil dipstick from tube.
(13) Remove upper intake manifold bolts (Fig.
110). Remove upper intake manifold.
CAUTION: Cover intake manifold to prevent foreign
material from entering engine.
INSPECTION
(1) Check manifold surfaces for flatness with
straight edge. Surface must be flat within 0.15 mm
per 300 mm (0.006 in. per foot) of manifold length.
(2) Inspect manifold for cracks or distortion.
Replace manifold if necessary.
INSTALLATION
(1) Clean manifold sealing surfaces.
(2) Apply a 1.5 mm (0.060 in.) bead MopartGas-
ket Maker to the perimeter of the lower intake man-
ifold runner openings.
(3) Install upper intake manifold and tighten fas-
teners to 28 N´m (250 in. lbs.) in sequence shown in
(Fig. 110). Repeat this procedures until all fasteners
are at specified torque.
(4) Install engine oil dipstick.
(5) Install upper bolt in intake manifold to front
support bracket (Fig. 109). Torque to 28 N´m (250 in.
lbs.).
(6) Install EGR tube. (Refer to 25 - EMISSIONS
CONTROL/EXHAUST GAS RECIRCULATION/
TUBE - INSTALLATION)
(7) Install throttle cables in bracket.
(8) Connect throttle and speed control (if equipped)
cables to throttle lever.
(9) Connect vacuum lines for power brake booster,
LDP, EGR transducer, and speed control vacuum res-
ervoir (if equipped) at upper intake manifold fittings.
(10) Connect vacuum lines for purge solenoid and
PCV valve.
(11) Connect electrical connectors for MAP sensor,
throttle position sensor (TPS), and idle air control
(IAC) motor.
(12) Install air cleaner upper housing and air
intake tube to throttle body.
(13) Connect inlet air temperature sensor connec-
tor (Fig. 106).
(14) Connect negative cable to battery.
Fig. 108 Throttle Body Electrical Connectors -
Typical
1 - IDLE AIR CONTROL MOTOR CONNECTOR
2 - TPS CONNECTOR
Fig. 109 Upper Intake Manifold Support Bracket
1 - NUT - BRACKET TO CYLINDER HEAD COVER
2 - BOLT - BRACKET TO UPPER INTAKE MANIFOLD
3 - UPPER INTAKE MANIFOLD SUPPORT BRACKET
Fig. 110 Upper Intake Manifold Tightening Sequence
- 2.4L
RSENGINE 2.4L9-61
INTAKE MANIFOLD - UPPER (Continued)

INTAKE MANIFOLD - LOWER
REMOVAL
(1) Perform fuel system pressure release proce-
durebefore attempting any repairs.(Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY - STANDARD
PROCEDURE)
(2) Remove upper intake manifold. (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
REMOVAL)
CAUTION: Cover intake manifold openings to pre-
vent foreign material from entering engine.
(3) Disconnect fuel line. (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/QUICK CONNECT FIT-
TING - STANDARD PROCEDURE)
(4) Drain the cooling system. (Refer to 7 - COOL-
ING - STANDARD PROCEDURE)
(5) Remove heater supply and radiator upper
hoses at intake manifold.
(6) Disconnect coolant temperature sensor/fuel
injector wire harness connector.
(7) Remove lower intake manifold support bracket
upper bolts (Fig. 111).
(8) Loosen the lower intake manfold support
bracket lower bolt (Fig. 111).
(9) Disconnect fuel injector harness.
(10) Remove the bolts attaching the power steering
reservoir to manifold. Set reservoir aside.Do not
disconnect line from reservoir.
(11) Remove lower intake manifold fasteners (Fig.
112). Remove the manifold from engine.(12) Inspect the manifold. (Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD - INSPECTION)INSPECTION
(1) Check manifold surfaces for flatness with
straight edge. Surface must be flat within 0.15 mm
per 300 mm (0.006 in. per foot) of manifold length.
(2) Inspect manifold for cracks or distortion.
Replace manifold if necessary.
INSTALLATION
If the following items were removed, install and
torque to specifications:
²Fuel rail bolts - 22 N´m (200 in. lbs.)
²Coolant outlet connector bolts - 28 N´m (250 in.
lbs.)
