drain bolt CHRYSLER CARAVAN 2005 User Guide

ENGINE COOLANT
THERMOSTAT - 2.4L
REMOVAL
(1) Drain cooling system below the thermostat
level. (Refer to 7 - COOLING - STANDARD PROCE-
DURE)
(2) Remove radiator upper hose from the coolant
outlet housing (Fig. 7).
(3) Remove coolant outlet housing bolts and hous-
ing (Fig. 8).
(4) Remove thermostat. Discard gasket and clean
both gasket sealing surfaces.
INSTALLATION
(1) Place a new gasket (dipped in clean water) on
the coolant outlet connector surface. Position thermo-
stat with air bleed at the 12 o'clock position in ther-
mostat housing (Fig. 8).
(2) Position the coolant outlet connector and gas-
ket over the thermostat, making sure thermostat is
seated in the thermostat housing.
(3) Position outlet connector to thermostat housing
and install bolts (Fig. 8). Tighten bolts to 28 N´m
(250 in. lbs.).
(4) Install the radiator upper hose to coolant outlet
housing (Fig. 7).
(5) Refill the cooling system. (Refer to 7 - COOL-
ING - STANDARD PROCEDURE)
ENGINE COOLANT
THERMOSTAT - 3.3/3.8L
REMOVAL
(1) Drain cooling system down below the thermo-
stat level. (Refer to 7 - COOLING - STANDARD
PROCEDURE)
(2) Remove radiator upper hose from coolant outlet
connector (Fig. 9).
Fig. 7 RADIATOR HOSES TO ENGINE - 2.4L
1 - UPPER HOSE
2 - LOWER HOSE
Fig. 8 Thermostat and Outlet Connector - 2.4L
Engine
1 - THERMOSTAT
2 - GASKET
3 - COOLANT OUTLET CONNECTOR
4 - BOLT
Fig. 9 RADIATOR HOSES TO ENGINE - 3.3/3.8L
1 - UPPER HOSE
2 - LOWER HOSE
7 - 24 ENGINERS

WATER PUMP - 2.4L
DESCRIPTION
The water pump has a cast aluminum body and
housing with a stamped steel impeller. The water
pump bolts directly to the block (Fig. 22). The cylin-
der block to water pump seal is provided by a rubber
O-ring. The water pump is driven by the engine tim-
ing belt.
REMOVAL
(1) Disconnect negative cable from battery.
(2) Raise vehicle on a hoist.
(3) Remove the right inner splash shield.
(4) Remove the accessory drive belts (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(5) Drain the cooling system (Refer to 7 - COOL-
ING - STANDARD PROCEDURE).
(6) Support engine from the bottom and remove
right engine mount. (Refer to 9 - ENGINE/ENGINE
MOUNTING/RIGHT MOUNT - REMOVAL).(7) Remove right engine mount bracket (Fig. 23).
(8) Remove the timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKET(S)
- REMOVAL).
(9) Remove timing belt idler pulley.
(10) Hold camshaft sprocket with Special tool
C-4687 and adaptor C-4687-1 while removing bolt.
Remove both cam sprockets.
(11) Remove the timing belt rear cover (Refer to 9
- ENGINE/VALVE TIMING/TIMING BELT COV-
ER(S) - REMOVAL).
(12) Remove the generator and bracket (Fig. 23).
(13) Remove water pump to engine attaching
screws (Fig. 24).
CLEANING
Clean gasket mating surfaces as necessary.
INSPECTION
Replace water pump body assembly if it has any of
these defects:
(1) Cracks or damage on the body.
(2) Coolant leaks from the shaft seal, evident by
wet coolant traces on the pump body.
(3) Loose or rough turning bearing.
(4) Impeller rubs either the pump body or the
engine block.
(5) Impeller loose or damaged.
(6) Sprocket or sprocket flange loose or damaged.
INSTALLATION
(1) Install new O-ring gasket in water pump body
O-ring locating groove (Fig. 25).
CAUTION: Make sure O-ring is properly seated in
water pump groove before tightening screws. An
improperly located O-ring may be damaged and
cause a coolant leak.
(2) Assemble pump body to block and tighten
screws to 12 N´m (105 in. lbs.) (Fig. 24). Pressurize
cooling system to 103.4 Kpa (15 psi) with pressure
tester and check water pump shaft seal and O-ring
for leaks.
(3) Rotate pump by hand to check for freedom of
movement.
(4) Install the timing belt rear cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT COVER(S)
- INSTALLATION).
(5) Install camshaft sprockets and torque bolts to
101 N´m (75 ft. lbs.) while holding camshaft sprocket
with Special tool C-4687 and adaptor C-4687-1.
Fig. 22 Water Pump
1 - CYLINDER BLOCK
2 - WATER PUMP
7 - 32 ENGINERS

