wheel CHRYSLER CARAVAN 2005 Service Manual

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)

(6) Install the accessory drive belt. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION)
(7) Install inner splash shield and right front
wheel.
(8) Connect negative cable to battery.
FLEX PLATE
REMOVAL
(1) Remove the transaxle (Refer to 21 - TRANS-
MISSION/TRANSAXLE/AUTOMATIC - 41TE -
REMOVAL).
(2) Remove flex plate attaching bolts.
(3) Remove the flex plate (Fig. 86).
INSTALLATION
(1) Position flex plate with backing plate on the
crankshaft (Fig. 86).
(2) Apply MopartLock & Seal Adhesive to the flex
plate bolts.
(3) Install flex plate bolts (Fig. 86). Tighten bolts
to 95 N´m (70 ft. lbs.).
(4) Install the transaxle (Refer to 21 - TRANSMIS-
SION/TRANSAXLE/AUTOMATIC - 41TE - INSTAL-
LATION).
Fig. 84 Vibration Damper - Removal
1 - SPECIAL TOOL 8450 - INSERT
2 - SPECIAL TOOL 1026-3JAWPULLER
Fig. 85 Vibration Damper - Installation
1 - FORCING SCREW / NUT FROM SPECIAL TOOL 8452
2 - VIBRATION DAMPER
3 - THRUST BEARING / WASHER
Fig. 86 FLEX PLATE
1 - FLEX PLATE
2 - BOLT (QTY. 8)
3 - BACKING PLATE
RSENGINE 3.3/3.8L9 - 133
VIBRATION DAMPER (Continued)

LEFT MOUNT
REMOVAL
(1) Raise the vehicle on hoist.
(2) Remove the left front wheel.
(3) Remove the left mount through bolt access
cover.
(4) Support the transaxle with a suitable jack.
(5) Remove the engine front mount through bolt to
allow left mount removal clearance (Fig. 88).
(6) Remove the left mount through frame rail bolt
(Fig. 89).
(7) Lower transaxle for access to horizontal bolts.
(8) Remove the horizontal bolts from the mount to
the transaxle (Fig. 90).
NOTE: To remove mount, additional lowering of
transaxle may be required.
(9) Remove left mount.
INSTALLATION
(1) Install left mount on transaxle (Fig. 90).
(2) Raise transaxle with jack until left mount is in
position.
(3) Install left mount through bolt (Fig. 89).
(4) Install left mount through bolt access cover.
(5) Install front mount through bolt (Fig. 88).
(6) Install left front wheel.
(7) Lower vehicle.
REAR MOUNT
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove the rear mount heat shield (Fig. 91).
(3) Remove the through bolt from the mount and
rear mount bracket (Fig. 92).
(4) Remove the mount bolts (Fig. 92).
(5) Remove the rear mount (Fig. 92).
(6) For rear mount bracket removal, remove the
bolts attaching bracket to transaxle (Fig. 93).
(7) Remove rear mount bracket.
Fig. 89 LEFT MOUNT TO BRACKET
1 - BOLT - BRACKET TO FRAME RAIL 68 N´m (50 ft. lbs.)
2 - BOLT - MOUNT TO RAIL THRU 75 N´m (55 ft. lbs.)
3 - BOLT - LEFT MOUNT TO TRANSAXLE 54 N´m (40 ft. lbs.)
4 - TRANSAXLE
5 - MOUNT - LEFT
6 - BRACKET - LEFT MOUNT
Fig. 90 LEFT MOUNT - 41TE TRANSAXLE
1 - LEFT MOUNT ASSEMBLY
2 - BOLT - 54 N´m (40 ft. lbs.)
3 - TRANSAXLE - 41TE
Fig. 91 Rear Mount Heat Shield
1 - BOLT - HEAT SHIELD 11 N´m (100 in. lbs.)
2 - HEAT SHIELD
3 - CLIP
4 - REAR MOUNT
9 - 136 ENGINE 3.3/3.8LRS

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)

