engine oil CHRYSLER CARAVAN 2005 Manual Online

(9) Using a blade or suitable hose cutter, cut trans-
axle oil cooler lines off flush with fittings. Plug cooler
lines and fittings to prevent debris from entering
transaxle or cooler circuit. A service splice kit will be
installed upon reassembly.
(10) Disconnect transmission shift linkage and
electrical connectors.
(11) Disconnect throttle body linkage.
(12) Disconnect engine wiring harness.
(13) Disconnect heater hoses from heater (Fig. 5).
(14) Discharge air conditioning system. (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING
- STANDARD PROCEDURE)
(15) Hoist vehicle and remove front wheels and
tires.
(16) Remove accessory drive belt splash shield.
(17) Remove accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)
(18) Remove axle shafts. (Refer to 3 - DIFFEREN-
TIAL & DRIVELINE/HALF SHAFT - REMOVAL)(19) Drain engine oil and remove oil filter. (Refer
to 9 - ENGINE/LUBRICATION/OIL - STANDARD
PROCEDURE)
(20) Remove crossmember cradle plate (Fig. 6).
Fig. 5 HEATER HOSES - 2.4L
1 - HEATER HOSES TO HEATER 3 - HEATER HOSE TO ENGINE - SUPPLY AND RETURN
2 - BOLT - HEATER TUBE SUPPORT
Fig. 6 Crossmember Cradle Plate
1 - CRADLE PLATE
RSENGINE 2.4L9-13
ENGINE 2.4L (Continued)

(21) Disconnect exhaust pipe from manifold (Fig.
7).
(22) Remove engine front mount and bracket from
engine. (Refer to 9 - ENGINE/ENGINE MOUNTING/
FRONT MOUNT - REMOVAL)
(23) Remove structural collar. (Refer to 9 -
ENGINE/ENGINE BLOCK/STRUCTURAL COVER -
REMOVAL)
(24) Remove rear engine mount bracket. (Refer to
9 - ENGINE/ENGINE MOUNTING/REAR MOUNT -
REMOVAL)
(25) Mark flex plate to torque converter and
remove torque converter bolts.
(26) Pinch-off power steering supply hose at pump.
Remove hose from pump.
(27) Remove and set aside the power steering
pump and bracket. Do not disconnect pressure line.
(28) Lower vehicle.
(29) Remove A/C lines at compressor and cap open-
ings.
(30) Remove engine ground straps (strap at engine
right mount and at starter).
(31) Raise vehicle enough to allow engine dolly
Special Tool 6135, cradle Special Tool 6710 with
Posts Special Tool 6848 to be installed under vehicle
(Fig. 8).
(32) Loosen cradle posts to allow movement for
proper positioning. Locate two rear posts (right side
of engine) into the holes on the engine bedplate.
Locate the two front posts (left side of engine) on the
oil pan rails (Fig. 8). Lower vehicle and position cra-
dle mounts until the engine is resting on mounts.Tighten mounts to cradle frame. This will keep
mounts from moving when removing or installing
engine and transmission.
(33) Install safety straps around the engine to cra-
dle. Tighten straps and lock.
(34) Lower vehicle so the weight ofONLY THE
ENGINE AND TRANSMISSIONare on the cradle.
(35) Remove engine and transmission mount bolts.
(36) Raise vehicle slowly. It may be necessary to
move the engine/transmission assembly with the
dolly to allow for removal around the body.
INSTALLATION - ENGINE ASSEMBLY
(1) Position engine and transmission assembly
under vehicle and slowly lower the vehicle over the
engine and transmission.
(2) Align engine and transmission mounts to
attaching points. Install mounting bolts at the right
(Fig. 9) and left mounts (Fig. 10).
(3) Remove safety straps.
(4) Slowly raise vehicle enough to remove the
engine dolly and cradle Special Tools 6135 and 6710.