WATER PUMP - 3.3/3.8L
DESCRIPTION
The water pump has a die-cast aluminum body
and a plastic impeller. It bolts directly to the timing
chain case cover, using a rubber seal for sealing (Fig.
26). It is driven by the accessory drive belt.
REMOVAL
(1) Drain the cooling system. (Refer to 7 - COOL-
ING - STANDARD PROCEDURE)
(2) Remove the accessory drive belt shield.
(3) Remove the accessory drive belt. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)
(4) Remove water pump pulley bolts (Fig. 26).
NOTE: To remove the water pump pulley, it MUST
first be positioned between water pump housing
and drive hub. The pulley can then be removed with
the water pump assembly.
(5) Rotate pulley until openings in pulley align
with water pump drive hub spokes (Fig. 27). Move
pulley inward between pump housing and hub (Fig.
27).
(6) Position pulley to allow access to water pump
mounting bolts. Remove water pump mounting bolts
(Fig. 28).
(7) Remove water pump with the pulley loosely
positioned between hub and the pump body.
Fig. 24 Water Pump - 2.4L
1 - CYLINDER BLOCK
2 - WATER PUMP
Fig. 25 Water Pump Body
1 - IMPELLER
2 - WATER PUMP BODY
3 - O-RING LOCATING GROOVE
Fig. 26 Water Pump - 3.3/3.8L Engine
1 - WATER PUMP
2 - PULLEY - WATER PUMP
3 - BOLT - PULLEY
4 - BOLT - WATER PUMP
5 - SEAL - WATER PUMP
7 - 34 ENGINERS
WATER PUMP - 2.4L (Continued)

(7) Install drive belt shield.
(8) Fill the cooling system. (Refer to 7 - COOLING
- STANDARD PROCEDURE)
WATER PUMP INLET TUBE -
2.4L
DESCRIPTION
The 2.4L engine uses a metal tube to connect the
engine block to the lower radiator hose and heater
return (Fig. 31). The tube has an O-ring for block to
tube sealing and bolts attach the tube to the engine
block.
REMOVAL
(1) Drain the cooling system. (Refer to 7 - COOL-
ING - STANDARD PROCEDURE)
(2) Remove radiator upper hose to access the hose
connections at the inlet tube.
(3) Remove radiator lower (Fig. 7) and heater
hoses from the inlet tube (Fig. 32).
(4) Remove the two fasteners that hold the inlet
tube to the block.
(5) Rotate tube while removing the tube from the
engine block.
INSTALLATION
(1) Inspect the O-ring for damage before installing
the tube into the cylinder block (Fig. 31).
(2) Lube O-ring with coolant and install inlet tube
into the cylinder block opening (Fig. 31).(3) Install the two inlet tube fasteners and tighten
to 12 N´m (105 in. lbs.).
(4) Connect the radiator lower hose (Fig. 7) and
heater hose to inlet tube (Fig. 32).
(5) Install the radiator upper hose.
(6) Fill the cooling system. (Refer to 7 - COOLING
- STANDARD PROCEDURE)
Fig. 30 Water Pump Seal
1 - WATER PUMP HOUSING
2 - SEAL
3 - IMPELLER
Fig. 31 Water Pump Inlet Tube - 2.4L Engine
1 - O-RING
2 - WATER PUMP INLET TUBE
Fig. 32 Water Pump Inlet Tube Hose Connections
1 - WATER PUMP INLET TUBE
2 - HOSE - HEATER RETURN
3 - COOLANT INLET
7 - 36 ENGINERS
WATER PUMP - 3.3/3.8L (Continued)

