2005 CHRYSLER CARAVAN oil pressure

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)

(4) Remove oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - REMOVAL).
(5) Remove crankshaft sprocket using Special
Tools 6793 and C-4685-C2 (Fig. 94).
(6) Remove crankshaft key (Fig. 95).
(7) Remove oil pick-up tube.
(8) Remove oil pump (Fig. 96) and front crankshaft
seal.
DISASSEMBLY
(1) To remove the relief valve, proceed as follows:
(a) Remove the threaded plug and gasket from
the oil pump (Fig. 97).
(b) Remove spring and relief valve (Fig. 97).
(2) Remove oil pump cover fasteners, and lift off
cover (Fig. 98).
(3) Remove pump rotors (Fig. 98).(4) Wash all parts in a suitable solvent and
inspect carefully for damage or wear.
CLEANING
(1) Clean all parts thoroughly in a suitable sol-
vent.
Fig. 94 Crankshaft Sprocket - Removal
1 - SPECIAL TOOL 6793
2 - SPECIAL TOOL C-4685±C2
3 - CRANKSHAFT SPROCKET
Fig. 95 Crankshaft Key
1 - CRANKSHAFT KEY
Fig. 96 Oil Pump
1 - BOLTS
2 - BOLTS
3 - OIL PUMP
Fig. 97 Oil Pressure Relief Valve
1 - PLUG
2 - OIL PUMP BODY
3 - RELIEF VALVE
4 - SPRING
5 - SEAL
RSENGINE 2.4L9-57
OIL PUMP (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)

NOTE: THE TIMING MARK ON THE SPROCKET, THE
(LOWER) NICKEL PLATED LINK, AND THE ARROW
ON THE SIDE OF THE GEAR COVER SHOULD LINE
UP WHEN THE BALANCE SHAFTS ARE TIMED
CORRECTLY.
(10) If the sprockets are timed correctly, install the
balance shaft bolts and tighten to 28 N´m (250 in.
lbs.). A wood block placed between crankcase and
crankshaft counterbalance will prevent crankshaft
and gear rotation.
(11)CHAIN TENSIONING:
(a) Install chain tensioner loosely assembled
withnewshouldered pivot screw and adjuster
screw.
(b) Position guide on double ended stud making
sure tab on the guide fits into slot on the gear
cover. Install and tighten nut/washer assembly to
12 N´m (105 in. lbs.).
(c) Place a shim 1 mm (0.039 in.) thick x 70 mm
(2.75 in.) long between tensioner and chain. Push
tensioner and shim up against the chain.Apply
firm pressure 2.5±3 Kg (5.5±6.6 lbs.) directly
behind the adjustment slot to take up all
slack.Chain must have shoe radius contact as
shown in (Fig. 143).
(d) With the load applied, tighten top tensioner
bolt first, then bottom pivot bolt. Tighten bolts to
12 N´m (105 in. lbs.). Remove shim.
(e) Install carrier covers and tighten screws to
12 N´m (105 in. lbs.).
(12) If removed, install oil pump (Refer to 9 -
ENGINE/LUBRICATION/OIL PUMP - INSTALLA-
TION).(13) Install pick-up tube and oil pan (Refer to 9 -
ENGINE/LUBRICATION/OIL PAN - INSTALLA-
TION).
(14) Fill engine crankcase with proper oil to cor-
rect level.
Fig. 143 Chain Tension Adjustment
1 - 1MM (0.039 IN.) SHIM
2 - TENSIONER (ADJUSTER) BOLT
3 - PIVOT BOLT
RSENGINE 2.4L9-75
BALANCE SHAFTS AND CARRIER ASSEMBLY (Continued)

ENGINE 3.3/3.8L
TABLE OF CONTENTS
page page
ENGINE 3.3/3.8L
DESCRIPTION.........................78
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION...........78
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - PERFORMANCE...........80
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - MECHANICAL.............82
DIAGNOSIS AND TESTING - ENGINE OIL
LEAK INSPECTION....................84
DIAGNOSIS AND TESTING - CYLINDER
COMPRESSION PRESSURE TEST........85
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE
TEST...............................85
STANDARD PROCEDURE
STANDARD PROCEDURE - MEASURING
BEARING CLEARANCE USING
PLASTIGAGE........................86
FORM-IN-PLACE GASKETS AND SEALERS . 86
STANDARD PROCEDURE - ENGINE
GASKET SURFACE PREPARATION........87
HYDROSTATIC LOCKED ENGINE.........87
STANDARD PROCEDURE - REPAIR OF
DAMAGED OR WORN THREADS.........88
STANDARD PROCEDURE - ENGINE CORE
AND OIL GALLERY PLUGS..............88
REMOVAL - ENGINE ASSEMBLY...........88
INSTALLATION - ENGINE ASSEMBLY........91
SPECIFICATIONS
3.3/3.8L ENGINE......................93
SPECIFICATIONS - TORQUE............97
SPECIAL TOOLS
3.3/3.8L ENGINE......................98
AIR CLEANER ELEMENT
REMOVAL............................101
INSTALLATION........................101
AIR CLEANER HOUSING
REMOVAL............................101
INSTALLATION........................102
CYLINDER HEAD
DESCRIPTION........................102
DIAGNOSIS AND TESTINGÐCYLINDER HEAD
GASKET...........................102
REMOVAL - CYLINDER HEAD............103
CLEANING...........................103
INSPECTION.........................104
INSTALLATION - CYLINDER HEAD.........104CYLINDER HEAD COVER(S)
DESCRIPTION........................105
CYLINDER HEAD COVER - RIGHT
REMOVAL............................106
INSTALLATION........................106
CYLINDER HEAD COVER - LEFT
REMOVAL............................107
INSTALLATION........................107
INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION........................107
OPERATION..........................107
STANDARD PROCEDURE - REFACING
VALVESANDVALVESEATS ............107
REMOVAL............................108
CLEANING...........................108
INSPECTION.........................108
INSTALLATION........................109
VALVE SPRINGS
DESCRIPTION........................109
OPERATION..........................109
REMOVAL
REMOVAL - CYLINDER HEAD OFF.......109
REMOVAL - CYLINDER HEAD ON........111
INSPECTION..........................111
INSTALLATION
INSTALLATION - CYLINDER HEAD OFF . . . 111
INSTALLATION - CYLINDER HEAD ON....111
ROCKER ARMS
DESCRIPTION
DESCRIPTION - ROCKER ARMS.........112
DESCRIPTION - PUSHRODS............112
OPERATION
OPERATION - ROCKER ARMS..........112
OPERATION - PUSHRODS.............112
REMOVAL - ROCKER ARMS AND SHAFT....112
DISASSEMBLY - ROCKER ARMS
AND SHAFT.........................113
ASSEMBLY - ROCKER ARMS AND SHAFT . . . 113
INSTALLATION - ROCKER ARMS
AND SHAFT.........................113
VALVE STEM SEALS
DESCRIPTION........................114
REMOVAL............................115
INSTALLATION........................115
ENGINE BLOCK
DESCRIPTION........................115
STANDARD PROCEDURE - CYLINDER BORE
HONING............................115
CLEANING...........................115
9 - 76 ENGINE 3.3/3.8LRS

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