(5) Install rear mount bracket and rear mount
through bolt. (Refer to 9 - ENGINE/ENGINE
MOUNTING/REAR MOUNT - INSTALLATION)
(6) Install the flex plate to torque converter bolts.
(7) Install structural collar. (Refer to 9 - ENGINE/
ENGINE BLOCK/STRUCTURAL COVER - INSTAL-
LATION)
(8) Install front mount bracket and front mount
through bolt. (Refer to 9 - ENGINE/ENGINE
MOUNTING/FRONT MOUNT - INSTALLATION)
(9) Connect exhaust system to manifold (Fig. 7).
(10) Install crossmember cradle plate (Fig. 6).
(11) Install new oil filter.
(12) Install power steering pump and bracket.
(13) Connect power steering supply line to pump
and remove pinch-off pliers.
(14) Connect A/C compressor hoses to compressor.
(15) Install accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION)
(16) Install axle shafts. (Refer to 3 - DIFFEREN-
TIAL & DRIVELINE/HALF SHAFT - INSTALLA-
TION)
(17) Install accessory drive belt splash shield.
(18) Install front wheels and tires.
(19) Remove plugs from transmission cooler hoses
and install transaxle oil cooler line service splice kit.
Refer to instructions included with kit.
(20) Connect the transaxle shift linkage and elec-
trical connectors.
(21) Connect heater hoses (Fig. 5).
(22) Install ground straps.
(23) Connect all engine and throttle body electrical
connections.
Fig. 7 Catalytic Converter to Exhaust Manifold
1 - CATALYTIC CONVERTER
2 - BOLT
3 - GASKET
4 - FLAG NUT
9 - 14 ENGINE 2.4LRS
ENGINE 2.4L (Continued)

(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 radiator lower and upper hoses.
(28) Install radiator fans. (Refer to 7 - COOLING/
ENGINE/RADIATOR FAN - INSTALLATION)
(29) Fill cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(30) Connect battery cables.
(31) Install air cleaner and inlet hose.
(32) Fill engine crankcase with proper oil to cor-
rect level.
(33) Start engine and run until operating temper-
ature is reached.
(34) Adjust transmission linkage, if necessary.
SPECIFICATIONS
SPECIFICATIONS - 2.4L ENGINE
GENERAL SPECIFICATIONS
DESCRIPTION SPECIFICATION
Type In-Line OHV, DOHC
Number of
Cylinders4
Firing Order 1-3-4-2
Compression
Ratio9.5:1
Max. Variation
Between
Cylinders25%
Metric Standard
Displacement 2.4 Liters 148 cu. in.
Bore 87.5 mm 3.445 in.
Stroke 101.0 mm 3.976 in.
Compression
Pressure1172-1551 kPa 170-225 psi
CYLINDER BLOCK
DESCRIPTION SPECIFICATIONS
Metric Standard
Cylinder Bore
Diameter87.4924 -
87.5076 mm3.4446 - 3.4452
in.
Out-of-Round
(Max.)0.051 mm 0.002 in.
Taper (Max.) 0.051 mm 0.002 in.
Fig. 9 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. 10 LEFT MOUNT TO FRAME BRACKET
1 - FRAME BRACKET
2 - FRAME RAIL - LEFT
3 - BOLT
4 - TRANSAXLE MOUNT
9 - 16 ENGINE 2.4LRS
ENGINE 2.4L (Continued)

PISTONS
DESCRIPTION SPECIFICATION
Metric Standard
Piston Diameter 87.463 - 87.481
mm3.4434 -3.4441
in.
Clearance @ 14
mm (0.551 in.)
from bottom of
skirt0.024 - 0.057
mm0.0009 - 0.0022
in.
Weight 331 - 339
grams11.67- 11.95 oz.
Land Clearance
(Diametrical)0.614 - 0.664
mm0.024 - 0.026 in.
Piston Length 66.25 mm 2.608 in.
Piston Ring
Groove Depth
No. 14.640 - 4.784
mm0.182 - 0.188 in.