WATER PUMP INLET TUBE -
3.3/3.8L
REMOVAL
(1) Drain the cooling system. (Refer to 7 - COOL-
ING - STANDARD PROCEDURE)
(2) Raise vehicle on hoist and remove the belt
splash shield.
(3) Remove the radiator lower hose from inlet tube
(Fig. 33).
(4) Remove the oil cooler outlet/heater return hose
from inlet tube (only if equipped with engine oil
cooler) (Fig. 34).
(5) Remove the inlet tube bolts (Fig. 35).
(6) Remove the inlet tube (Fig. 35). Discard the
O-ring seal.
INSTALLATION
(1) Clean the inlet tube O-ring sealing surfaces on
the timing cover housing and tube.
(2) Apply MopartDielectric Grease or equivalent
to the O-ring before installation.
(3) Position new O-ring seal on inlet tube (Fig. 35).
(4) Install the inlet tube (Fig. 35). Tighten bolts to
28 N´m (250 in. lbs.).
(5) Connect radiator lower hose (Fig. 33) and
heater return hose (if equipped with engine oil
cooler) (Fig. 34) to the inlet tube.(6) Install the drive belt splash shield and lower
vehicle.
(7) Fill the cooling system. (Refer to 7 - COOLING
- STANDARD PROCEDURE)
Fig. 33 RAD HOSES TO ENGINE - 3.3/3.8L
1 - UPPER HOSE
2 - LOWER HOSE
Fig. 34 Engine Oil Cooler Hoses (Engine Oil Cooler
Equipped)
1 - OIL COOLER INLET TUBE
2 - INLET HOSE
3 - OIL COOLER OUTLET TUBE
4 - OUTLET HOSE
5 - WATER PUMP INLET TUBE
Fig. 35 WATER PUMP INLET TUBE
1 - TIMING CHAIN COVER
2 - INLET TUBE
3 - BOLT
4 - BOLT
5 - O-RING
RSENGINE7-37

REMOVAL
The battery cables on this vehicle may include por-
tions of wiring circuits for the generator and other
components on the vehicle. If battery cable replace-
ment is required, it will be necessary to extract the
cables out of the engine wire harness assembly. Use
care not to damage the other wires and circuits
which are also packaged into the engine wire harness
assembly.
(1) Turn the ignition switch to the Off position. Be
certain that all electrical accessories are turned off.
(2) Disconnect and isolate the battery negative
cable.
(3) Remove the battery thermowrap (if equipped)
from the battery tray.
(4) Remove the tape from the engine wire harness
assembly, to access the desired battery cable.
(5) One at a time, trace and disconnect the battery
cable retaining fasteners and routing clips until the
desired cable is free from the vehicle.
(6) Feed the battery cable out of the vehicle.
INSTALLATION
(1) Position the battery cable in the vehicle.
(2) One at a time, trace and install the battery
cable retaining fasteners and routing clips until the
desired cable is properly installed in the engine wire
harness assembly.
(3) Install the tape on the engine wire harness
assembly.
(4) Install the battery thermowrap (if equipped) on
the battery tray.
(5) Connect the battery negative cable.
BATTERY TRAY
DESCRIPTION
The battery is mounted in a molded plastic battery
tray and support unit located in the left front corner
of the engine compartment. The battery tray and
support unit is secured with two nuts, one is located
directly under the battery and the other is located on
the right side of the tray which also serves as a cool-
ant bottle neck retaining bolt. An additional bolt is
located directly under the battery.
The battery tray and support unit also includes a
engine vacuum reservoir, located in the rear of the
unit (Fig. 17). And a drainage hose, located in the
front of the unit (Fig. 17).
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Disconnect and isolate the battery positive
cable.(3) Remove the battery from the vehicle. (Refer to
8 - ELECTRICAL/BATTERY SYSTEM/BATTERY -
REMOVAL).
(4) Remove the battery tray retaining fasteners
(Fig. 18).
Fig. 17 RS BATTERY TRAY
1 - ENGINE VACUUM RESERVOIR
2 - BATTERY TRAY ASSEMBLY
3 - DRAINAGE HOSE
Fig. 18 BATTERY TRAY POSITION & ORIENTATION
1 - BATTERY TRAY RETAINING FASTENERS
RSBATTERY SYSTEM8F-19
BATTERY CABLES (Continued)