(4) Apply force in the reverse direction to the fol-
lowing torque:
²41 N´m (30 ft. lb.) with cylinder heads installed
²20 N´m (15 ft. lb.) with cylinder heads removed
(5) Measure amount of sprocket/chain movement.
(6) Install a new timing chain and sprockets if
movement exceeds 3.175 mm (1/8 in.).
TIMING CHAIN COVER
REMOVAL
(1) Disconnect negative cable from battery.
(2) Drain cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(3) Raise vehicle on hoist.
(4) Drain engine oil.
(5) Remove right wheel and inner splash shield.
(6) Remove oil pan. (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - REMOVAL)
(7) Remove oil pick-up tube (Fig. 134).
(8) Remove accessory drive belt. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)
(9) Remove A/C compressor and set aside.
(10) Remove crankshaft vibration damper. (Refer
to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL)
(11) Remove radiator lower hose.
(12) Remove heater hose from timing chain cover
housing (Fig. 135) or water pump inlet tube (if
engine oil cooler equipped) (Fig. 136).
(13) Remove the right side engine mount. (Refer to
9 - ENGINE/ENGINE MOUNTING/RIGHT MOUNT
- REMOVAL)
(14) Remove idler pulley from engine bracket (Fig.
137).
(15) Remove the engine mount bracket (Fig. 137).(16) Remove camshaft position sensor from timing
chain cover (Fig. 137).
Fig. 133 Measuring Timing Chain Wear
1 - TORQUE WRENCH
Fig. 134 OIL PICKUP TUBE
1 - BOLT
2 - OIL PICK-UP TUBE
3 - O-RING
Fig. 135 HEATER RETURN HOSE (Without Engine
Oil Cooler)
1 - CAP AND CLAMP (OIL COOLER EQUIPPED ONLY)
2 - HOSE ASSEMBLY - HEATER RETURN
3 - BOLT - HEATER TUBE ATTACHING
4 - BOLT - HEATER TUBE ATTACHING
9 - 156 ENGINE 3.3/3.8LRS
VALVE TIMING (Continued)

(17) Install accessory drive belt. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION)
(18) Install oil pump pick-up tube with new
O-ring. Tighten attaching bolt to 28 N´m (250 in.
lbs.).
(19) Install oil pan. (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION)
(20) Install inner splash shield and right front
wheel.
(21) Fill crankcase with engine oil to proper level.
(22) Fill cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(23) Connect negative cable to battery.
TIMING CHAIN AND
SPROCKETS
REMOVAL
REMOVAL - TIMING CHAIN AND CAMSHAFT
SPROCKET
(1) Disconnect negative cable from battery.
(2) Remove the timing chain cover. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL)
(3) Rotate engine by turning crankshaft until the
timing marks are aligned as shown in (Fig. 141).
(4) Remove camshaft sprocket attaching bolt.
(5) Remove the timing chain with camshaft
sprocket.
(6) Remove the crankshaft sprocket. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - REMOVAL)
REMOVAL - CRANKSHAFT SPROCKET
(1) Remove the timing chain. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - REMOVAL)
(2) Using Special Tools 8539, 5048-6, and 5048-1,
remove the crankshaft sprocket while holding the
crankshaft from turning (Fig. 142). Be careful not to
damage the crankshaft surfaces.
Fig. 141 Timing Mark Alignment
1 - CAMSHAFT SPROCKET TIMING MARK (DOT)
2 - PLATED LINK
3 - CRANKSHAFT SPROCKET TIMING MARK (DOT)
4 - ARROWS
Fig. 142 CRANKSHAFT SPROCKET - REMOVAL
1 - SPECIAL TOOL 5048-6
2 - SPECIAL TOOL 5048-1
3 - SPECIAL TOOL 8450
4 - CRANKSHAFT SPROCKET
5 - SPECIAL TOOL 8539
RSENGINE 3.3/3.8L9 - 159
TIMING CHAIN COVER (Continued)

INSPECTION
WARNING: THE NORMAL OPERATING TEMPERA-
TURE OF THE EXHAUST SYSTEM IS VERY HIGH.
THEREFORE, NEVER ATTEMPT TO SERVICE ANY
PART OF THE EXHAUST SYSTEM UNTIL IT IS
COOLED. SPECIAL CARE SHOULD BE TAKEN
WHEN WORKING NEAR THE CATALYTIC CON-
VERTER. THE TEMPERATURE OF THE CONVERTER
RISES TO A HIGH LEVEL AFTER A SHORT PERIOD
OF ENGINE OPERATION TIME.
Check catalytic converter for a flow restriction.
(Refer to 11 - EXHAUST SYSTEM - DIAGNOSIS
AND TESTING) Exhaust System Restriction Check
for procedure.
Visually inspect the catalytic converter element by
using a borescope or equivalent. Remove oxygen sen-
sor(s) and insert borescope. If borescope is not avail-
able, remove converter and inspect element using a
flashlight. Inspect element for cracked or melted sub-
strate.
NOTE: Before replacing a catalytic converter, deter-
mine the root cause of failure. Most catalytic con-
verter failures are caused by air, fuel or ignition
problems. (Refer to Appropriate Diagnostic Informa-
tion) for test procedures.
INSTALLATION
(1) Position new gasket onto the manifold flange
and install catalytic converter (Fig. 5). Tighten fas-
teners to 37 N´m (325 in. lbs.).
NOTE: Be careful not to twist or kink the oxygen
sensor wires.
(2) Install (if removed) and connect the down-
stream oxygen sensor (Fig. 4).
(3) Install the muffler/resonator assembly. (Refer
to 11 - EXHAUST SYSTEM/MUFFLER - INSTALLA-
TION)
(4) Start the engine and inspect for exhaust leaks.
Repair exhaust leaks as necessary.
(5) Check the exhaust system for contact with the
body panels. Make the necessary adjustments, if
needed.
CROSS-OVER PIPE - 3.3/3.8L
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove the fasteners attaching the left bank
manifold connection to cross-over pipe (Fig. 6).
(3) Raise vehicle and remove the left front wheel.(4) Access the lower right bank pipe connection
fastener through the left front wheel opening using a
long ratchet extension. Loosen and remove the lower
fastener.
(5) Remove the upper right bank pipe connection
fastener by accessing though the catalytic converter
floor pan tunnel.
(6) Lower the vehicle.
(7) Remove the cross-over pipe (Fig. 6).
(8) Remove gaskets and discard (Fig. 6).
INSTALLATION
(1) Position cross-over pipe to the manifold connec-
tions (Fig. 6).
(2) Position new gasket on left bank (front) pipe
connection and loosely install fasteners (Fig. 6).
(3) Raise the vehicle.
(4) Position new gasket on the right bank pipe con-
nection and install fasteners.
(5) Tighten right bank upper fastener to 41 N´m
(30 ft. lbs.).
(6) Tighten right bank lower fastener to 41 N´m
(30 ft. lbs.) using a long ratchet extension accessing
through the left wheel opening.
(7) Install the left front wheel and lower vehicle.
(8) Tighten the left bank pipe connection fasteners
to 41 N´m (30 ft. lbs.) (Fig. 6).
(9) Start the engine and inspect for exhaust leaks.
Repair exhaust leaks as necessary.
(10) Check the exhaust system for contact with the
body panels. Make the necessary adjustments, if
needed.
Fig. 6 CROSS-OVER PIPE
1 - CROSS-OVER PIPE
2 - BOLT
3 - GASKET
4 - FLAG NUT
11 - 6 EXHAUST SYSTEMRS
CATALYTIC CONVERTER (Continued)