Piston Ring
Groove Depth
No. 24.575 - 4.719
mm(0.180 - 0.185
in.)
Piston Ring
Groove Depth
No. 34.097 - 4.236
mm0.161 - 0.166 in.
PISTON PINS
DESCRIPTION SPECIFICATION
Metric Standard
Clearance in
Piston0.005 - 0.018
mm0.0002 - 0.0008
in.
Clearance in
Connecting RodInterference
Diameter 21.998 - 22.003
mm0.8660 - 0.8662
in.
End Play None
Length 72.75 - 73.25
mm2.864 - 2.883 in.
PISTON RINGS
DESCRIPTION SPECIFICATION
Metric Standard
Ring Gap
To p
Compression
Ring0.25 - 0.51 mm 0.0098 - 0.020
in.
Wear Limit 0.8 mm 0.031 in.
2nd
Compression
Ring0.23 - 0.48 mm 0.009 - 0.018 in.
Wear Limit 0.8 mm 0.031 in.
Oil Control Steel
Rails0.25 - 0.64 mm 0.0098 - 0.025
in.
Wear Limit 1.00 mm 0.039 in.
Compression
Rings0.030 - 0.080
mm0.0011 - 0.0031
in.
Wear Limit 0.10 mm 0.004 in.
Ring Side
Clearance - Oil
Ring Pack0.012 - 0.178
mm0.0004 - 0.0070
in.
Ring Width -
Compression
Rings1.47 - 1.50 mm 0.057 - 0.059 in.
Ring Width - Oil
Ring Pack2.72 - 2.88 mm 0.107 - 0.1133
in.
CONNECTING ROD
DESCRIPTION SPECIFICATION
Metric Standard
Bearing
Clearance0.025 - 0.071
mm0.0009 - 0.0027
in.
Wear Limit 0.075 mm 0.003 in.
Bore Diameter -
Piston Pin20.96 - 20.98
mm0.8252 - 0.8260
in.
Bore Diameter -
Crankshaft End53.007 - 52.993
mm2.0868 - 2.0863
in.
Side Clearance 0.13 - 0.38 mm 0.005 - 0.015 in.
Wear Limit 0.40 mm 0.016 in.
Weight - Total
(Less Bearing)565.8 grams 19.96 oz.
RSENGINE 2.4L9-17
ENGINE 2.4L (Continued)

VALVE SPRINGS
DESCRIPTION SPECIFICATION
Metric Standard
Free Length
(Approx.)48.4 mm 1.905 in.
Nominal Force
(Valve Closed)338 N @ 38.0
mm75.98 lbs. @
1.496 in.
Nominal Force
(Valve Open)607 N @ 29.75
mm136 lbs. @
1.172 in.
Installed Height 38.00 mm 1.496 in.
Number of Coils 7.82
Wire Diameter 3.86 mm 1.496 in
OIL PUMP
DESCRIPTION SPECIFICATION
Metric Standard
Clearance Over
Rotors (Max.)0.10 mm 0.004 in.
Cover
Out-of-Flat
(Max.)0.025 mm 0.001 in.
Inner Rotor
Thickness (Min.)9.40 mm 0.370 in.
Outer Rotor
Thickness (Min.)9.40 mm 0.370 in.
Outer Rotor
Clearance
(Max.)0.039 mm 0.015 in.
Outer Rotor
Diameter (Min.)79.95 mm 3.148 in.
Tip Clearance
Between Rotors
(Max.)0.20 mm 0.008 in.
OIL PRESSURE
DESCRIPTION SPECIFICATION
Metric Standard
At Curb Idle
Speed*25 kPa 4 psi
At 3000 rpm 170 - 550 kPa 25 - 80 psi
CAUTION:
*If pressure is ZERO at curb idle, DO NOT run engine
at 3000 rpm.
SPECIFICATIONS - TORQUE
DESCRIPTION N´m Ft.
