2005 CHRYSLER CARAVAN spark plugs

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. 132).
Manifold surface flatness limits should not exceed
1.0 mm (0.039 in.).
INSTALLATION
(1) Position exhaust manifold on cylinder head
(Fig. 131). Install bolts to center runner (cylinder #4)
and initial tighten to 2.8 N´m (25 in. lbs.).
(2) Using a new gasket, attach crossover pipe to
exhaust manifold and tighten bolts to 41 N´m (30 ft.
lbs.) (Fig. 130).
NOTE: Inspect crossover pipe fasteners for damage
from heat and corrosion. The cross-over bolts are
made of a special stainless steel alloy. If replace-
ment is required, OEM bolts are highly recom-
mended.
(3) Position heat shield on manifold (Fig. 131).
(4) Install the remaining manifold attaching bolts.
Tighten all bolts to 23 N´m (200 in. lbs.).
(5) Install and tighten heat shield attaching nut to
12 N´m (105 in. lbs.) (Fig. 131).
(6) Connect battery negative cable.
VALVE TIMING
STANDARD PROCEDURE
STANDARD PROCEDURE - VALVE TIMING
VERIFICATION
(1) Remove front cylinder head cover and all 6
spark plugs.
(2) Rotate engine until the #2 piston is at TDC of
the compression stroke.
(3) Install a degree wheel on the crankshaft pulley.
(4) With proper adaptor, install a dial indicator
into #2 spark plug hole. Using the indicator find TDC
on the compression stroke.
(5) Position the degree wheel to zero.
(6) Remove dial indicator from spark plug hole.
(7) Place a 5.08 mm (0.200 in.) spacer between the
valve stem tip of #2 intake valve and rocker arm pad.
Allow tappet to bleed down to give a solid tappet
effect.
(8) Install a dial indicator so plunger contacts the
#2 intake valve spring retainer as nearly perpendic-
ular as possible. Zero the indicator.
(9) Rotate the engine clockwise until the intake
valve has lifted .254 mm (0.010 in.).
CAUTION: Do not turn crankshaft any further clock-
wise as intake valve might bottom and result in
serious damage.
(10) Degree wheel should read 6 degrees BTDC to
6 degrees ATDC.
STANDARD PROCEDURE - MEASURING
TIMING CHAIN WEAR
NOTE: This procedure must be performed with the
timing chain cover removed (Refer to 9 - ENGINE/
VALVE TIMING/TIMING CHAIN COVER - REMOVAL).
(1) Position a scale next to timing chain so that
any movement of chain may be measured (Fig. 133).
(2) Position a torque wrench and socket on the
camshaft sprocket attaching bolt. Apply force in the
direction of crankshaft rotation to take up slack to
the following torque:
²41 N´m (30 ft. lb.) with cylinder heads installed
²20 N´m (15 ft. lb.) with cylinder heads removed
NOTE: With torque applied to the camshaft
sprocket bolt, crankshaft should not be permitted to
move. It may be necessary to block crankshaft to
prevent rotation.
(3) Holding a measuring scale along edge of chain
links (Fig. 133).
Fig. 132 Check Exhaust Manifold Mounting
1 - STRAIGHT EDGE
2 - CROSSOVER PIPE MOUNTING SURFACE
3 - FEELER GAUGE
RSENGINE 3.3/3.8L9 - 155
EXHAUST MANIFOLD - LEFT (Continued)

Catalyst operation is dependent on its ability to
store and release the oxygen needed to complete the
emissions-reducing chemical reactions. As a catalyst
deteriorates, its ability to store oxygen is reduced.
Since the catalyst's ability to store oxygen is some-
what related to proper operation, oxygen storage can
be used as an indicator of catalyst performance.
Refer to the appropriate Diagnostic Information for
diagnosis of a catalyst related Diagnostic Trouble
Code (DTC).
