2005 CHRYSLER CARAVAN seats

NOTE: Valve seats which are worn or burned can
be reworked, provided that correct angle and seat
width are maintained. Otherwise cylinder head must
be replaced.
(4) When seat is properly positioned the width of
intake and exhaust seats should be 1.50±2.00 mm
(0.059±0.078 in.) (Fig. 27).
(5) After grinding the valve seats or faces, install
the valve in cylinder head and check valve installed
height by measuring from valve tip to spring seat
(Fig. 31). Remove valve from cylinder head and grind
valve tip until within specifications. Check valve tip
for scoring. The tip chamfer should be reground (if
necessary) to prevent seal damage when the valve is
installed.(6) Check the valve spring installed height after
refacing the valve and seat (Fig. 31).
If valves and/or seats are reground, measure
the installed height of springs (Fig. 31), make
sure measurements are taken from top of
spring seat to the bottom surface of spring
retainer. If height is greater than specifica-
tions, install a 0.794 mm (0.0312 in.) spacer in
head counterbore to bring spring height back
within specifications.
REMOVAL
(1) With cylinder head removed, compress valve
springs using Valve Spring Compressor Tool
C-3422-D with adapter 8464 (Refer to 9 - ENGINE -
SPECIAL TOOLS).
(2) Remove valve retaining locks.
(3) Slowly release valve spring compressor.
Remove valve spring retainer, valve spring, and valve
stem seal.
(4) Before removing valves,remove any burrs
from valve stem lock grooves to prevent dam-
age to the valve guides.Identify valves to insure
installation in original location.
CLEANING
(1) Clean all valves thoroughly and discard
burned, warped and cracked valves.
INSPECTION
VALVES
(1) Clean and inspect valves thoroughly. Replace
burned, warped and cracked valves.
Fig. 29 Refacing Valve Seats
1 - REFACING STONE MUST NOT CUT INTO CYLINDER HEAD
2-STONE
3 - PILOT
4 - SEAT
Fig. 30 Measurement of Valve Seat Runout
1 - DIAL INDICATOR
Fig. 31 Checking Valve and Spring Installed Height
1 - SPRING RETAINER
2 - VALVE INSTALLED HEIGHT* - 48.1±49.7 mm (1.89±1.95 in.)
3 - CYINDER HEAD SURFACE
4 - SPRING INSTALLED HEIGHT* - 41.1±42.7 mm (1.61±1.68 in.)
*(MEASURED FROM TOP OF SPRING SEAT)
9 - 108 ENGINE 3.3/3.8LRS
INTAKE/EXHAUST VALVES & SEATS (Continued)

(2) Measure valve stems for wear (Fig. 32). For
valve specifications, (Refer to 9 - ENGINE - SPECI-
FICATIONS).
NOTE: Valve stems are chrome plated and should
not be polished (Fig. 32).
VALVE GUIDES
(1) Remove carbon and varnish deposits from
inside of valve guides with a reliable guide cleaner.
(2) Measure valve stem-to-guide clearance as fol-
lows:
(3) Install valve into cylinder head so it is 15 mm
(0.590 inch.) off the valve seat. A small piece of hose
may be used to hold valve in place.
(4) Attach dial indicator Tool C-3339 to cylinder
head and set it at right angle of valve stem being
measured (Fig. 33).
(5) Move valve to and from the indicator. For cler-
ance specifications, (Refer to 9 - ENGINE - SPECIFI-
CATIONS).
NOTE: Replace cylinder head if stem-to-guide clear-
ance exceeds specifications, or if guide is loose in
cylinder head.
INSTALLATION
(1) Coat valve stems with clean engine oil and
insert them in cylinder head.
(2) Install valve spring seat on head (Fig. 35).
(3) Install new seals on all valve stems and over
valve guides (Fig. 35). Install valve springs and valve
retainers (Fig. 35).(4) Install the valve springs. (Refer to 9 -
ENGINE/CYLINDER HEAD/VALVE SPRINGS -
INSTALLATION)
VALVE SPRINGS
DESCRIPTION
There are two interchangeable, floating (spring
rotates during operation), valve spring designs. Type
A may be identified by the counterclockwise (spring
spirals down and to the left) appearance, And Type B
may be identified by the clockwise (spring spirals
down and to the right) appearance. Both of the valve
springs are a bee-hive shaped design but have differ-
ent specifications (Fig. 34). The springs are seated on
a steel washer on the cylinder head with retainers
and locks retaining the springs (Fig. 35). The springs
are installed with the smaller diameter against
spring retainer (Fig. 34).
OPERATION
The valve spring returns the valve against its seat
for a positive seal of the combustion chamber.
REMOVAL
REMOVAL - CYLINDER HEAD OFF
(1) With the cylinder head on a bench, position
Special Tool C-3422-D with 8464 Adapter on the
valve and spring retainer (Fig. 36).
(2) Compress the spring only enough to remove the
valve retainer locks.
(3) Slowly release the spring tension and remove
the valve spring and retainer.
(4) For removal of the valve stem seal (Refer to 9 -
ENGINE/CYLINDER HEAD/VALVE STEM SEALS -
REMOVAL).
Fig. 32 Intake and Exhaust Valves
1 - MARGIN
2-FACE
3 - STEM
4 - VALVE SPRING RETAINER LOCK GROOVES
Fig. 33 Measuring Valve Guide Wear - Typical
RSENGINE 3.3/3.8L9 - 109
INTAKE/EXHAUST VALVES & SEATS (Continued)

