oil CHRYSLER CARAVAN 2005 Service Manual

DESCRIPTION SPECIFICATION
Metric Standard
Ring Width-2nd
Compression
Ring 3.3L and
3.8L1.46-1.49 mm 0.0575-0.058 in.
Ring Width-Oil
Ring (Steel
Rails) 3.3L0.435-0.490
mm-.017-0.019 in.
Ring Width-Oil
Ring (Steel
Rails) 3.8L0.435-0.510
mm0.017-0.020
CAMSHAFT
DESCRIPTION SPECIFICATION
Metric Standard
Journal
Diameter
#1 50.724-50.775
mm1.997-1.999 in.
#2 50.317-50.368
mm1.9809-1.9829
in.
#3 49.936-49.987
mm1.9659-1.9679
in.
#4 49.530-49.581
mm1.9499-1.9520
in.
Bearing
Clearance-
Diametrical0.025-0.101
mm0.001-0.004 in.
Bearing
Clearance
(Max.Allowable)0.127 mm 0.005 in.
End Play 0.254-0.508
mm0.010-0.020 in.
Camshaft
Bearing
Diameter
#1 50.800-50.825 1.9999-2.0009
in.
#2 50.393-50.419
mm1.9839-1.9849
in.
#3 50.013-50.038
mm1.9690-1.9699
in.
#4 49.606-49.632
mm1.9529-1.954 in.
Exhaust Valve
Timing
Closes-3.3L
(ATDC)- 13É
Closes-3.8L
(ATDC)- 18É
Opens-3.3L
(BBDC)- 43É
Opens-3.8L
(BBDC)- 46É
Duration-3.3L - 236É
Duration-3.8L - 244É
Intake Valve
Timing
Closes-3.3L
(ABDC)- 52É
Closes-3.8L
(ABDC)- 63É
Opens-3.3L
(ATDC)-6É
Opens-3.8L
(ATDC)-1É
Duration-3.3L - 226É
Duration-3.8L - 242É
Valve Overlap-
3.3L-7É
Valve Overlap-
3.8L- 17É
HYDRAULIC LIFTER
DESCRIPTION SPECIFICATION
Metric Standard
Type Hydraulic Roller
Outside
Diameter22.949-22.962
mm0.903-0.904 in.
Clearance in
Block0.020-0.061
mm0.0007-0.0024
in.
CYLINDER HEAD
DESCRIPTION SPECIFICATION
Metric Standard
Gasket
Thickness
(Compressed)0.65-0.75 mm 0.0007-0.0024
in.
RSENGINE 3.3/3.8L9-95
ENGINE 3.3/3.8L (Continued)