The combustion reaction caused by the catalyst
releases additional heat in the exhaust system, caus-
ing temperature increases in the area of the reactor
under severe operating conditions. Such conditions
can exist when the engine misfires or otherwise does
not operate at peak efficiency.Do notremove spark
plug wires from plugs or by any other means short
out cylinders. Failure of the catalytic converter can
occur due to temperature increases caused by
unburned fuel passing through the converter. This
deterioration of the catalyst core can result in exces-
sively high emission levels, noise complaints, and
exhaust restrictions.
Unleaded gasoline must be used to avoid ruining
the catalyst core. Do not allow engine to operate
above 1200 RPM in neutral for extended periods over
5 minutes. This condition may result in excessive
exhaust system/floor pan temperatures because of no
air movement under the vehicle.
The flex joint allows flexing as the engine moves,
preventing breakage that could occur from the back-
and-forth motion of a transverse mounted engine.
CAUTION: Due to exterior physical similarities of
some catalytic converters with pipe assemblies,
extreme care should be taken with replacement
parts. There are internal converter differences
required in some parts of the country (particularly
vehicles built for States with strict emission
requirements) and between model years.
REMOVAL
(1) Loosen clamp and disconnect the muffler/reso-
nator assembly from catalytic converter pipe.
(2) Disconnect downstream oxygen sensor electri-
cal connector (Fig. 4). For removal of downstream
oxygen sensor, (Refer to 14 - FUEL SYSTEM/FUEL
INJECTION/O2 SENSOR - REMOVAL).
(3) Remove catalytic converter to exhaust manifold
attaching fasteners (Fig. 5).
(4) Remove catalytic converter and gasket (Fig. 5).
Fig. 4 Downstream Oxygen Sensor
1 - OXYGEN SENSOR CONNECTOR
2 - CATALYTIC CONVERTER
3 - DOWNSTREAM OXYGEN SENSOR
4 - ENGINE HARNESS CONNECTOR
Fig. 5 Catalytic Converter to Exhaust Manifold
1 - FLAG NUT
2 - GASKET
3 - BOLT
4 - CATALYTIC CONVERTER
RSEXHAUST SYSTEM11-5
CATALYTIC CONVERTER (Continued)

The major non-monitored circuits are listed below
along with examples of failures modes that do not
directly cause the PCM to set a DTC, but for a sys-
tem that is monitored.
FUEL PRESSURE
The fuel pressure regulator controls fuel system
pressure. The PCM cannot detect a clogged fuel
pump inlet filter, clogged in-line fuel filter, or a
pinched fuel supply or return line. However, these
could result in a rich or lean condition causing the
PCM to store an oxygen sensor, fuel system, or mis-
fire diagnostic trouble code.
SECONDARY IGNITION CIRCUIT
The PCM cannot detect an inoperative ignition coil,
fouled or worn spark plugs, ignition cross firing, or
open spark plug cables. The misfire will however,
increase the oxygen content in the exhaust, deceiving
the PCM in to thinking the fuel system is too lean.
Also see misfire detection. There are DTC's that can
detect misfire and Ionization shorts in the secondary
ignition circuit, refer to the Powertrain Diagnostic
manual for more information
CYLINDER COMPRESSION
The PCM cannot detect uneven, low, or high engine
cylinder compression. Low compression lowers O2
content in the exhaust. Leading to fuel system, oxy-
gen sensor, or misfire detection fault.
EXHAUST SYSTEM
The PCM cannot detect a plugged, restricted or
leaking exhaust system. It may set a EGR (if
equipped) or Fuel system or O2S fault.
FUEL INJECTOR MECHANICAL MALFUNCTIONS
The PCM cannot determine if a fuel injector is
clogged, the needle is sticking or if the wrong injector
is installed. However, these could result in a rich or
lean condition causing the PCM to store a diagnostic
trouble code for either misfire, an oxygen sensor, or
the fuel system.
EXCESSIVE OIL CONSUMPTION
Although the PCM monitors engine exhaust oxygen
content when the system is in closed loop, it cannot
determine excessive oil consumption.
