INTRODUCTION
Use this article to quickly find specifications related to servicing and on-vehicle adjustments. This article may be used for quick reference when you are familiar with proper adjustment procedures and only need a specification.
CAPACITIES
| Load Test (Amps) | (1) CCA Rating @ 0°F (Amps) | (2) Reserve Capacity (Min.) |
|---|
| 200 | 500 | 110 |
| 250 | 600 | 120 |
| 300 | 600 | 120 |
| 315 | 685 | 125 |
| 375 | 750 | 125 |
| 405 | 810 | 133 |
| 535 | 1075 | 160 |
| (1) CCA rating is current a battery can deliver for 30 seconds and maintain a terminal voltage of 7.2 volts or greater at specified temperature. (2) Reserve capacity is length of time a battery can deliver 25 amps and maintain a minimum terminal voltage of 10.5 volts at 80°F (27°C). |
| (1) | CCA rating is current a battery can deliver for 30 seconds and maintain a terminal voltage of 7.2 volts or greater at specified temperature. |
| (2) | Reserve capacity is length of time a battery can deliver 25 amps and maintain a minimum terminal voltage of 10.5 volts at 80°F (27°C). |
FLUID CAPACITIES (AWD & FWD)
| Application | Specification |
|---|
| Cooling System (Includes Recovery Tank) |
| 2.5L | (1) 9.5 Qts. (9.0L) |
| 3.0L & 3.3L | (1) 10.0 Qts. (9.5L) |
| Crankcase (Includes Filter) | 4.5 Qts. (4.3L) |
| Automatic Transaxle (Dexron-II) |
| 3-Speed A-413/30TH & A670/31TH (Exc. Fleet) | 8.5 Qts. (8.0L) |
| 3-Speed A-413/30TH & A670/31TH (Fleet) | 9.2 Qts. (8.7L) |
| 4-Speed A-604/41TE | 9.1 Qts. (8.6L) |
| Manual Transmission (SAE 5W-30 SG/API GL-4) |
| 5-Speed A-523 | 2.4 Qts. (2.3L) |
| Power Steering Fluid (2) |
| All Models | 1.7 Pts. (0.8L) |
| (1) Add 1 qt. (.95L) if equipped with rear heater. (2) DO NOT use Automatic Transmission Fluid (ATF). |
| (1) | Add 1 qt. (.95L) if equipped with rear heater. |
| (2) | DO NOT use Automatic Transmission Fluid (ATF). |
FLUID CAPACITIES (AWD & FWD)
FLUID CAPACITIES (RWD & 4WD)
| Application | Specification |
|---|
| Cooling System (Includes Recovery Tank) |
| Dakota |
| 2.5L | 9.8 Qts. (9.3L) |
| 3.9L | 14.0 Qts. (13.2L) |
| 5.2L | 14.3 Qts. (13.5L) |
| Except Dakota |
| 3.9L | 15.1 Qts. (14.3L) |
| 5.2L 2WD | 17.0 Qts. (16.1L) |
| 5.2L 4WD | 16.5 Qts. (15.6L) |
| 5.9L 2WD (1) | 15.5 Qts. (14.7L) |
| 5.9L 4WD (1) | 15.0 Qts. (14.2L) |
| Crankcase (Includes Filter) |
| 5.2L Dakota | 5.0 Qts. (4.7L) |
| All Other Models | 4.5 Qts. (4.3L) |
| Transfer Case |
| NP-205 (2) | 4.5 Pts. (2.1L) |
| NP-231 (2) | 2.5 Pts. (1.2L) |
| NP-241 (3) | 6.0 Pts. (2.8L) |
| Rear Axle (SAE 80W-90/API GL-4) |
| Chrysler 7 1/4" | 3.0 Pts. (1.4L) |
| Chrysler 8 1/4" | 4.4 Pts. (2.0L) |
| Chrysler 9 1/4" | 4.5 Pts. (2.1L) |
| Dana 60 | 6.0 Pts. (2.8L) |
| Dana 70 | 7.0 Pts. (3.3L) |
| Front Axle (SAE 80W-90/API GL-4) |
| Dakota | 2.6 Pts. (1.2L) |
| Except Dakota |
| Spicer 44FBJ | 5.6 Pts. (2.6L) |
| Spicer 60F | 6.5 Pts. (3.1L) |
| Automatic Transmission (Dexron-II) |
| A-500/42RH (3.9L) | 10.2 Qts. (9.6L) |