Lbs.In.
Lbs.
Balance Shaft Carrier to
BlockÐBolts54 40 Ð
Balance Shaft Gear
CoverÐDouble Ended
Fastener12 Ð 105
Balance Shaft SprocketÐ
Bolt28 Ð 250
Balance Shaft Chain
TensionerÐBolts12 Ð 105
Balance Shaft Carrier
CoverÐBolts12 Ð 105
Camshaft SprocketÐBolt 101 75 Ð
Connecting Rod
CapÐBolts27 +
1¤4
turn20
+1¤4
turnÐ
Crankshaft Main Bearing
Cap/Bedplate
ÐM8 Bolts 28 250
ÐM11 Bolts 41 +
1¤4
Turn30
+1¤4
TurnÐ
Crankshaft Damper 136 100 Ð
Cylinder HeadÐBolts (Refer to 9 - ENGINE/
CYLINDER HEAD -
INSTALLATION)
Cylinder Head CoverÐ
Bolts12 Ð 105
Flex Plate to Crankshaft 95 70 Ð
Engine Mount Bracket
RightÐBolts61 45 Ð
Engine MountingÐBolts (Refer to 9 ENGINE/
ENGINE MOUNTING)
Exhaust Manifold to
Cylinder HeadÐBolts19 Ð 170
Exhaust Manifold Heat
ShieldÐBolts12 Ð 105
Intake Manifold - Lower
ÐBolts28 Ð 250
Intake Manifold -
UpperÐBolts28 Ð 250
Oil Filter 12 Ð 105
Oil PanÐBolts 12 Ð 105
Oil Pan DrainÐPlug 28 20 Ð
Oil Pressure Switch 21 Ð 190
9 - 20 ENGINE 2.4LRS
ENGINE 2.4L (Continued)

DESCRIPTION N´m Ft.
Lbs.In.
Lbs.
Oil Pump to BlockÐBolts 28 20 Ð
Oil Pump Cover
PlateÐBolts12 Ð 105
Oil Pump Pick-up
TubeÐBolt28 20 Ð
Oil Pump Relief
ValveÐCap41 30 Ð
Spark Plugs 18 13 Ð
Structural Collar (Refer to 9 - ENGINE/
ENGINE BLOCK/
STRUCTURAL COVER -
INSTALLATION)
Timing Belt Covers
- Front Covers to Rear
CoverÐBolts6Ð50
- Rear CoverÐM6 Bolts 12 Ð 105
ÐM8 Bolts 28 Ð 250
Timing Belt Idler Pulley 61 45 Ð
Timing Belt Tensioner
Lock Bolt25 Ð 220
Timing Belt Tensioner
AssemblyÐBolts61 45 Ð
SPECIAL TOOLS
2.4L ENGINE
Puller 1026
Crankshaft Damper Removal Insert 6827A
Dolly 6135
Cradle 6710A
Post Kit Engine Cradle 6848
Camshaft Sprocket Holder 6847
Camshaft Seal Remover C-4679A
RSENGINE 2.4L9-21
ENGINE 2.4L (Continued)

Crankshaft Sprocket Remover Insert C-4685-C2
Front Crankshaft Oil Seal Remover 6771
Front Crankshaft Oil Seal Installer 6780
Oil Pressure Gauge C-3292
Adapter 8406
Rear Crankshaft Oil Seal Installer 6926
Driver Handle C-4171
Balance Shaft Sprocket Installer 6052
RSENGINE 2.4L9-23
ENGINE 2.4L (Continued)

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 bolt for air box at upper radiator
cross member.
(5) Pull air box up and off over the single locating
pin.
(6) Remove air box from vehicle
INSTALLATION
(1) Install air box into vehicle and onto the locat-
ing pin.
(2) Install bolt to hold air box to the upper radia-
tor cross member.
(3) Install the inlet hose to the throttle body.
(4) Connect the inlet air temperature sensor (Fig.