THROTTLE BODY AIR FLOW
The PCM cannot detect a clogged or restricted air
cleaner inlet or filter element.
VACUUM ASSIST
The PCM cannot detect leaks or restrictions in the
vacuum circuits of vacuum assisted engine control
system devices. However, these could cause the PCMto store a MAP sensor diagnostic trouble code and
cause a high idle condition.
PCM SYSTEM GROUND
The PCM cannot determine a poor system ground.
However, one or more diagnostic trouble codes may
be generated as a result of this condition. The mod-
ule should be mounted to the body at all times,
including when diagnostics are performed.
PCM CONNECTOR ENGAGEMENT
The PCM may not be able to determine spread or
damaged connector pins. However, it might store
diagnostic trouble codes as a result of spread connec-
tor pins.
DESCRIPTION - MONITORED SYSTEMS
There are new electronic circuit monitors that
check fuel, emission, engine and ignition perfor-
mance. These monitors use information from various
sensor circuits to indicate the overall operation of the
fuel, engine, ignition and emission systems and thus
the emissions performance of the vehicle.
The fuel, engine, ignition and emission systems
monitors do not indicate a specific component prob-
lem. They do indicate that there is an implied prob-
lem within one of the systems and that a specific
problem must be diagnosed.
If any of these monitors detect a problem affecting
vehicle emissions, the Malfunction Indicator (Check
Engine) Lamp will be illuminated. These monitors
generate Diagnostic Trouble Codes that can be dis-
played with the a scan tool.
The following is a list of the system monitors:
²EGR Monitor (if equipped)
²Misfire Monitor
²Fuel System Monitor
²Oxygen Sensor Monitor
²Oxygen Sensor Heater Monitor
²Catalyst Monitor
²Evaporative System Leak Detection Monitor (if
equipped)
Following is a description of each system monitor,
and its DTC.
Refer to the appropriate Powertrain Diagnos-
tics Procedures manual for diagnostic proce-
dures.
OXYGEN SENSOR (O2S) MONITOR
Effective control of exhaust emissions is achieved
by an oxygen feedback system. The most important
element of the feedback system is the O2S. The O2S
is located in the exhaust path. Once it reaches oper-
ating temperatures of 300É to 350ÉC (572É to 662ÉF),
the sensor generates a voltage that is inversely pro-
portional to the amount of oxygen in the exhaust.
25 - 6 EMISSIONS CONTROLRS
EMISSIONS CONTROL (Continued)

PANEL TOP COVER - REMOVAL,INSTRUMENT ....................... 23-72
PANEL TOP PAD ASSEMBLY - INSTALLATION, INSTRUMENT ...........23-77
PANEL TOP PAD ASSEMBLY - REMOVAL, INSTRUMENT ....................... 23-77
PANEL/FENDER AIR EXHAUSTER - DESCRIPTION, REAR QUARTER .........23-59
PANEL/FENDER AIR EXHAUSTER - INSTALLATION, REAR QUARTER .........23-60
PANEL/FENDER AIR EXHAUSTER - REMOVAL, REAR QUARTER ............23-59
PANEL-THIRD ROW - FOLD-IN-FLOOR - INSTALLATION, BOTTOM OF SEAT
CUSHION PAN ...................... 23-152
PANEL-THIRD ROW - FOLD-IN-FLOOR - REMOVAL, BOTTOM OF SEAT
CUSHION PAN ...................... 23-152