(7) Disconnect the wire connectors from back of
the wiper motor.
INSTALLATION
(1) Connect the wire harness connector.
(2) Install the linkage on the wiper unit.
(3) Install the nut holding the linkage to the wiper
unit.
(4) Install the cowl cover brackets to the wiper
nut.
(5) Install the front wiper unit (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
INSTALLATION).
(6) Install the cowl cover.
(7) Install the wiper arms and blades.
WIPER MODULE
REMOVAL
(1) Release the hood latch and open hood.
(2) Disconnect and isolate the battery negative
cable.
(3) Remove the wiper arms.
(4) Remove the cowl cover (Refer to 23 - BODY/
EXTERIOR/COWL GRILLE - REMOVAL).
(5) Disconnect the positive lock on the wiper mod-
ule wire connector (Fig. 7).
(6) Disconnect the wiper module wire connector
from the engine compartment wire harness.
(7) Disconnect the windshield washer hose from
coupling outside the module.
(8) Disconnect the drain tubes from nipples on bot-
tom of the wiper module.(9) Remove nuts holding wiper module to lower
windshield fence.
(10) Remove bolts holding the wiper module to the
dash panel (Fig. 8).
(11) Lift wiper module from weld-studs on lower
windshield fence.
CAUTION: Do not allow wiper module to rest on
brake master cylinder reservoir, damage to brake
system can result.
(12) Remove wiper module.
INSTALLATION
(1) Position the wiper module into the cowl.
(2) Install the bolts that secure the wiper module
to the dash (Fig. 8).
(3) Install the nuts that retain the wiper module.
(4) Connect the drain tubes to the nipples on the
wiper module.
(5) Connect the windshield washer tube.
(6) Connect the wire harness connector to the
wiper module (Fig. 8).
(7) Connect the positive lock on the wiper module
wire connector (Fig. 7).
CAUTION: Do not allow wiper module to rest on
brake master cylinder reservoir, damage to brake
system can result.
(8) Install the cowl cover (Refer to 23 - BODY/EX-
TERIOR/COWL GRILLE - INSTALLATION).
(9) Install the wiper arms and blades.
(10) Connect the battery negative cable.
(11) Close the hood.
Fig. 7 WIPER MODULE WIRE CONNECTOR
1 - WIPER SYSTEM WIRE CONNECTOR
2 - LOCK TAB
3 - POSITIVE LOCK
4 - WIPER MODULE
Fig. 8 WIPER MODULE
1 - BOLT
2 - NUTS
3 - BOLT
4 - WIPER MODULE
5 - WINDSHIELD
8R - 14 WIPERS/WASHERSRS
WIPER LINKAGE (Continued)

²Drill motor with 3M RolocŸ Bristle Disc (white
or yellow) (Fig. 3)
CAUTION: Excessive pressure or high RPM (beyond
the recommended speed), can damage the sealing
surfaces. The mild (white, 120 grit) bristle disc is
recommended. If necessary, the medium (yellow, 80
grit) bristle disc may be used on cast iron surfaces
with care.
STANDARD PROCEDURE - MEASURING
BEARING CLEARANCE USING PLASTIGAGE
Engine crankshaft bearing clearances can be deter-
mined by use of Plastigage or equivalent. The follow-
ing is the recommended procedure for the use of
Plastigage:
(1) Remove oil film from surface to be checked.
Plastigage is soluble in oil.
(2) Place a piece of Plastigage across the entire
width of the bearing shell in the cap approximately
6.35 mm (1/4 in.) off center and away from the oil
holes (Fig. 4). (In addition, suspected areas can be
checked by placing the Plastigage in the suspected
area). Torque the bearing cap/bed plate bolts of the
bearing being checked to the proper specifications.
(3) Remove the bearing cap and compare the
width of the flattened Plastigage with the metric
scale provided on the package. Locate the band clos-
est to the same width. This band shows the amount
of clearance in thousandths of a millimeter. Differ-
ences in readings between the ends indicate the
amount of taper present. Record all readings taken.
Compare the clearance measurements to specsifica-
tions found in the engine specifications table(Refer to9 - ENGINE - SPECIFICATIONS).Plastigage gen-
erally is accompanied by two scales. One scale
is in inches, the other is a metric scale.
NOTE: Plastigage is available in a variety of clear-
ance ranges. Use the most appropriate range for
the specifications you are checking.
(4) Install the proper crankshaft bearings to
achieve the specified bearing clearances.
REMOVAL - ENGINE ASSEMBLY
(1) Perform fuel pressure release procedure (Refer
to 14 - FUEL SYSTEM/FUEL DELIVERY - STAN-
DARD PROCEDURE)
(2) Disconnect battery negative cable.
(3) Remove air cleaner housing and inlet tube.
(4) Disconnect the fuel line from fuel rail. (Refer to
14 - FUEL SYSTEM/FUEL DELIVERY/FUEL LINES
- STANDARD PROCEDURE)
(5) Disconnect all vacuum hoses.
(6) Drain cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(7) Remove radiator fans. (Refer to 7 - COOLING/
ENGINE/RADIATOR FAN - REMOVAL)
(8) Remove radiator upper and lower hoses.
NOTE: When the transaxle cooler lines are removed
from the rolled-groove type fittings at the transaxle,
damage to the inner wall of the hose will occur. To
prevent prevent potential leakage, the cooler hoses
must be cut off flush at the transaxle fitting, and a
service cooler hose splice kit must be installed
upon reassembly.
Fig. 3 Proper Tool Usage For Surface Preparation
1 - ABRASIVE PAD
2 - 3M ROLOCŸ BRISTLE DISC
3 - PLASTIC/WOOD SCRAPER
Fig. 4 Plastigage Placed in Lower ShellÐTypical
1 - PLASTIGAGE
9 - 12 ENGINE 2.4LRS
ENGINE 2.4L (Continued)

(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)

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)