Fig. 34 Valve Spring - Type A
1 - VALVE SPRING (TOP - SMALLER DIAMETER)
Fig. 35 VALVE COMPONENTS
1 - VALVE LOCKS 5 - SPRING SEATS
2 - RETAINERS 6 - CYLINDER HEAD
3 - VALVE SPRINGS 7 - VALVE - EXHAUST
4 - VALVE STEM SEALS 8 - VALVE - INTAKE
Fig. 36 VALVE SPRING - REMOVE/INSTALL
1 - SPECIAL TOOL C-3422-D SPRING COMPRESSOR
2 - SPECIAL TOOL 8464 ADAPTER
9 - 110 ENGINE 3.3/3.8LRS
VALVE SPRINGS (Continued)

CRANKSHAFT REAR OIL SEAL
RETAINER
REMOVAL
(1) Remove crankshaft rear oil seal (Refer to 9 -
ENGINE/ENGINE BLOCK/CRANKSHAFT OIL
SEAL - REAR - REMOVAL).
(2) Remove oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - REMOVAL).
(3) Remove oil seal retainer screws (Fig. 83).
(4) Remove oil seal retainer (Fig. 83).
(5) Clean engine block and retainer of oil and gas-
ket material. Make sure surfaces are clean and free
of oil.
INSTALLATION
(1) Position new gasket and install retainer on
block (Fig. 83). Tighten attaching screws to 12 N´m
(105 in. lbs.).
(2) Install oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION).
(3) Install oil seal (Refer to 9 - ENGINE/ENGINE
BLOCK/CRANKSHAFT OIL SEAL - REAR -
INSTALLATION).
VIBRATION DAMPER
REMOVAL
(1) Disconnect negative cable from battery.
(2) Raise vehicle on hoist.
(3) Remove the right front wheel and inner splash
shield.
(4) Remove the accessory drive belt. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)
(5) Remove vibration damper bolt.
(6) Insert Special Tool 8450 into crankshaft nose
(Fig. 84).
(7) Position 3-jaw puller Special Tool 1026 on
damper as shown in (Fig. 84). Turn puller forcing
screw until damper releases from crankshaft.
(8) Remove the crankshaft vibration damper.
INSTALLATION
(1) Install crankshaft vibration damper using the
forcing screw, nut, and thrust bearing/washer from
Special Tool 8452 (Fig. 85).
NOTE: To minimize friction and prolong tool life,
lubricate the threads on the forcing screw of Spe-
cial Tool 8452.
(2) Position vibration damper on crankshaft.
(3) Screw Special Tool 8452 into crankshaft until
the bolt seats. Turn the nut to install damper until it
seats fully.
(4) Remove Special Tool 8452.
(5) Install vibration damper bolt. Torque bolt to 54
N´m (40 ft. lbs.).
Fig. 82 Rear Crankshaft Oil SealÐInstallation
1 - SPECIAL TOOLS:
2 - C-4171 HANDLE
3 - 6926±2 INSTALLER
4 - 6926±1 GUIDE
5 - SEAL
Fig. 83 CRANKSHAFT REAR OIL SEAL
1 - OIL SEAL
2 - BOLT
3 - RETAINER - OIL SEAL
4 - GASKET
9 - 132 ENGINE 3.3/3.8LRS
CRANKSHAFT OIL SEAL - REAR (Continued)

