body CHRYSLER CARAVAN 2005 Service Manual

(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)

CRANKSHAFT
DESCRIPTION SPECIFICATION
Metric Standard
Connecting Rod
Journal
Diameter49.984 - 50.000
mm1.968 - 1.9685
in.
Main Bearing
Journal
Diameter59.992 - 60.008
mm2.362 - 2.3625
in.
Journal
Out-of-Round
(Max.)0.0035 mm 0.0003 in.
Journal Taper
(Max.)0.007 mm 0.0001 in.
End Play 0.09 - 0.24 mm 0.0035 - 0.0094
in.
Wear Limit 0.38 mm 0.015 in.
Main Bearing
Diametrical
Clearance0.018 - 0.062
mm0.0007 - 0.0024
in.
HYDRAULIC LASH ADJUSTER
DESCRIPTION SPECIFICATION
Metric Standard
Body Diameter 15.901 - 15.913
mm0.626 - 0.6264
in.
Plunger Travel
Minimum (Dry)3.0 mm 0.118 in.
CYLINDER HEAD CAMSHAFT BEARING BORE
DIAMETER
DSECRIPTION SPECIFICATION
Metric Standard
Journals No.1 -
626.020 - 26.041
mm1.024 - 1.025 in.
CAMSHAFT
DESCRIPTION SPECIFICATION
Metric Standard
Journal
Diameter No. 1
-625.951 - 25.970
mm1.021 - 1.022 in.
Bearing
Clearance -
Diametrical0.069 - 0.071
mm0.0027 - 0.003
in.
End Play 0.05 - 0.17 mm 0.0019 - 0.0066
in.
Lift (Zero Lash)
Intake 8.25 mm 0.324 in.
Exhaust 6.60 mm 0.259 in.
Intake Valve
Timing*
Closes (ABDC) 51É
Opens (BTDC) 1É
Duration 232É
Exhaust Valve
Timing*
Closes (ATDC) 7É
Opens (BBDC) 47É
Duration 234É
Valve Overlap 8É
*
All reading in degrees. Timing points @4É from top of
ramp.
CYLINDER HEAD
DESCRIPTION SPECIFICATION
Metric Standard
Material Cast Aluminum
Gasket
Thickness
(Compressed)0.71 mm 0.028 in.
9 - 18 ENGINE 2.4LRS
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

INSTALLATION
(1) Install rear mount bracket, if removed (Fig.
84).
(2) Install the rear mount and bolts (Fig. 83).
Tighten bolts to 54 N´m (40 ft. lbs.).
(3) Install the mount through bolt to the mount
and bracket (Fig. 83). Tighten through bolt to 54 N´m
(40 ft. lbs.).
(4) Install the rear mount heat shield (Fig. 82).
(5) Lower vehicle on hoist.
RIGHT MOUNT
REMOVAL
(1) Remove air cleaner housing lid and clean air
hose from throttle body.
(2) Remove air cleaner element and housing.
(3) Disconnect make-up air hose from cylinder
head cover.
(4) Remove the load on the right engine mount by
carefully supporting the engine assembly with a floor
jack.
(5) Disconnect electrical harness support clips from
engine mount bracket.(6) Remove the vertical bolts attaching the engine
mount to the frame rail (Fig. 85).
(7) Loosen the horizontal bolt attaching the engine
mount to the frame rail (Fig. 85).
(8) Remove the bolts attaching the engine mount
to the engine bracket (Fig. 85).
(9) Remove the right engine mount (Fig. 85).
INSTALLATION
(1) Position right engine mount and install frame
rail to mount vertical bolts (Fig. 85).
(2) Tighten engine right mount to rail horizontal
bolt (Fig. 85).
(3) Install mount to engine bracket bolts (Fig. 85).
(4) Connect electrical harness support clips to
engine mount bracket.
(5) Remove jack from under engine.
(6) Connect make-up air hose to cylinder head
cover.
(7) Install air cleaner housing and element.
(8) Install air cleaner housing lid and clean air
tube to throttle body.
Fig. 84 Rear Mount Bracket - (all engines)
1 - BOLT - VERTICAL 102 N´m (75 ft. lbs.)
2 - BRACKET - REAR MOUNT3 - BOLT - HORIZONTAL 102 N´m (75 ft. lbs.)
9 - 52 ENGINE 2.4LRS
REAR MOUNT (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)

INSTALLATION
(1) Make sure all surfaces are clean and free of oil
and dirt.
(2) Apply MopartGasket Maker to oil pump as
shown in (Fig. 102). Install O-ring into oil pump body
discharge passage.
(3) Prime oil pump with engine oil before installa-
tion.
(4) Align oil pump rotor flats with flats on crank-
shaft. Install the oil pump to the block (Fig. 96).
CAUTION: To align, the front crankshaft seal MUST
be out of pump, or damage may result.
(5) Install new front crankshaft seal using Special
Tool 6780 (Fig. 103).
(6) Install crankshaft key (Fig. 95).
CAUTION: The crankshaft sprocket is set to a pre-
determined depth from the factory for correct tim-
ing belt tracking. If removed, use of Special Tool
6792 is required to set the sprocket to original
installation depth. An incorrectly installed sprocket
will result in timing belt and engine damage.
(7) Install crankshaft sprocket using Special Tool
6792 (Fig. 104).
(8) Install oil pump pick-up tube.
(9) Install oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION).
(10) Install timing belt rear cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT COVER(S)
- INSTALLATION).
(11) Install timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
INSTALLATION).
Fig. 102 Oil Pump Sealing
1 - O-RING
2 - SEALER LOCATION
Fig. 103 Front Crankshaft Seal - Installation
1 - PROTECTOR
2 - SEAL
3 - SPECIAL TOOL 6780
Fig. 104 Crankshaft Sprocket - Installation
1 - SPECIAL TOOL 6792
2 - TIGHTEN NUT TO INSTALL
RSENGINE 2.4L9-59
OIL PUMP (Continued)