²Coolant temperature sensor - 7 N´m (60 in. lbs.)
(1) Position a new gasket on cylinder head and
install lower manifold.
(2) Install and tighten intake manifold fasteners to
28 N´m (250 in. lbs.) in the sequence shown in (Fig.
112). Repeat procedure until all bolts are at specified
torque.
(3) Install lower intake manifold support bracket
bolts (Fig. 111) and tighten to:
²Bolts to intake 28 N´m (250 in. lbs.)
²Bolt to engine block 54 N´m (40 ft. lbs.)
(4) Position power steering reservoir on manifold
and install bolts.
(5) Connect the fuel line. (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/QUICK CONNECT FIT-
TING - STANDARD PROCEDURE)
(6) Connect coolant temperature sensor/fuel injec-
tor wiring harness electrical connector.
(7) Install the radiator upper and heater supply
hoses.
Fig. 111 Lower Intake Manifold Support Bracket
1 - SUPPORT BRACKET
2 - BOLTS - UPPER TO MANIFOLD
3 - BOLT - LOWER TO ENGINE BLOCK
Fig. 112 Lower Intake Manifold Tightening Sequence
9 - 62 ENGINE 2.4LRS

(8) Install the upper intake manifold. (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSTALLATION)
(9) Fill the cooling system. (Refer to 7 - COOLING
- STANDARD PROCEDURE)
EXHAUST MANIFOLD
REMOVAL
(1) Raise vehicle and disconnect exhaust pipe from
the exhaust manifold.
(2) Disconnect upstream oxygen sensor connector
at the rear of exhaust manifold.
(3) Remove the bolts attaching the manifold to the
cylinder head.
(4) Remove exhaust manifold.
(5) Inspect the manifold. (Refer to 9 - ENGINE/
MANIFOLDS/EXHAUST MANIFOLD - INSPEC-
TION)
CLEANING
(1) Discard gasket (if equipped) and clean all sur-
faces of manifold and cylinder head.
INSPECTION
(1) Inspect manifold gasket surfaces for flatness
with straight edge. Surface must be flat within 0.15
mm per 300 mm (0.006 in. per foot) of manifold
length.
(2) Inspect manifolds for cracks or distortion.
Replace manifold as necessary.
INSTALLATION
(1) Install exhaust manifold with a new gasket.
Tighten attaching nuts in the sequence shown in
(Fig. 113) to 19 N´m (170 in. lbs.).
(2) Attach exhaust pipe to exhaust manifold and
tighten fasteners to 37 N´m (27 ft. lbs.).
(3) Install and connect the oxygen sensor. (Refer to
14 - FUEL SYSTEM/FUEL INJECTION/O2 SENSOR
- COMPONENT LOCATION)
TIMING BELT COVER(S)
REMOVAL
FRONT COVER - UPPER
(1) Remove upper timing belt cover fasteners (Fig.
114) and remove cover.
FRONT COVER - LOWER
(1) Remove crankshaft vibration damper (Refer to
9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL).(2) Remove generator drive belt tensioner assem-
bly (Refer to 7 - COOLING/ACCESSORY DRIVE/
BELT TENSIONERS - REMOVAL).
(3) Remove timing belt front cover bolts (Fig. 114)
and remove covers.
Fig. 113 Exhaust Manifold Tightening Sequence
Fig. 114 Front Timing Belt Covers
1 - BOLTS - UPPER FRONT COVER 6 N´m (50 in. lbs.)
2 - BOLTS - LOWER FRONT COVER 6 N´m (50 in. lbs.)
RSENGINE 2.4L9-63
INTAKE MANIFOLD - LOWER (Continued)

CONNECTING RODS
DESCRIPTION SPECIFICATION
Metric Standard
Bearing
Clearance0.019-0.065
mm.0.017-0.020 in.
Wear Limit 0.074 mm 0.003 in.
Side Clearance 0.13-0.32 mm 0.005-0.013 in.
Wear Limit 0.38 mm 0.015 in.
PISTONS
DESCRIPTION SPECIFICATION
Metric Standard
Piston Diameter
3.3L-Measured
39.8 mm (1.567
in) From Piston
To p92.968-92.998
mm.3.660-3.661 in.