INSTALLATION
INSTALLATION - CRANKSHAFT SPROCKET
(1) Position the sprocket on the crankshaft (timing
mark out) with the timing slot aligned with the tim-
ing pin.
(2) Install sprocket using Special Tool 8452 (Fig.
143). Install sprocket until it is fully seats on the
crankshaft.(3) Install the timing chain and camshaft sprocket.
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT/CHAIN AND SPROCKETS - INSTALLATION)INSTALLATION - TIMING CHAIN AND
CAMSHAFT SPROCKET
(1) Rotate crankshaft so the timing arrow is to the
12 o'clock position (Fig. 141).
NOTE: Lubricate timing chain and sprockets with
clean engine oil before installation.
(2) While holding camshaft sprocket and chain in
hand, place timing chain around the sprocket, align-
ing the plated link with the dot on the sprocket. Posi-
tion the timing arrow to the 6 o'clock position (Fig.
141).
(3) Place timing chain around crankshaft sprocket
with the plated link lined up with the dot on the
sprocket. Install camshaft sprocket into position.
(4) Use a straight edge to check alignment of tim-
ing marks.
(5) Install camshaft sprocket bolt and washer.
Tighten bolt to 54 N´m (40 ft. lbs.).
(6) Rotate crankshaft 2 revolutions and check tim-
ing mark alignment (Fig. 141). If timing marks do
not line up, remove camshaft sprocket and realign.
(7) Install the timing chain cover. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION)
(8) Connect negative cable to battery.
Fig. 143 CRANKSHAFT SPROCKET - INSTALLATION
1 - SPECIAL TOOL 8452-3
2 - SPECIAL TOOL 8452-1
3 - CRANKSHAFT SPROCKET
4 - THRUST BEARING / WASHER
9 - 160 ENGINE 3.3/3.8LRS
TIMING CHAIN AND SPROCKETS (Continued)

FRAME & BUMPERS
TABLE OF CONTENTS
page page
BUMPERS
SPECIFICATIONS - TORQUE...............1
FRONT FASCIA
REMOVAL.............................1
INSTALLATION..........................1
FRONT BUMPER REINFORCEMENT
REMOVAL.............................3
INSTALLATION..........................3
REAR FASCIA
REMOVAL.............................4
INSTALLATION..........................4
REAR BUMPER REINFORCEMENT
REMOVAL.............................5
INSTALLATION..........................5
REAR FASCIA - SCUFF PAD
REMOVAL.............................5
INSTALLATION..........................5FRAME
SPECIFICATIONS
SPECIFICATIONS - FRAME DIMENSIONS . . . 6
SPECIFICATIONS - FRAME DIMENSIONS -
FOLD-IN-FLOOR SEATS ONLY...........11
SPECIFICATIONS - TORQUE............14
FRONT CRADLE CROSSMEMBER
DESCRIPTION
DESCRIPTION - FRONT CRADLE
CROSSMEMBER......................14
DESCRIPTION - FRONT CRADLE
CROSSMEMBER THREAD REPAIR........14
REMOVAL.............................15
INSTALLATION.........................16
FRONT CROSSMEMBER MOUNT BUSHINGS
REMOVAL.............................17
INSTALLATION.........................17
BUMPERS
SPECIFICATIONS - TORQUE
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Front bumper reinforcement attaching nut 54 40 Ð
Rear bumper reinforcement attaching nut 27 20 Ð
FRONT FASCIA
REMOVAL
(1) Release hood latch and open hood.
(2) Remove the headlamp assemblies (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
HEADLAMP - REMOVAL).
(3) Hoist vehicle and support with safety stands.
(4) Remove the five push pin fasteners attaching
bottom of fascia/air dam to radiator closure panel.
(5) Remove front wheels.
(6) Remove front wheelhouse splash shields fasten-
ers as necessary to gain access to bolts attaching
front fascia to fender. (Refer to 23 - BODY/EXTERI-
OR/ WHEELHOUSE SPLASH SHIELD -
REMOVAL).(7) Remove the two bolts and two nuts attaching
fascia to the front fenders (Fig. 1) and (Fig. 2).
(8) Disconnect fog lamp wire connectors, if neces-
sary.
(9) Lower vehicle.
(10) Remove two bolts attaching the upper grille
support to the headlamp mounting panel at each side
of the grille.
(11) Remove bumper fascia from vehicle.
INSTALLATION
(1) Position front bumper fascia on vehicle (Fig. 1)
and (Fig. 2).
(2) Install the two bolts attaching fascia to head-
lamp mounting panel at each side of grille.
(3) Hoist vehicle and support with safety stands.
RSFRAME & BUMPERS13-1