INTAKE MANIFOLD
DESCRIPTION
The intake manifold is a two piece aluminum cast-
ing (Fig. 105) that attaches to the cylinder head with
fasteners. The manifold is a long branch design to
enhance low and mid-range torque
DIAGNOSIS AND TESTING - INTAKE
MANIFOLD LEAKS
An intake manifold air leak is characterized by
lower than normal manifold vacuum. Also, one or
more cylinders may not be functioning.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
(1) Start the engine.
(2) Spray a small stream of water (Spray Bottle) at
the suspected leak area.
(3) If engine RPM'S change, the area of the sus-
pected leak has been found.
(4) Repair as required.
INTAKE MANIFOLD - UPPER
REMOVAL
(1) Disconnect negative cable from battery.(2) Disconnect connector from inlet air tempera-
ture sensor (Fig. 106).
(3) Disconnect air intake tube at throttle body and
remove upper air cleaner housing.
(4) Disconnect connector from throttle position
sensor (TPS) (Fig. 108).
(5) Disconnect connector from idle air control (IAC)
motor (Fig. 108).
(6) Disconnect connector from MAP sensor (Fig.
107).
(7) Remove vacuum lines for purge solenoid and
PCV valve at intake manifold.
(8) Remove vacuum lines for power brake booster,
LDP, EGR transducer, and speed control vacuum res-
ervoir (if equipped) at upper intake manifold fittings.
Fig. 105 Intake Manifold - Upper and Lower
1 - UPPER INTAKE MANIFOLD
2 - LOWER INTAKE MANIFOLD
Fig. 106 Inlet Air Temperature Sensor - 2.4L
Fig. 107 Map Sensor - 2.4L
1 - MAP SENSOR
9 - 60 ENGINE 2.4LRS

(9) Disconnect throttle and speed control (if
equipped) cables from throttle lever and bracket.
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
THROTTLE CONTROL CABLE - REMOVAL)
(10) Remove the EGR tube. (Refer to 25 - EMIS-
SIONS CONTROL/EXHAUST GAS RECIRCULA-
TION/TUBE - REMOVAL)
(11) Remove the upper manifold support bracket
bolt to manifold (Fig. 109).
(12) Remove engine oil dipstick from tube.
(13) Remove upper intake manifold bolts (Fig.
110). Remove upper intake manifold.
CAUTION: Cover intake manifold to prevent foreign
material from entering engine.
INSPECTION
(1) Check manifold surfaces for flatness with
straight edge. Surface must be flat within 0.15 mm
per 300 mm (0.006 in. per foot) of manifold length.
(2) Inspect manifold for cracks or distortion.
Replace manifold if necessary.
INSTALLATION
(1) Clean manifold sealing surfaces.
(2) Apply a 1.5 mm (0.060 in.) bead MopartGas-
ket Maker to the perimeter of the lower intake man-
ifold runner openings.
(3) Install upper intake manifold and tighten fas-
teners to 28 N´m (250 in. lbs.) in sequence shown in
(Fig. 110). Repeat this procedures until all fasteners
are at specified torque.
(4) Install engine oil dipstick.
(5) Install upper bolt in intake manifold to front
support bracket (Fig. 109). Torque to 28 N´m (250 in.
lbs.).
(6) Install EGR tube. (Refer to 25 - EMISSIONS
CONTROL/EXHAUST GAS RECIRCULATION/
TUBE - INSTALLATION)
(7) Install throttle cables in bracket.
(8) Connect throttle and speed control (if equipped)
cables to throttle lever.
(9) Connect vacuum lines for power brake booster,
LDP, EGR transducer, and speed control vacuum res-
ervoir (if equipped) at upper intake manifold fittings.
(10) Connect vacuum lines for purge solenoid and
PCV valve.
(11) Connect electrical connectors for MAP sensor,
throttle position sensor (TPS), and idle air control
(IAC) motor.
(12) Install air cleaner upper housing and air
intake tube to throttle body.
(13) Connect inlet air temperature sensor connec-
tor (Fig. 106).
(14) Connect negative cable to battery.
Fig. 108 Throttle Body Electrical Connectors -
Typical
1 - IDLE AIR CONTROL MOTOR CONNECTOR
2 - TPS CONNECTOR
Fig. 109 Upper Intake Manifold Support Bracket
1 - NUT - BRACKET TO CYLINDER HEAD COVER
2 - BOLT - BRACKET TO UPPER INTAKE MANIFOLD
3 - UPPER INTAKE MANIFOLD SUPPORT BRACKET
Fig. 110 Upper Intake Manifold Tightening Sequence
- 2.4L
RSENGINE 2.4L9-61
INTAKE MANIFOLD - UPPER (Continued)