VALVE SPRING
DESCRIPTION SPECIFICATION
Metric Standard
Free Length-
Type A51.4 mm 2.02 in.
Free Length-
Type B53.4 mm 2.10 in.
Wire Diameter
Type A3.95-4.77 mm 0.15-0.19 in.
Wire Diameter
Type B4.19-4.29 mm 0.16-0.17 in.
Number of Coils
Type A7.52
Number of Coils
Type B7.25
Spring Tension
(Valve Closed)
Type A376.4-424.4 N
@ 41.9 mm84.6-95.6 lbs.
@ 1.65 in.
Spring Tension
(Valve Open)
Type A863.9-959.9 N
@ 41.9 mm194.2-215.8 lbs.
@ 1.65 in.
Spring Tension
(Valve Closed)
Type B377-423 N @
41.9 mm84.8-95.2 lbs.
@ 1.65 in.
Spring Tension
(Valve Open)
Type B880-962 N @
30.91 mm197.9-216.3 lbs.
@ 122 in.
Installed Height 41.1-42.7 mm 1.61-1.68 in
LUBRICATION
DESCRIPTION SPECIFICATION
Metric Standard
At Curb Idle
Speed*
(Minimum with
engine at
operating
temperature)34.47 kPa 5 psi
At 3000 RPM 205-551 kPa 30-80 psi
Oil Filter
By-Pass Valve
Setting62-103 kPa 9-15 psi
Oil Pressure
Switch Actuating
Pressure14-28 Kpa 2-4 psi
caution:
*If pressure is ZERO at curb idle, DO NOT run engine
at 3000 rpm.
OIL PUMP
DESCRIPTION SPECIFICATION
Metric Standard
Clearance Over
rotors-Inner and
Outer0.10 mm 0.004 in.
Cover
Out-Of-Flat
(Max.)0.025 mm 0.001 in.
Inner Rotor
Thickness7.64 mm 0.301 in.
Outer Rotor
Thickness (Min)7.64 mm 0.301 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.
SPECIFICATIONS - TORQUE
DESCRIPTION N´m Ft.
Lbs.In.
Lbs.
Camshaft SprocketÐBolt 54 40 Ð
Camshaft Thrust
PlateÐBolts12 Ð 105
Connecting Rod
CapÐBolts54 +
1¤4
turn40
+1¤4
turnÐ
Crankshaft Main Bearing
CapÐBolts41 +
1¤4
turn30
+1¤4
turnÐ
Crankshaft Main Bearing
Cap Cross Bolts (3.8L)61 45 Ð
Crankshaft Oil Seal
Retainer RearÐBolts12 Ð 105
Crankshaft DamperÐBolt 54 40 Ð
Cylinder Block Drain
Plugs20 15 Ð
Cylinder HeadÐBolts (Refer to 9 - ENGINE/
CYLINDER HEAD -
INSTALLATION)
Cylinder Head CoverÐ
Bolts12 Ð 105
Flex Plate to Crankshaft 95 70 Ð
RSENGINE 3.3/3.8L9-97
ENGINE 3.3/3.8L (Continued)

DESCRIPTION N´m Ft.
Lbs.In.
Lbs.
Engine Mounting (Refer to 9 - ENGINE/
ENGINE MOUNTING)
Exhaust ManifoldÐBolts 23 Ð 200
Exhaust Crossover
PipeÐBolts54 40 Ð
Intake Manifold -
LowerÐBolts23 Ð 200
Intake Manifold - Lower
Gasket RetainerÐBolts12 Ð 105
Intake Manifold
UpperÐBolts12 Ð 105
Lifter Yoke RetainerÐ
Bolts12 Ð 105
Oil Filter Attaching Fitting 54 40 Ð
Oil Cooler Attaching
Fitting27 20 Ð
Oil Filter 20 15 Ð
Oil Filter AdapterÐBolts 28 Ð 250
Oil Gallery Plug 27 20 Ð
Oil PanÐBolts 12 Ð 105
Oil Pan DrainÐPlug 27 20 Ð
Oil Pressure Switch 23 Ð 200
Oil Pump Cover
PlateÐScrews12 Ð 105
Oil Pump Pick-up
TubeÐBolt28 Ð 250
Oil Dipstick HousingÐ
Bolts48 35 Ð
Rocker Arm ShaftÐBolts 23 Ð 200
Spark Plug 16 12 Ð
Timing Chain Case Cover
ÐM8 Bolt 27 20 Ð
ÐM10 Bolt 54 40 Ð
Water PumpÐBolts 12 Ð 105
Water Pump PulleyÐ
Bolts28 Ð 250SPECIAL TOOLS
3.3/3.8L ENGINE
Dolly 6135
Cradle 6710A
Adapter 6909A
Adapter 8444
9 - 98 ENGINE 3.3/3.8LRS
ENGINE 3.3/3.8L (Continued)

Valve Spring Compressor Off-vehicle C-3422-D
Adapter, Valve Spring Compressor Off-vehicle 8464
Remover, Valve Tappet C-4129-A
Remover, Crankshaft Front Seal 6341A
Installer, Crankshaft Front Seal C-4992
Remover and Installer, Crankshaft Main Bearing
C-3059
Rear Crankshaft Oil Seal Installer 6926
Oil Pressure Gauge C-3292
Adapter 8406
Cooling System Tester 7700
9 - 100 ENGINE 3.3/3.8LRS
ENGINE 3.3/3.8L (Continued)