SPECIFICATIONS - FRAME DIMENSIONS -
FOLD-IN-FLOOR SEATS ONLY
INDEX
DESCRIPTION FIGURE
FRAME - PLAN VIEW 12
FRAME - SIDE VIEW 13
RSFRAME & BUMPERS13-11
FRAME (Continued)

QUICK CONNECT FITTING
STANDARD PROCEDURE - QUICK-CONNECT
FITTINGS
REMOVAL
When disconnecting a quick-connect fitting, the
retainer will remain on the fuel tube nipple.
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE DISCONNECTING A QUICK-CONNECT FIT-
TINGS. REFER TO THE FUEL PRESSURE RELEASE
PROCEDURE. THIS MAY RESULT IN PERSONAL
INJURY OR DEATH.
(1) Perform Fuel Pressure Release Procedure.
Refer to the Fuel Pressure Release Procedure in this
section.
(2) Disconnect negative cable from battery or aux-
iliary jumper terminal.
(3) Squeeze retainer tabs together and pull fuel
tube/quick-connect fitting assembly off of fuel tube
nipple. The retainer will remain on fuel tube.
INSTALLATION
CAUTION: Make sure that the o-ring in installed in
fitting. Never install a quick-connect fitting without
the retainer being either on the fuel tube or already
in the quick-connect fitting. In either case, ensure
the retainer locks securely into the quick-connect
fitting by firmly push-pulling-push on fuel tube and
fitting to ensure it is secured.
(1) Using a clean lint free cloth, clean the fuel tube
nipple and retainer.
(2) Prior to connecting the fitting to the fuel tube,
coat the fuel tube nipple with clean engine oil.
(3) Push the quick-connect fitting over the fuel
tube until theretainer seats and a click is heard.
(4) The plastic quick-connect fitting has windows
in the sides of the casing. When the fitting com-
pletely attaches to the fuel tube, the retainer locking
ears and the fuel tube shoulder are visible in the
windows. If they are not visible, the retainer was not
properly installed (Fig. 36).Do not rely upon the
audible click to confirm a secure connection.
(5) Connect negative cable to battery or auxiliary
jumper terminal.
CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) Relay remains energized
for several minutes, until the test is stopped, or
until the ignition switch is turned to the Off posi-
tion.(6) Use the DRB IIItscan tool ASD Fuel System
Test to pressurize the fuel system. Check for leaks.
TWO-TAB TYPE FITTING
This type of fitting is equipped with tabs located on
both sides of the fitting (Fig. 37). These tabs are sup-
plied for disconnecting the quick-connect fitting from
component being serviced.
CAUTION: The interior components (O-rings, spac-
ers) of this type of quick-connect fitting are not ser-
viced separately, but new plastic retainers are
available. Do not attempt to repair damaged fittings
or fuel lines/tubes. If repair is necessary, replace
the complete fuel tube assembly.
Fig. 36 Plastic Quick-Connect Fitting/Fuel Tube
Connection
1 - WINDOW
2-TAB(2)
3 - EAR
4 - SHOULDER (ON TUBE)
Fig. 37 Typical Two-Tab Type Quick-Connect Fitting
1 - TAB(S)
2 - QUICK-CONNECT FITTING
14 - 18 FUEL DELIVERYRS