| A-518/46RH (5.2L & 5.9L) | 10.7 Qts. (10.2L) |
| A-727/36RH (5.2L & 5.9L) | 8.4 Qts. (7.9L) |
| A-999/32RH (3.9L & 5.2L) | 8.6 Qts. (8.1L) |
| Manual Transmission |
| AX-15 (4) | 3.3 Qts. (3.1L) |
| Getrag 360 (5-Speed) (5) | 3.5 Qts. (3.3L) |
| NV-4500 (6) | 4.0 Qts. (3.8L) |
| Power Steering Fluid (7) |
| Dakota RWD | 1.7 Pts. (0.8L) |
| Dakota 4WD | 2.5 Pts. (1.2L) |
| Except Dakota | 2.7 Pts. (1.3L) |
| (1) Add 1 qt. (.95L) if equipped with rear heater. (2) Recommended lubricant for the NP205 and NP231 is SAE 90W API GL-5 Multipurpose gear oil. (3) Recommended lubricant for the NP241 is Mopar ATF Plus, type 7176, or DexronIII. (4) Use SAE 75W-90 API GL-5 fluid. (5) Use SAE 5W-30 SG/API GL-4. (6) Use synthetic 75W-90 API GL-4 fluid. (7) DO NOT use Automatic Transmission Fluid (ATF). |
| (1) | Add 1 qt. (.95L) if equipped with rear heater. |
| (2) | Recommended lubricant for the NP205 and NP231 is SAE 90W API GL-5 Multipurpose gear oil. |
| (3) | Recommended lubricant for the NP241 is Mopar ATF Plus, type 7176, or DexronIII. |
| (4) | Use SAE 75W-90 API GL-5 fluid. |
| (5) | Use SAE 5W-30 SG/API GL-4. |
| (6) | Use synthetic 75W-90 API GL-4 fluid. |
| (7) | DO NOT use Automatic Transmission Fluid (ATF). |
FLUID CAPACITIES (RWD & 4WD)
REPLACEMENT INTERVALS (AWD & FWD)
| Component | Miles |
|---|
| 2.5L, 3.0L & 3.3L |
| Air Filter | 30,000 |
| Coolant | (1) 52,500 |
| Fuel Filter | As Necessary |
| Oil | 7500 |
| Oil Filter | (2) 15,000 |
| Spark Plugs | 30,000 |
| (1) Every 30,000 thereafter. (2) If mileage is less than 7500 miles (5000 miles on turbo) each 12 months, replace filter at each oil change. |
| (1) | Every 30,000 thereafter. |
| (2) | If mileage is less than 7500 miles (5000 miles on turbo) each 12 months, replace filter at each oil change. |
REPLACEMENT INTERVALS (AWD & FWD)
REPLACEMENT INTERVALS (RWD & 4WD)
| Component | Miles |
|---|
| Light-Duty Service |
| Air Filter | 30,000 |
| Coolant | (1) 52,500 |
| Oil | 7500 |
| Oil Filter | (2) 15,000 |
| Spark Plugs | 30,000 |
| Heavy-Duty Service |
| Air Filter | 24,000 |
| Coolant | (3) |
| Fuel Filter | As Necessary |
| Oil | 6000 |
| Oil Filter | 12,000 |
| Spark Plugs | 30,000 |
| (1) Every 30,000 thereafter. (2) If mileage is less than 7500 miles each 12 months, replace filter at each oil change. (3) Change coolant at 36 months and every 30,000 miles thereafter. |
| (1) | Every 30,000 thereafter. |
| (2) | If mileage is less than 7500 miles each 12 months, replace filter at each oil change. |
| (3) | Change coolant at 36 months and every 30,000 miles thereafter. |
REPLACEMENT INTERVALS (RWD & 4WD)
DRIVE BELT TENSION ADJUSTMENT - 4-CYLINDER
| Application | New Belt Lbs. (kg) | (1) Used Belt Lbs. (kg) |
|---|
| Caravan & Voyager |
| A/C Compressor | 125 (56.7) | 80 (36.3) |
| Alternator/Water Pump Poly "V" | 130 (60.0) | 80 (36.3) |
| Power Steering Pump | 105 (47.6) | 80 (36.3) |
| Dakota |
| A/C Compressor | 160 (72.6) | 80 (36.3) |