PARK ASSIST DISPLAY - DESCRIPTION ....8B-3
PARK ASSIST DISPLAY - INSTALLATION . . . 8B-4
PARK ASSIST DISPLAY - OPERATION .....8B-3
PARK ASSIST DISPLAY - REMOVAL .......8B-4
PARK ASSIST MODULE - DESCRIPTION ....8B-4
PARK ASSIST MODULE - INSTALLATION . . . 8B-6
PARK ASSIST MODULE - OPERATION .....8B-5
PARK ASSIST MODULE - REMOVAL .......8B-5
PARK ASSIST SENSOR - DESCRIPTION ....8B-6
PARK ASSIST SENSOR - INSTALLATION . . . 8B-6
PARK ASSIST SENSOR - OPERATION ......8B-6
PARK ASSIST SENSOR - REMOVAL .......8B-6
PARK SWITCH - DIAGNOSIS AND TESTING, FAILED ..................... 8R-2
PARKING BRAKE - INSTALLATION, LEVER .............................. 5-76
PARKING BRAKE - INSTALLATION, SHOES .............................. 5-84
PARKING BRAKE - REMOVAL, LEVER ......5-75
PARKING BRAKE - REMOVAL, SHOES .....5-78
PARKING BRAKE AUTOMATIC ADJUSTER TENSION RELEASE - STANDARD
PROCEDURE ......................... 5-63
PARKING BRAKE AUTOMATIC ADJUSTER TENSION RESET - STANDARD
PROCEDURE ......................... 5-64
PARKING BRAKE CABLES - ADJUSTMENT ........................ 5-65
PARKING BRAKE INTERMEDIATE - INSTALLATION, CABLE .................5-69
PARKING BRAKE INTERMEDIATE - REMOVAL, CABLE ..................... 5-69
PARKING BRAKE LEVER AND FRONT CABLE - INSTALLATION ................5-77
PARKING BRAKE LEVER AND FRONT CABLE - REMOVAL .................... 5-77
PARKING BRAKE SHOES - ADJUSTMENT . . . 5-85
PARK/TURN SIGNAL LAMP - INSTALLATION ....................... 8L-18
PARK/TURN SIGNAL LAMP - REMOVAL . . . 8L-18
PARTS - DESCRIPTION, FFV REPLACEMENT ....................... 14-2
PASSENGER AIRBAG - DESCRIPTION ....8O-30
PASSENGER AIRBAG - INSTALLATION ....8O-32
PASSENGER AIRBAG - OPERATION ......8O-30
PASSENGER AIRBAG - REMOVAL ........8O-30
PASSENGER AIRBAG DISABLED INDICATOR - DESCRIPTION ............8O-33
PASSENGER AIRBAG DISABLED INDICATOR - INSTALLATION ............8O-34
PASSENGER AIRBAG DISABLED INDICATOR - OPERATION ..............8O-33
PASSENGER AIRBAG DISABLED INDICATOR - REMOVAL ...............8O-34
PASSENGER BENCH - INSTALLATION, SEAT BELT BUCKLE - SECOND ROW -
THREE ............................. 8O-40
PASSENGER BENCH - REMOVAL, SEAT BELT BUCKLE - SECOND ROW - THREE . . . 8O-40
PATTERNS - DIAGNOSIS AND TESTING, TIRE WEAR ......................... 22-16
PCM GROUND - OPERATION ...........8E-14
PCM INPUT - OPERATION, DATA BUS COMMUNICATION RECEIVE .............8E-14
PCM INPUT - OPERATION, IGNITION SENSE ............................. 8E-14
PCM INPUT - OPERATION, SENSOR RETURN ............................ 8E-14
PCM OUTPUT - OPERATION, 5 VOLT SUPPLY ............................ 8E-15PCM/SKIM PROGRAMMING - STANDARD
PROCEDURE ......................... 8E-1
PCV SYSTEM - DIAGNOSIS AND TESTING ........................... 25-18
PCV VALVE - DESCRIPTION ............25-18
PCV VALVE - OPERATION ..............25-18
PEDAL - INSTALLATION, ACCELERATOR . . . 14-28
PEDAL - REMOVAL, ACCELERATOR ......14-28
PEDAL TORQUE SHAFT - RHD - INSTALLATION ........................ 5-44
PEDAL TORQUE SHAFT - RHD - REMOVAL ........................... 5-44