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.
INSPECTION
(1) Before cleaning, check for leaks, damage and
cracks.
(2) Clean cylinder head and oil passages.
(3) Check cylinder head for flatness (Fig. 19).
(4) Cylinder head must be flat within:
²Standard dimension = less than 0.05 mm (0.002
inch.)
²Service Limit = 0.2 mm (0.008 inch.)
²Grinding Limit = Maximum of 0.2 mm (0.008
inch.) is permitted.
CAUTION: 0.20 mm (0.008 in.) MAX is a combined
total dimension of the stock removal limit from cyl-
inder head and block top surface (Deck) together.
INSTALLATION - CYLINDER HEAD
(1) Clean all sealing surfaces of engine block and
cylinder heads. (Refer to 9 - ENGINE - STANDARD
PROCEDURE)
(2) Position new gasket(s) on engine block (Fig.
20). The left bank gasket is identified with the ªLº
stamped in the exposed area of the gasket located at
front of engine (shown in (Fig. 20)). The right bank
gasket is identified with a ªRº stamped in the
exposed area of the gasket also, but is located at the
rear of the engine.
(3)The cylinder head bolts are torqued using
the torque yield method, they should be exam-
ined BEFORE reuse. If the threads are necked
down, the bolts must be replaced(Fig. 21).
Fig. 18 DIPSTICK & TUBE
1 - DIPSTICK
2 - BOLT
3 - TUBE
Fig. 19 Checking Cylinder Head FlatnessÐTypical
Fig. 20 Head Gasket Installation
1 - CYLINDER HEAD GASKET
2 - LOCATION IDENTIFICATION (L = LEFT BANK, R = RIGHT
BANK)
9 - 104 ENGINE 3.3/3.8LRS
CYLINDER HEAD (Continued)

(4) 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.
(5) Tighten the cylinder head bolts 1±8 in the
sequence shown in (Fig. 22). Using the 4 step torque
turn method, tighten according to the following val-
ues:
²Step 1: Bolts1±8to61N´m(45ft.lbs.)
²Step 2: Bolts1±8to88N´m(65ft.lbs.)
²Step 3: Bolts1±8(again) to 88 N´m (65 ft. lbs.)
²Step 4: Bolts1±8turn an additional 1/4 Turn.
(Do not use a torque wrench for this step.)
NOTE: Bolt torque after 1/4 turn should be over 122
N´m (90 ft. lbs.). If not, replace the bolt.
(6) Inspect push rods and replace worn or bent
rods.
(7) Install the push rods.
(8) Install the rocker arm and shaft assemblies.
(Refer to 9 - ENGINE/CYLINDER HEAD/ROCKER
ARMS - INSTALLATION)
(9) Install the cylinder head covers. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION)
(10) Install the exhaust manifolds. (Refer to 9 -
ENGINE/MANIFOLDS/EXHAUST MANIFOLD -
INSTALLATION)(11) Install new O-ring on dipstick tube. Install
dipstick tube assembly (Fig. 18).
(12) Install the spark plugs.
(13) Install upper and lower intake manifolds.
(Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANI-
FOLD - INSTALLATION)
(14) Fill the cooling system. (Refer to 7 - COOL-
ING - STANDARD PROCEDURE)
(15) Connect negative cable to battery.
CYLINDER HEAD COVER(S)
DESCRIPTION
The cylinder head covers are made of stamped
steel. The covers are sealed with steel reinforced sil-
icon rubber gaskets. The cylinder head cover uses
rubber isolators at each fastener location (Fig. 23).
NOTE: Due to the tight packaging near the cylinder
head covers, which makes spill clean-up difficult, a
spill during an engine oil change may be misinter-
preted as an oil leak. When investigating an oil leak
in the location of the cylinder head covers and
intake manifold, follow the procedure found in Oil
Leak Diagnosis (Refer to 9 - ENGINE - DIAGNOSIS
AND TESTING) for determining the source of a leak.Fig. 21 Checking Bolts for Stretching (Necking)
1 - STRETCHED BOLT
2 - THREADS ARE NOT STRAIGHT ON LINE
3 - THREADS ARE STRAIGHT ON LINE
4 - UNSTRETCHED BOLT
Fig. 22 CYLINDER HEAD TIGHTENING SEQUENCE
Fig. 23 Cylinder Head Cover
1 - CYLINDER HEAD COVER
2 - BOLT
RSENGINE 3.3/3.8L9 - 105
CYLINDER HEAD (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)