12).
(5) Connect the negative battery cable.
CYLINDER HEAD
DESCRIPTION
The cross flow designed, aluminum cylinder head
contains dual over-head camshafts with four valves
per cylinder (Fig. 13). The valves are arranged in two
in-line banks. The intake valves face toward the
front of the vehicle. The exhaust valves face the dash
panel. The cylinder head incorporates powdered
metal valve guides and seats. The cylinder head is
sealed to the block using a multi-layer steel head
gasket and retaining bolts.Integral oil galleries provide lubrication passages
to the hydraulic lash adjusters, camshafts, and valve
mechanisms.
DIAGNOSIS AND TESTINGÐCYLINDER HEAD
GASKET
A cylinder head gasket leak can be located between
adjacent cylinders or between a cylinder and the
adjacent water jacket.
Possible indications of the cylinder head gasket
leaking between adjacent cylinders are:
²Loss of engine power
²Engine misfiring
²Poor fuel economy
Possible indications of the cylinder head gasket
leaking between a cylinder and an adjacent water
jacket are:
²Engine overheating
²Loss of coolant
²Excessive steam (white smoke) emitting from
exhaust
²Coolant foaming
Fig. 12 IAT Sensor 2.4L
Fig. 13 Cylinder Head and Camshafts
1 - CAMSHAFT BEARING CAPS
2 - PLUG
3 - CAMSHAFT
4 - CYLINDER HEAD
5 - CAMSHAFT OIL SEAL
RSENGINE 2.4L9-25

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 - ENGINE - DIAGNOSIS AND TESTING). An
engine cylinder head gasket leaking between adja-
cent cylinders will result in approximately a 50±70%
reduction in compression pressure.
CYLINDER-TO-WATER JACKET LEAKAGE TEST
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING WITH COOLANT PRES-
SURE CAP REMOVED.
VISUAL TEST METHOD
With the engine cool, remove the coolant pressure
cap. Start the engine and allow it to warm up until
thermostat opens.
If a large combustion/compression pressure leak
exists, bubbles will be visible in the coolant.
COOLING SYSTEM TESTER METHOD
WARNING: WITH COOLING SYSTEM TESTER IN
PLACE, PRESSURE WILL BUILD UP FAST. EXCES-
SIVE PRESSURE BUILT UP, BY CONTINUOUS
ENGINE OPERATION, MUST BE RELEASED TO A
SAFE PRESSURE POINT. NEVER PERMIT PRES-
SURE TO EXCEED 138 kPa (20 psi).
Install Cooling System Tester 7700 or equivalent to
pressure cap neck. Start the engine and observe the
tester's pressure gauge. If gauge pulsates with every
power stroke of a cylinder a combustion pressure
leak is evident.
CHEMICAL TEST METHOD
Combustion leaks into the cooling system can also
be checked by using Bloc-Chek Kit C-3685-A or
equivalent. Perform test following the procedures
supplied with the tool kit.
REMOVAL - CYLINDER HEAD
(1) Perform fuel system pressure release procedure
before attempting any repairs.(Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY - SPECIFICA-
TIONS)
(2) Disconnect battery negative cable.
(3) Drain cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(4) Remove air filter housing and inlet tube.
(5) Remove upper intake manifold. (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
REMOVAL)(6) Remove heater tube support bracket from cyl-
inder head.
(7) Disconnect radiator upper and heater supply
hoses from intake manifold water outlet connections.
(8) Remove accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)
(9) Raise vehicle and remove exhaust pipe from
manifold.
(10) Remove power steering pump reservoir and
line support bracket from lower intake manifold and
set aside. Do not disconnect lines.
(11) Remove ignition coil and wires from engine.
(12) Disconnect cam sensor and fuel injector wir-
ing connectors.
(13) Remove timing belt and camshaft sprockets.