PEDALS - ADJUSTABLE - INSTALLATION . . . 5-43
PEDALS - ADJUSTABLE - REMOVAL .......5-40
PEDALS SWITCH - INSTALLATION, ADJUSTABLE ......................... 5-11
PEDALS SWITCH - REMOVAL, ADJUSTABLE ......................... 5-11
PERFORMANCE - DIAGNOSIS AND TESTING, ENGINE DIAGNOSIS ........9-4,9-80
PERFORMANCE TEST, DIAGNOSIS AND TESTING - A/C ........................ 24-7
PERFORMANCE TEST, DIAGNOSIS AND TESTING - HEATER ................... 24-10
PIN BUSHINGS (CONTINENTAL TEVES BRAKES) - ASSEMBLY, CALIPER GUIDE ....5-25
PIN BUSHINGS (CONTINENTAL TEVES BRAKES) - DISASSEMBLY, CALIPER
GUIDE .............................. 5-24
PINCH SENSOR - DESCRIPTION .........8N-17
PINCH SENSOR - INSTALLATION ........8N-18
PINCH SENSOR - OPERATION ..........8N-17
PINCH SENSOR - REMOVAL ............8N-18
PINION FACTOR SETTING - STANDARD PROCEDURE ........................ 8E-15
PINS (TRW BRAKES) - INSTALLATION, DISC BRAKE CALIPER GUIDE ............5-32
PINS (TRW BRAKES) - REMOVAL, DISC BRAKE CALIPER GUIDE ................5-31
PIPE - 3.3/3.8L - INSTALLATION, CROSS-OVER ........................ 11-6
PIPE - 3.3/3.8L - REMOVAL, CROSS- OVER ............................... 11-6
PIPE - INSTALLATION, AIR INTAKE ......24-115
PIPE - REMOVAL, AIR INTAKE .........24-115
PIPES - INSTALLATION, HEATER ........24-120
PIPES - REMOVAL, HEATER ...........24-119
PISTON & CONNECTING ROD - DESCRIPTION ................... 9-119,9-44
PISTON & CONNECTING ROD - INSTALLATION ........................ 9-45
PISTON & CONNECTING ROD - REMOVAL ........................... 9-44
PISTON AND SEAL - ASSEMBLY, CALIPER ........................ 5-26,5-30
PISTON AND SEAL - DISASSEMBLY, CALIPER ........................ 5-24,5-28
PISTON RING, FITTING .................9-47
PISTON RING FITTING - STANDARD PROCEDURE ........................ 9-124
PISTON RINGS - INSTALLATION .........9-124
PISTON RINGS - REMOVAL ............9-124
PISTON TO CYLINDER BORE FITTING - STANDARD PROCEDURE ................9-44
PISTONS - STANDARD PROCEDURE, FITTING ............................ 9-120
PLANETARY GEARTRAIN - DESCRIPTION ................ 21-112,21-263
PLANETARY GEARTRAIN - OPERATION . . 21-112, 21-263
PLASTIC BODY PANEL REPAIR - STANDARD PROCEDURE ................23-3
PLASTIC GROCERY BAG RETAINER - INSTALLATION ...................... 23-149
PLASTIC GROCERY BAG RETAINER - REMOVAL ......................... 23-149
PLASTIGAGE - STANDARD PROCEDURE, MEASURING BEARING CLEARANCE
USING .......................... 9-12,9-86
PLATINUM PLUGS - DESCRIPTION ........8I-9
PLAYER - DESCRIPTION, DVD ..........8A-12
PLAYER - INSTALLATION, DVD ..........8A-12
PLAYER - REMOVAL, DVD .............8A-12
PLUG CABLE - DESCRIPTION, SPARK .....8I-10
PLUG CABLE RESISTANCE, SPECIFICATIONS - SPARK ...............8I-2
PLUG, SPECIFICATIONS - SPARK .........8I-2
PLUGS - DESCRIPTION, PLATINUM ........8I-9PLUGS - STANDARD PROCEDURE,
ENGINE CORE AND OIL GALLERY ....9-10,9-88
PLUMBING - FRONT - DESCRIPTION .....24-65
PLUMBING - FRONT - OPERATION .......24-65
POINTS - DESCRIPTION, LUBRICATION .....0-7