HEAT SHIELDS
DESCRIPTION
The exhaust system heat shields (Fig. 7), (Fig. 8),
or (Fig. 9) are attached to the under body of the vehi-
cle. On vehicles equipped with All Wheel Dive
(AWD), an additional heat shield is mounted to the
catalytic converter.
OPERATION
Heat shields are needed to protect both the vehicle
and the environment from the high temperatures
developed near the catalytic converter.Avoid application of rust prevention com-
pounds or undercoating materials to exhaust
system floor pan heat shields on cars so
equipped. Light over spray near the edges is
permitted. Application of coating will greatly
reduce the efficiency of the heat shields result-
ing in excessive floor pan temperatures and
objectionable fumes.
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove fasteners attaching applicable heat
shield (Fig. 7), (Fig. 8), or (Fig. 9).
(3) Remove heat shield(s).
INSTALLATION
(1) Position heat shield(s) to underbody.
(2) Install heat shield fasteners and tighten to 2.6
N´m (23 in. lbs.) (Fig. 7), (Fig. 8), or (Fig. 9).
(3) Lower vehicle.
(4) Start the engine and inspect for exhaust leaks.
Repair exhaust leaks as necessary.
(5) Check the exhaust system for contact with the
body panels. Make the necessary adjustments, if
needed.
MUFFLER
REMOVAL
(1) Raise vehicle on a body contact type hoist.
NOTE: To provide removal clearance between muf-
fler/resonator pipe and rear axle parts, the rear sus-
pension must be relieved of all body weight.
(2) Apply a penetrating oil to clamp nuts of com-
ponent requiring removal.
Fig. 7 CATALYTIC CONVERTER HEAT SHIELD
1 - HEAT SHIELD - CATALYTIC CONVERTER
2 - SCREW (QTY. 4)
Fig. 8 MUFFLER HEAT SHIELD
1 - HEAT SHIELD - MUFFLER
2 - SCREW (QTY. 6)
Fig. 9 RESONATOR PIPE HEAT SHIELD
1 - SCREW (QTY. 3)
2 - HEAT SHIELD - RESONATOR PIPE
3 - MUFFLER
RSEXHAUST SYSTEM11-7

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

(4) Install the two bolts and two nuts attaching
fascia to the front fenders. The fascia should be flush
to fender.
(5) Install front wheelhouse splash shields fasten-
ers. (Refer to 23 - BODY/EXTERIOR/ WHEEL-
HOUSE SPLASH SHIELD - INSTALLATION).
(6) Install front wheels.(7) Connect fog lamp wire connectors, if necessary.
(8) Install the five push pin fasteners attaching
bottom of fascia to radiator closure panel.
(9) Lower the vehicle.
(10) Install the headlamp assemblies. (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
HEADLAMP - INSTALLATION).
Fig. 1 FRONT FASCIA
1 - FRONT BUMPER FASCIA
2 - GRILLE
3 - BUMPER REINFORCEMENT4 - RADIATOR ENCLOSURE
5 - AIR DAM
13 - 2 FRAME & BUMPERSRS
FRONT FASCIA (Continued)