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT/CHAIN AND SPROCKETS - REMOVAL)
(14) Remove timing belt idler pulley and rear tim-
ing belt cover. (Refer to 9 - ENGINE/VALVE TIM-
ING/TIMING BELT / CHAIN COVER(S) -
REMOVAL)
(15) Remove cylinder head cover. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL)
(16) Remove camshafts (Refer to 9 - ENGINE/
CYLINDER HEAD/CAMSHAFT(S) - REMOVAL).
NOTE: Identify rocker arm position to ensure cor-
rect re-installation in original position, if reused.
(17) Remove rocker arms. (Refer to 9 - ENGINE/
CYLINDER HEAD/ROCKER ARMS - REMOVAL)
(18) Remove cylinder head bolts in REVERSE
sequence of tightening (Fig. 19).
(19) Remove cylinder head from engine block.
(20) Inspect and clean cylinder head. (Refer to 9 -
ENGINE/CYLINDER HEAD - INSPECTION) (Refer
to 9 - ENGINE/CYLINDER HEAD - CLEANING)
CLEANING
To ensure engine gasket sealing, proper surface
preparation must be performed, especially with the
use of aluminum engine components and multi-layer
steel cylinder head gaskets.
NOTE: Multi-Layer Steel (MLS) head gaskets require
a scratch free sealing surface.
Remove all gasket material from cylinder head and
block (Refer to 9 - ENGINE - STANDARD PROCE-
DURE). Be careful not to gouge or scratch the alumi-
num head sealing surface.
Clean all engine oil passages.
9 - 26 ENGINE 2.4LRS
CYLINDER HEAD (Continued)

INSPECTION
(1) Cylinder head must be flat within 0.1 mm
(0.004 in.) (Fig. 14).
(2) Inspect camshaft bearing journals for scoring.
(3) Remove carbon and varnish deposits from
inside of valve guides with a reliable guide cleaner.
(4) Using a small hole gauge and a micrometer,
measure valve guides in 3 places top, middle and bot-
tom (Fig. 15). (Refer to 9 - ENGINE - SPECIFICA-
TIONS) Replace guides if they are not within
specification.
(5) Check valve guide height (Fig. 16).
INSTALLATION - CYLINDER HEAD
NOTE: The Cylinder head bolts should be examined
BEFORE reuse. If the threads are necked down, the
bolts must be replaced (Fig. 17).Necking can be checked by holding a scale or
straight edge against the threads. If all the threads
do not contact the scale, the bolt should be replaced.
(1) Before installing the bolts, the threads should
be coated with engine oil.
(2) Position cylinder head gasket on engine block
(Fig. 18).
(3) Install cylinder head on engine block.
(4) Tighten the cylinder head bolts in the sequence
shown in (Fig. 19). Using the 4 step torque turn
method, tighten according to the following values:
²First All to 34 N´m (25 ft. lbs.)
²Second All to 68 N´m (50 ft. lbs.)
²Third All to 68 N´m (50 ft. lbs.)
CAUTION: Do not use a torque wrench for the fol-
lowing step.
²Fourth Turn an additional 1/4 Turn,
Fig. 14 Checking Cylinder Head Flatness
1 - FEELER GAUGE
2 - STRAIGHT EDGE
Fig. 15 Checking Wear on Valve GuideÐTypical
1-TOP
2 - MIDDLE
3 - BOTTOM
4 - CUT AWAY VIEW OF VALVE GUIDE MEASUREMENT
LOCATIONS
Fig. 16 Valve Guide Height
1 - VALVE GUIDE
2 - 13.25 - 13.75 MM (0.521 - 0.541 IN.)
3 - SPRING SEAT
Fig. 17 Checking Bolts for Stretching (Necking)
1 - STRETCHED BOLT
2 - THREADS ARE NOT STRAIGHT ON LINE
3 - THREADS ARE STRAIGHT ON LINE
4 - UNSTRETCHED BOLT
RSENGINE 2.4L9-27
CYLINDER HEAD (Continued)