POLISHING - DESCRIPTION, FINESSE SANDING/BUFFING .................. 23-101
PORT REPAIR - STANDARD PROCEDURE, INTAKE MANIFOLD
VACUUM ........................... 9-148
PORT VALVE CORE - DESCRIPTION, SERVICE ........................... 24-95
PORT VALVE CORE - INSTALLATION, SERVICE ........................... 24-95
PORT VALVE CORE - REMOVAL, SERVICE ........................... 24-95
POSITION SENSOR - DESCRIPTION, CAMSHAFT ........................... 8I-4
POSITION SENSOR - DESCRIPTION, CRANKSHAFT ....................... 14-29
POSITION SENSOR - DESCRIPTION, THROTTLE .......................... 14-40
POSITION SENSOR - OPERATION, CAMSHAFT ........................... 8I-4
POSITION SENSOR - OPERATION, CRANKSHAFT ....................... 14-29
POSITION SENSOR - OPERATION, THROTTLE .......................... 14-41
POSITION SENSOR - REMOVAL, CRANKSHAFT ....................... 14-30
POTENTIAL - STANDARD PROCEDURE, TESTING OF VOLTAGE ..............8W-01-9
POWER - INSTALLATION, WINDOW REGULATOR ........................ 23-22
POWER - REMOVAL, WINDOW REGULATOR ........................ 23-22
POWER ADJUSTER - INSTALLATION, FRONT SEAT TRACK .................23-124
POWER ADJUSTER - REMOVAL, FRONT SEAT TRACK ....................... 23-124
POWER BRAKE BOOSTER - DESCRIPTION ........................ 5-45
POWER BRAKE BOOSTER - DIAGNOSIS AND TESTING ........................ 5-46
POWER BRAKE BOOSTER - OPERATION . . . 5-46
POWER DISTRIBUTION SYSTEM - DESCRIPTION .....................8W -97-1
POWER DISTRIBUTION SYSTEM - OPERATION .......................8W -97-1
POWER DISTRIBUTION SYSTEMS, SPECIAL TOOLS ...................8W -97-1
POWER FOLDAWAY MIRROR SWITCH - EXPORT - DESCRIPTION ...............8N-29
POWER FOLDAWAY MIRROR SWITCH - EXPORT - INSTALLATION ..............8N-30
POWER FOLDAWAY MIRROR SWITCH - EXPORT - OPERATION ................8N-29
POWER FOLDAWAY MIRROR SWITCH - EXPORT - REMOVAL .................. 8N-29
POWER LIFTGATE CONTROL MODULE - DESCRIPTION ....................... 8E-10
POWER LIFTGATE CONTROL MODULE - OPERATION ......................... 8E-10
POWER LIFTGATE CONTROL MODULE, DIAGNOSIS AND TESTING .............8E-10
POWER LIFTGATE LEARN CYCLE, STANDARD PROCEDURE ...............8N-8
POWER LIFTGATE SYSTEM - DESCRIPTION ........................ 8N-2
POWER LIFTGATE SYSTEM - OPERATION . . 8N-2
POWER LIFTGATE SYSTEM, DIAGNOSIS AND TESTING ........................ 8N-3
POWER LOCKS - DESCRIPTION .........8N-20
POWER LOCKS - OPERATION ...........8N-21
POWER MIRRORS - DESCRIPTION ......8N-26
POWER MIRRORS - OPERATION ........8N-26
POWER MIRRORS, DIAGNOSIS AND TESTING ........................... 8N-27
POWER MODULE - BLOWER MOTOR - DESCRIPTION ....................... 24-30
POWER MODULE - BLOWER MOTOR - INSTALLATION ....................... 24-31
POWER MODULE - BLOWER MOTOR - OPERATION ......................... 24-30
POWER MODULE - BLOWER MOTOR - REMOVAL .......................... 24-30
POWER MODULE - DESCRIPTION, INTEGRATED ......................8W -97-1
RS INDEX23
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