2005 CHRYSLER CARAVAN check oil

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)

(6) Install oil pressure switch and connector. (Refer
to 9 - ENGINE/LUBRICATION/OIL PRESSURE
SENSOR/SWITCH - INSTALLATION)
OIL
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. Remove dipstick and observe oil level. Add
oil only when the level is at or below the ADD mark
(Fig. 87).
STANDARD PROCEDURE - ENGINE OIL AND
FILTER CHANGE
Change engine oil at mileage and time intervals
described in the Maintenance Schedule. (Refer to
LUBRICATION & MAINTENANCE/MAINTE-
NANCE SCHEDULES - DESCRIPTION)
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY. CONTACT YOUR DEALER OR GOVERN-
MENT AGENCY FOR LOCATION OF COLLECTION
CENTER IN YOUR AREA.
Run engine until achieving normal operating tem-
perature.
(1) Position the vehicle on a level surface and turn
engine off.
(2) Remove oil fill cap.(3) Hoist and support vehicle on safety stands.
Refer to Hoisting and Jacking Recommendations.
(Refer to LUBRICATION & MAINTENANCE/HOIST-
ING - STANDARD PROCEDURE)
(4) Place a suitable drain pan under crankcase
drain.
(5) Remove drain plug from crankcase and allow
oil to drain into pan. Inspect drain plug threads for
stretching or other damage. Replace drain plug and
gasket if damaged.
(6) Remove oil filter. (Refer to 9 - ENGINE/LUBRI-
CATION/OIL FILTER - REMOVAL)
(7) Install and tighten drain plug in crankcase.
(8) Install new oil filter. (Refer to 9 - ENGINE/LU-
BRICATION/OIL FILTER - INSTALLATION)
(9) Lower vehicle and fill crankcase with specified
type and amount of engine oil. (Refer to LUBRICA-
TION & MAINTENANCE/FLUID TYPES -
DESCRIPTION)
(10) Install oil fill cap.
(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.
OIL FILTER
DESCRIPTION
The engine oil filter (Fig. 88) is a high quality full-
flow, disposable type. Replace the oil filter with a
Mopartor the equivalent.
REMOVAL
(1) Raise vehicle on hoist.
(2) Position an oil collecting container under oil fil-
ter location.
CAUTION: When servicing the oil filter avoid
deforming the filter can by installing the remove/in-
stall tool band strap against the can to base lock
seam. The lock seam joining the can to the base is
reinforced by the base plate.
(3) Using a suitable filter wrench, turn oil filter
(Fig. 88) counterclockwise to remove.
INSTALLATION
(1) Clean and check filter mounting surface. The
surface must be smooth, flat and free of debris or
pieces of gasket.
(2) Lubricate new oil filter gasket with clean
engine oil.
Fig. 87 Oil Level
1 - ENGINE OIL LEVEL DIPSTICK
9 - 54 ENGINE 2.4LRS
LUBRICATION (Continued)

(1) Apply3-4mmdiameter bead of MOPARt
Engine RTV around the perimeter of the oil pan
flange, 1 mm away from the chamfer on the inner
edge of the oil pan (Fig. 92).
(2) Position oil pan on bedplate.
(3) Install oil pan attatching bolts and tighten to
12 N´m (105 in. lbs.).
(4) Install air conditioning compressor bracket to
oil pan bolt.(5) Install structural collar (Refer to 9 - ENGINE/
ENGINE BLOCK/STRUCTURAL COVER - INSTAL-
LATION).
(6) Lower vehicle and fill engine crankcase with
proper oil to correct level.
(7) Connect negative battery cable.
(8) Start engine and check for leaks.
OIL PRESSURE SWITCH
REMOVAL
(1) Raise vehicle.
(2) Position oil collecting container under pressure
switch location.
(3) Disconnect oil pressure switch electrical con-
nector and remove switch (Fig. 93).
INSTALLATION
(1) Install oil pressure switch. Torque switch to 21
N´m (190 in. lbs.) (Fig. 93).
(2) Connect electrical connector
(3) Lower vehicle.
(4) Start engine and allow to run a minimum of 2
minutes.
(5) Shut engine off and check engine oil level.
Adjust level as necessary.
OIL PUMP
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
REMOVAL).
(3) Remove timing belt rear cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT COVER(S)
- REMOVAL).
Fig. 91 Left Rear Pry Point
1 - PPRY POINT
2 - OIL PAN
3 - BED PLATE
Fig. 92 Oil Pan Sealing
1-1mmFROM CHAMFER
2 - RTV BEAD
Fig. 93 Engine Oil Pressure Switch
9 - 56 ENGINE 2.4LRS
OIL PAN (Continued)