Piston Diameter
3.8L-Measured
33.01 mm (1.30
in) From Piston
To p95.968-95.998
mm.3.778-3.779 in.
Clearance in
Bore @ Size
Location (New)-0.005-0.039
mm-0.0002±0.0015
in.
Weight 3.3L 362   5 grams 12.77   0.1764
oz.
Weight 3.8L 426   5 grams 15.03   0.1764
oz.
PISTON PINS
DESCRIPTION SPECIFICATION
Metric Standard
Type Press Fit in Rod (Serviced as a
Assembly)
Clearance in
Piston @ 21C
(70ÉF)0.006-0.019
mm0.0002-0.0007
in.
Clearance in
Connecting RodInterference Fit
Diameter 22.87-22.88
mm0.9007-0.9009
in.
Length 3.3L 67.25-67.75
mm2.648-2.667 in.
Length 3.8L 71.25-71.75
mm2.805-2.824 in.
PISTON RINGS
DESCRIPTION SPECIFICATION
Metric Standard
Ring End Gap
To p
Compression
Ring0.18-0.38 mm 0.007-0.015 in.
Second
Compression
Ring0.28-0.57 mm 0.011-0.022 in.
Oil Control
(Steel Rails)0.23-0.78 mm 0.009-0.030 in.
Wear Limit-
Compression
Rings1.0 mm 0.039 in.
Wear Limit-Oil
Control Steel
Rails1.88 mm 0.074 in.
Ring Side
Clearance
To p
Compression
Ring 3.3L0.030-0.080
mm0.0012-0.0031
in.
To p
Compression
Ring 3.8L0.030-0.069
mm0.0012-0.0027
in.
Second
Compression
Ring 3.3L0.030-0.095
mm0.0012-0.0037
in.
Second
Compression
Ring 3.8L0.041-0.085
mm0.0016-0.0033
in.
Oil Ring (Steel
Ring)0.039-0.200
mm0.0015-0.0078
in.
Wear Limit- Top
Ring0.10 mm 0.004 in.
Wear Limit-2nd
Ring0.13 mm 0.005
Wear Limit Oil
Ring Pack0.266 mm 0.009
Ring Width-Top
Compression
Ring 3.3L1.46-1.49 mm 0.0575-0.058 in.
Ring Width-Top
Compression
Ring 3.8L1.175-1.190
mm0.0462-0.0468
9 - 94 ENGINE 3.3/3.8LRS
ENGINE 3.3/3.8L (Continued)

VALVES
DESCRIPTION SPECIFICATION
Metric Standard
Face Angle-
Intake- 45-45.5É
Face Angle-
Exhaust- 45-45.5É
Head Diameter-
Intake47.87-48.13
mm1.88-1.89 in.
Head Diameter-
Exhaust35.37-35.63
mm1.39-1.40 in.
Valve Lift (Zero
Lash)-Intake
and Exhaust-
3.3L9.80 mm 0.385 in.
Valve Lift (Zero
Lash)-Intake
and Exhaust-
3.8L11.0 mm 0.433 in.
Valve Length-
Intake125.84-126.6
mm4.95-4.98 in.
Valve Length-
Exhaust127.20-127.96 5.00-5.04 in.
Valve Stem to
Tip Height
(valve tip to
spring seat
washer)-Intake48.1-49.7 mm 1.89-1.95 in.
Valve Stem to
Tip Height
(valve tip to
spring seat
washer)-
Exhaust48.53-50.09
mm1.91-1.97 in.
VALVE SEAT
DESCRIPTION SPECIFICATION
Metric Standard
Angle - 44.5-45É
Run Out
(Service Limits)0.0762 mm 0.003 in.
Width-Intake
and Exhaust1.50-2.00 mm 0.057-0.078 in.
VALVE GUIDE
DESCRIPTION SPECIFICATION
Metric Standard
Guide Bore
Diameter (Std.)6.975-7.00 mm 0.274-0.275 in.
VALVE MARGIN
DESCRIPTION SPECIFICATION
Metric Standard
Intake 0.825-0.973
mm0.032-0.038 in.
Exhaust 1.565-1.713
mm0.061-0.067 in.