valve stem as guide.Do Not Forceseal against top
of guide. When installing the valve retainer locks,
compress the springonly enoughto install the locks
(Fig. 39).
CAUTION: Do not pinch seal between retainer and
top of valve guide.
(2) Follow the same procedure on the remaining 5
cylinders using the firing sequence 1-2-3-4-5-6.Make
sure piston in cylinder is at TDC on the valve
spring that is being covered.
(3) Remove spark plug adapter tool.
(4) Install rocker arms and shaft assembly. (Refer
to 9 - ENGINE/CYLINDER HEAD/ROCKER ARMS -
INSTALLATION)
(5) Install cylinder head covers. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION)
(6) Install spark plugs and connect wires.
(7) Connect negative cable to battery.
ROCKER ARMS
DESCRIPTION
DESCRIPTION - ROCKER ARMS
The rocker arms are installed on the rocker arm
shaft. The rocker arms and shaft assembly is
attached to the cylinder head with seven billeted
bolts and retainers. The rocker arms are made of
stamped steel.
DESCRIPTION - PUSHRODS
The pushrods are made of steel and are a hollow
design. The pushrods are positioned between the
hydraulic lifter and the rocker arm.
OPERATION
OPERATION - ROCKER ARMS
The rocker arm pivots on the rocker shaft. Rocker
arms are used to translate up and down motions pro-
vided by the camshaft, hydraulic lifter, and pushrod
on one end, into a down and up motions on the valve
stem on the opposing end.
OPERATION - PUSHRODS
The pushrod is a solid link between the hydraulic
lifter and the rocker arm. Also, the pushrod supplies
engine oil from the hydraulic lifter to the rocker arm.
REMOVAL - ROCKER ARMS AND SHAFT
(1) Remove the cylinder head cover(s). (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL)
NOTE: Rocker arm shaft bolts are captured to the
shaft.
(2) Loosen the rocker shaft bolts (Fig. 40), rotating
one turn each, until all valve spring pressure is
relieved.
(3) Remove the rocker arms and shaft assembly
(Fig. 40).
(4) For rocker arm disassembly procedures, (Refer
to 9 - ENGINE/CYLINDER HEAD/ROCKER ARMS -
DISASSEMBLY).
Fig. 39 VALVE SPRING INSTALLED
1 - VALVE SPRING RETAINER
2 - VALVE INSTALLED HEIGHT
3 - CYLINDER HEAD SURFACE
4 - VALVE SPRING SEAT SURFACE
5 - VALVE SPRING INSTALLED HEIGHT
Fig. 40 ROCKER ARMS AND SHAFT
1 - ROCKER ARMS AND SHAFT ASSEMBLY
2 - ROCKER SHAFT BOLTS
9 - 112 ENGINE 3.3/3.8LRS
VALVE SPRINGS (Continued)

(3) Slowly tighten rocker shaft bolts evenly until
shaft is seated. Tighten bolts to 23 N´m (200 in. lbs.)
(Fig. 43).
(4) Install the cylinder head cover(s). (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION)VALVE STEM SEALS
DESCRIPTION
The valve stem seals are made of Viton rubber. The
seals are positioned over the valve stem and seated
on the valve guide (Fig. 44).
Fig. 42 ROCKER ARMS AND SHAFT
1 - BOLT (ROCKER SHAFT OIL FEED - LONGER LENGTH) 5 - ROCKER ARM - EXHAUST
2 - SHAFT RETAINER/SPACER - 21.5 mm (0.84 in.) 6 - WASHER
3 -SHAFT RETAINER/SPACER - 37.5 mm (1.47 in.) 7 - ROCKER ARM - INTAKE (LARGER OFFSET)
4 - SHAFT RETAINER/SPACER - 40.9 mm (1.61 in.) 8 - ROCKER ARMS LUBRICATION FEED HOLE (POSITION
UPWARD & TOWARD VALVE SPRING)
Fig. 43 ROCKER ARMS AND SHAFT
1 - ROCKER ARMS AND SHAFT ASSEMBLY
2 - ROCKER SHAFT BOLTS
Fig. 44 Valve Stem Seal
9 - 114 ENGINE 3.3/3.8LRS
ROCKER ARMS (Continued)