INSPECTION
(1) Inspect the mating surfaces of the oil pump
cover. Surface should be smooth. Replace pump cover
if scratched or grooved.
(2) Lay a straightedge across the pump cover sur-
face (Fig. 99). If a 0.025 mm (0.001 in.) feeler gauge
can be inserted between cover and straight edge,
cover should be replaced.
(3) Measure thickness and diameter of outer rotor.
If outer rotor thickness measures 9.40 mm (0.370 in.)
or less (Fig. 100), or if the diameter is 79.95 mm
(3.148 in.) or less, replace outer rotor.
(4) If inner rotor measures 9.40 mm (0.370 in.) or
less replace inner rotor (Fig. 101).
ASSEMBLY
(1) Assemble pump, using new parts as required.
Install the inner rotor with chamfer facing the
cast iron oil pump cover.
(2) Prime oil pump before installation by filling
rotor cavity with engine oil.
(3) Install cover and tighten fasteners to 12 N´m
(105 in. lbs.) (Fig. 98).
CAUTION: Oil pump pressure relief valve must be
installed as shown in (Fig. 97) or serious engine
damage may occur.
(4) Install relief valve, spring, gasket and cap as
shown in (Fig. 97). Tighten cap to 41 N´m (30 ft.
lbs.).
Fig. 98 Oil Pump
1 - O-RING
2 - SEAL
3 - INNER ROTOR
4 - OIL PUMP COVER
5 - FASTENER
6 - OUTER ROTOR
7 - OIL PUMP BODY
Fig. 99 Checking Oil Pump Cover Flatness
1 - STRAIGHT EDGE
2 - FEELER GAUGE
3 - OIL PUMP COVER
Fig. 100 Measuring Outer Rotor Thickness
Fig. 101 Measuring Inner Rotor Thickness
9 - 58 ENGINE 2.4LRS
OIL PUMP (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)

INSPECTION..........................115
HYDRAULIC LIFTERS (CAM IN BLOCK)
DESCRIPTION........................116
DIAGNOSIS AND TESTING - HYDRAULIC
LIFTERS...........................116
REMOVAL............................117
INSTALLATION........................117
CAMSHAFT & BEARINGS (IN BLOCK)
DESCRIPTION........................118
OPERATION..........................118
REMOVAL............................118
INSPECTION..........................118
INSTALLATION........................118
PISTON & CONNECTING ROD
DESCRIPTION........................119
STANDARD PROCEDURE
STANDARD PROCEDURE - FITTING
CONNECTING RODS..................119
STANDARD PROCEDURE - FITTING
PISTONS...........................120
REMOVAL............................120
INSTALLATION........................121
CONNECTING ROD BEARINGS
STANDARD PROCEDURE - MEASURING
CONNECTING ROD BEARING
CLEARANCE........................123
PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING............................124
REMOVAL............................124
INSTALLATION........................124
CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDURE - MAIN BEARING
FITTING............................125
REMOVAL - CRANKSHAFT MAIN BEARINGS . 127
INSTALLATION - CRANKSHAFT MAIN
BEARINGS..........................127
CRANKSHAFT
DESCRIPTION
DESCRIPTION - 3.3L..................128
DESCRIPTION - 3.8L..................128
STANDARD PROCEDURE - MEASURING
CRANKSHAFT END PLAY..............128
REMOVAL............................128
INSTALLATION........................129
CRANKSHAFT OIL SEAL - FRONT
REMOVAL............................130
INSTALLATION........................130
CRANKSHAFT OIL SEAL - REAR
REMOVAL............................131
INSTALLATION........................131
CRANKSHAFT REAR OIL SEAL RETAINER
REMOVAL............................132
INSTALLATION........................132
VIBRATION DAMPER
REMOVAL............................132
INSTALLATION........................132FLEX PLATE
REMOVAL............................133
INSTALLATION........................133
ENGINE MOUNTING
DESCRIPTION........................134
FRONT MOUNT
REMOVAL............................134
INSTALLATION........................134
LEFT MOUNT
REMOVAL............................136
INSTALLATION........................136
REAR MOUNT
REMOVAL............................136
INSTALLATION........................137
RIGHT MOUNT
REMOVAL............................138
INSTALLATION........................138
LUBRICATION
DESCRIPTION........................138
OPERATION..........................138
DIAGNOSIS AND TESTING - ENGINE OIL
PRESSURE.........................138
OIL
STANDARD PROCEDURE
STANDARD PROCEDURE - ENGINE OIL
AND FILTER CHANGE.................139
STANDARD PROCEDURE - ENGINE OIL
LEVEL CHECK.......................140
OIL COOLER & LINES
DESCRIPTION........................141
OPERATION..........................141
REMOVAL............................141
INSTALLATION........................141
OIL FILTER
REMOVAL............................141
INSTALLATION........................141
OIL FILTER ADAPTER
REMOVAL............................142
INSTALLATION........................142
OIL PAN
REMOVAL............................142
CLEANING...........................142
INSPECTION.........................143
INSTALLATION........................143
OIL PRESSURE RELIEF VALVE
REMOVAL............................143
INSTALLATION........................144
OIL PRESSURE SWITCH
DESCRIPTION........................144
OPERATION..........................144
REMOVAL............................144
INSTALLATION........................144
OIL PUMP
DESCRIPTION........................144
REMOVAL............................144
DISASSEMBLY........................145
CLEANING...........................145
RSENGINE 3.3/3.8L9-77

DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE
CONDITION POSSIBLE CAUSE CORRECTION
ENGINE WILL NOT START 1. Weak battery. 1. Test battery. Charge or replace
as necessary. (Refer to 8 -
ELECTRICAL/BATTERY SYSTEM -
DIAGNOSIS AND TESTING)
2. Corroded or loose battery
connections.2. Clean and tighten battery
connections. Apply a coat of light
mineral grease to terminals.
3. Faulty starter. 3. Test starting system. (Refer to 8 -
ELECTRICAL/STARTING -
DIAGNOSIS AND TESTING)
4. Faulty coil(s) or control unit. 4. Test and replace as needed.
(Refer to Appropriate Diagnostic
Information)
5. Incorrect spark plug gap. 5. Set gap. (Refer to 8 -
ELECTRICAL/IGNITION CONTROL
- SPECIFICATIONS)
6. Contamination in fuel system. 6. Clean system and replace fuel
filter.
7. Faulty fuel pump. 7. Test fuel pump and replace as
needed. (Refer to Appropriate
Diagnostic Information)
8. Incorrect engine timing. 8. Check for a skipped timing
belt/chain.
ENGINE STALLS OR IDLES
ROUGH1. Idle speed too low. 1. Test minimum air flow. (Refer to
Appropriate Diagnostic Information)
2. Incorrect fuel mixture. 2. (Refer to Appropriate Diagnostic
Information)
3. Intake manifold leakage. 3. Inspect intake manifold, manifold
gasket, and vacuum hoses.
4. Faulty ignition coil(s). 4. Test and replace as necessary.
(Refer to Appropriate Diagnostic
Information)
9 - 80 ENGINE 3.3/3.8LRS
ENGINE 3.3/3.8L (Continued)

DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL
CONDITION POSSIBLE CAUSES CORRECTION
NOISY VALVES 1. High or low oil level in
crankcase.1. Check and correct engine oil
level.
2. Thin or diluted oil. 2. Change oil to correct viscosity.
3. Thick oil 3. (a) Change engine oil and filter.
(b) Run engine to operating
temperature.
(c) Change engine oil and filter
again.
4. Low oil pressure. 4. Check and correct engine oil
pressure problem.
5. Dirt in hydraulic lifters/lash
adjusters.5. Replace hydraulic lifters/lash
adjusters.
6. Worn rocker arms. 6. Inspect oil supply to rocker arms.
7. Worn hydraulic lifters/lash
adjusters.7. Replace hydraulic lifters/lash
adjusters.
8. Worn valve guides. 8. Replace cylinder head assembly.
9. Excessive runout of valve seats
on valve faces.9. Grind valve seats and valves.
CONNECTING ROD NOISE 1. Insufficient oil supply. 1. Check engine oil level.
2. Low oil pressure. 2. Check engine oil level. Inspect oil
pump relief valve and spring.
3. Thin or diluted oil. 3. Change oil to correct viscosity.
4. Thick oil 4. (a) Change engine oil and filter.
(b) Run engine to operating
temperature.
(c) Change engine oil and filter
again.
5. Excessive bearing clearance. 5. Measure bearings for correct
clearance. Repair as necessary.
6. Connecting rod journal
out-of-round.6. Replace crankshaft or grind
surface.
7. Misaligned connecting rods. 7. Replace bent connecting rods.
9 - 82 ENGINE 3.3/3.8LRS
ENGINE 3.3/3.8L (Continued)