VALVE STEM DIAMETER
DESCRIPTION SPECIFICATION
Metric Standard
Intake
(Standard)6.935-6.953
mm0.2718-0.2725
in.
Exhaust
(Standard)6.906-6.924
mm0.2718-0.2725
in.
VALVE STEM TO GUIDE CLEARANCE
DESCRIPTION SPECIFICATION
Metric Standard
Intake 0.025-0.065
mm0.001-0.0025 in.
Exhaust 0.059-0.094
mm0.002-0.0037 in.
Max Allowable-
Intake (Rocking
Method)0.247 mm 0.010 in.
Max Allowable-
Exhaust
(Rocking
Method)0.414 mm 0.016 in.
PUSH RODS
DESCRIPTION SPECIFICATION
Metric Standard
Length 135.438 mm 5.33 in.
9 - 96 ENGINE 3.3/3.8LRS
ENGINE 3.3/3.8L (Continued)

VALVE SPRING
DESCRIPTION SPECIFICATION
Metric Standard
Free Length-
Type A51.4 mm 2.02 in.
Free Length-
Type B53.4 mm 2.10 in.
Wire Diameter
Type A3.95-4.77 mm 0.15-0.19 in.
Wire Diameter
Type B4.19-4.29 mm 0.16-0.17 in.
Number of Coils
Type A7.52
Number of Coils
Type B7.25
Spring Tension
(Valve Closed)
Type A376.4-424.4 N
@ 41.9 mm84.6-95.6 lbs.
@ 1.65 in.
Spring Tension
(Valve Open)
Type A863.9-959.9 N
@ 41.9 mm194.2-215.8 lbs.
@ 1.65 in.
Spring Tension
(Valve Closed)
Type B377-423 N @
41.9 mm84.8-95.2 lbs.
@ 1.65 in.
Spring Tension
(Valve Open)
Type B880-962 N @
30.91 mm197.9-216.3 lbs.
@ 122 in.
Installed Height 41.1-42.7 mm 1.61-1.68 in
LUBRICATION
DESCRIPTION SPECIFICATION
Metric Standard
At Curb Idle
Speed*
(Minimum with
engine at
operating
temperature)34.47 kPa 5 psi
At 3000 RPM 205-551 kPa 30-80 psi
Oil Filter
By-Pass Valve
Setting62-103 kPa 9-15 psi
Oil Pressure
Switch Actuating
Pressure14-28 Kpa 2-4 psi
caution:
*If pressure is ZERO at curb idle, DO NOT run engine
at 3000 rpm.
OIL PUMP
DESCRIPTION SPECIFICATION
Metric Standard
Clearance Over
rotors-Inner and
Outer0.10 mm 0.004 in.
Cover
Out-Of-Flat
(Max.)0.025 mm 0.001 in.
Inner Rotor
Thickness7.64 mm 0.301 in.
Outer Rotor
Thickness (Min)7.64 mm 0.301 in.
Outer Rotor
Clearance
(Max)0.039 mm 0.015 in.
Outer Rotor
Diameter (Min)79.95 mm 3.148 in.
Tip Clearance
Between Rotors
(Max)0.20 mm 0.008 in.
SPECIFICATIONS - TORQUE
DESCRIPTION N´m Ft.
Lbs.In.
Lbs.
Camshaft SprocketÐBolt 54 40 Ð
Camshaft Thrust
PlateÐBolts12 Ð 105
Connecting Rod
CapÐBolts54 +
1¤4
turn40
+1¤4
turnÐ
Crankshaft Main Bearing
CapÐBolts41 +
1¤4
turn30
+1¤4
turnÐ
Crankshaft Main Bearing
Cap Cross Bolts (3.8L)61 45 Ð
Crankshaft Oil Seal
Retainer RearÐBolts12 Ð 105
Crankshaft DamperÐBolt 54 40 Ð
Cylinder Block Drain
Plugs20 15 Ð
Cylinder HeadÐBolts (Refer to 9 - ENGINE/
CYLINDER HEAD -
INSTALLATION)
Cylinder Head CoverÐ
Bolts12 Ð 105
Flex Plate to Crankshaft 95 70 Ð
RSENGINE 3.3/3.8L9-97
ENGINE 3.3/3.8L (Continued)