REMOVAL
(1) Remove the valve springs. (Refer to 9 -
ENGINE/CYLINDER HEAD/VALVE SPRINGS -
REMOVAL)
(2) Remove the valve stem seal (Fig. 44).
INSTALLATION
(1) Install the valve stem seal squarely over the
valve guide, using the valve stem as a guide (Fig.
44). Do not force the seal against top of the valve
guide.
(2) Install the valve spring. (Refer to 9 - ENGINE/
CYLINDER HEAD/VALVE SPRINGS - INSTALLA-
TION)
ENGINE BLOCK
DESCRIPTION
The cylinder block is made of cast iron and is a
deep skirt design.
STANDARD PROCEDURE - CYLINDER BORE
HONING
(1) Used carefully, the cylinder bore resizing hone,
recommended tool C-823 or equivalent, equipped
with 220 grit stones, is the best tool for this honing
procedure. In addition to deglazing, it will reduce
taper and out-of-round as well as removing light
scuffing, scoring or scratches. Usually a few strokes
will clean up a bore and maintain the required lim-
its.
(2) Deglazing of the cylinder walls may be done
using a cylinder surfacing hone, recommended tool
C-3501 or equivalent, equipped with 280 grit stones,
if the cylinder bore is straight and round. 20±60
strokes depending on the bore condition, will be suf-
ficient to provide a satisfactory surface. Use a light
honing oil.Do not use engine or transmission oil,
mineral spirits or kerosene.Inspect cylinder walls
after each 20 strokes.
(3) Honing should be done by moving the hone up
and down fast enough to get a cross-hatch pattern.
When hone marksintersectat 40-60 degrees, the
cross hatch angle is most satisfactory for proper seat-
ing of rings (Fig. 45).
(4) A controlled hone motor speed between
200±300 RPM is necessary to obtain the proper cross-
hatch angle. The number of up and down strokes per
minute can be regulated to get the desired 40±60
degree angle. Faster up and down strokes increase
the cross-hatch angle.
(5) After honing, it is necessary that the block be
cleaned again to remove all traces of abrasive.CAUTION: Ensure all abrasives are removed from
engine parts after honing. It is recommended that a
solution of soap and hot water be used with a
brush and the parts then thoroughly dried. The bore
can be considered clean when it can be wiped
clean with a white cloth and cloth remains clean.
Oil the bores after cleaning to prevent rusting.
CLEANING
Clean cylinder block thoroughly using a suitable
cleaning solvent.
INSPECTION
ENGINE BLOCK
(1) Clean cylinder block thoroughly and check all
core hole plugs for evidence of leaking.
(2) If new core plugs are to be installed, (Refer to 9
- ENGINE - STANDARD PROCEDURE - ENGINE
CORE AND OIL GALLERY PLUGS).
(3) Examine block and cylinder bores for cracks or
fractures.
(4) Check block deck surfaces for flatness. Deck
surface must be within service limit of 0.1 mm (0.004
in.).
CYLINDER BORE
NOTE: The cylinder bores should be measured at
normal room temperature, 21ÉC (70ÉF).
The cylinder walls should be checked for out-of-
round and taper with Tool C119 or equivalent (Fig.
Fig. 45 Cylinder Bore Cross-Hatch Pattern
1 - CROSS-HATCH PATTERN
2 - 40ɱ60É
RSENGINE 3.3/3.8L9 - 115
VALVE STEM SEALS (Continued)