2005 CHRYSLER CARAVAN radiator

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Page 1189 of 2339

CHRYSLER CARAVAN 2005  Service Manual ²Drill motor with 3M RolocŸ Bristle Disc (white
or yellow) (Fig. 3)
CAUTION: Excessive pressure or high RPM (beyond
the recommended speed), can damage the sealing
surfaces. The mild (white, 120 grit

Page 1193 of 2339

CHRYSLER CARAVAN 2005  Service Manual (24) Connect all vacuum lines.
(25) Connect the throttle cables.
(26) Connect the fuel line. (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY/QUICK CONNECT FIT-
TING - STANDARD PROCEDURE)
(27) Connect radiato

Page 1202 of 2339

CHRYSLER CARAVAN 2005  Service Manual AIR CLEANER HOUSING
REMOVAL
(1) Disconnect the negative battery cable.
(2) Disconnect the inlet air temperature sensor
(Fig. 12).
(3) Remove the inlet hose to throttle body (Fig. 11).
(4) Remove the b

Page 1203 of 2339

CHRYSLER CARAVAN 2005  Service Manual CYLINDER-TO-CYLINDER LEAKAGE TEST
To determine if an engine cylinder head gasket is
leaking between adjacent cylinders, follow the proce-
dures in Cylinder Compression Pressure Test (Refer
to 9 - ENGI

Page 1205 of 2339

CHRYSLER CARAVAN 2005  Service Manual (5) Install rocker arms. (Refer to 9 - ENGINE/
CYLINDER HEAD/ROCKER ARMS - INSTALLA-
TION)
(6) Install camshafts. (Refer to 9 - ENGINE/CYL-
INDER HEAD/CAMSHAFT(S) - INSTALLATION).
(7) Install cylinder

Page 1239 of 2339

CHRYSLER CARAVAN 2005  Service Manual 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

Page 1265 of 2339

CHRYSLER CARAVAN 2005  Service Manual (3) Place a shop towel around the spark plugs
when removing them from the engine. This will catch
any fluid that may possibly be in the cylinder under
pressure.
(4) With all spark plugs removed, rotat

Page 1266 of 2339

CHRYSLER CARAVAN 2005  Service Manual (13) Disconnect the EGR transducer electrical con-
nector (if equipped).
(14) Disconnect the vacuum hoses from throttle
body.
(15) Disconnect the brake booster and speed con-
trol vacuum hoses.
(16) D