| Alternator/Water Pump Poly "V" | 160 (72.6) | 80 (36.3) |
| Power Steering Pump | 120 (54.4) | 80 (36.3) |
| (1) Belt is considered used after 15 minutes of service. |
| (1) | Belt is considered used after 15 minutes of service. |
BELT TENSION ADJUSTMENT - 4-CYLINDER
DRIVE BELT TENSION ADJUSTMENT - V6
| Application | New Belt Lbs. (kg) | (1) Used Belt Lbs. (kg) |
|---|
| 3.0L |
| A/C Compressor | 125 (56.7) | 80 (36.3) |
| Serpentine | (2) | (2) |
| 3.3L |
| A/C Compressor | (2) | (2) |
| Serpentine | (2) | (2) |
| 3.9L |
| Serpentine | (2) | (2) |
| (1) Belt is considered used after 15 minutes of service. (2) Dynamic tensioner equipped; no adjustment required. |
| (1) | Belt is considered used after 15 minutes of service. |
| (2) | Dynamic tensioner equipped; no adjustment required. |
BELT TENSION ADJUSTMENT - V6
DRIVE BELT TENSION ADJUSTMENT - V8
| Application | Tension - Lbs. (kg) |
|---|
| 5.2L & 5.9L |
| Serpentine | (1) |
| (1) Dynamic tensioner equipped, no adjustment required. |
| (1) | Dynamic tensioner equipped, no adjustment required. |
BELT TENSION ADJUSTMENT - V8
ENGINE COMPRESSION
Check engine compression with engine at normal operating temperature at specified cranking speed, all spark plugs removed and throttle wide open.
| Application | Specification |
|---|
| Compression Ratio |
| 2.5L | 8.9:1 |
| 3.0L | 8.85:1 |
| 3.3L | 8.9:1 |
| 3.9L | 9.1:1 |
| 5.2L | 9.1:1 |
| 5.9L | 9.1:1 |
| Compression Pressure |
| 3.0L | (1) 178 psi (12.5 kg/cm 2 ) |
| All Other Engines | (2) 100 psi (7.0 kg/cm 2 ) |
| (1) At 250 RPM. (2) Minimum compression pressure is given. Maximum difference between each cylinder should not exceed 25 percent. |
| (2) | Minimum compression pressure is given. Maximum difference between each cylinder should not exceed 25 percent. |
COMPRESSION SPECIFICATIONS
VALVE CLEARANCE
All engines are equipped with hydraulic lifters and do not require valve adjustment. Valve clearance is zero lash with engine at operating temperature.
IGNITION COIL
| Application | Primary | Secondary |
|---|
| 2.5L & 3.0L |
| Diamond | 0.97-1.18 | 11,300-15,300 |
| Toyodenso | 0.95-1.20 | 11,300-13,300 |
| 3.3L |
| Diamond | 0.52-0.63 | 11,600-15,800 |
| Toyodenso | 0.51-0.61 | 11,500-13,500 |
| 3.9L, 5.2L & 5.9L |
| Diamond | 0.96-1.18 | 11,300-15,300 |
| Toyodenso | 0.95-1.20 | 11,300-13,300 |
IGNITION COIL RESISTANCE - Ohms @ 70-80°F (21-27°C)
HIGH TENSION WIRE RESISTANCE
| Application | Minimum Ohms | Maximum Ohms |
|---|
| All Wires | 250 Per Inch | 1000 Per Inch |
HIGH TENSION WIRE RESISTANCE
SPARK PLUGS
| Application | Champion No. |
|---|
| 2.5L | RN12YC |
| 3.0L |
| Standard | RN11YC4 |
| Optional | BPR5ES-II |
| 3.3L | RN14MC5/RN16YC5 |
| 3.9L, 5.2L & 5.9L | RC12YC |
| Application | Gap In. (mm) | Torque Ft. Lbs. (N.m) |
|---|
| 2.5L | .035 (.89) | 20 (28) |
| 3.0L | .041 (1.04) | 20 (28) |
| 3.3L | .050 (1.27) | 20 (28) |
| 3.9L & 5.2L | .035 (.89) | 20 (28) |
| 5.9L | .035 (.89) | 30 (41) |
SPARK PLUG SPECIFICATIONS
FIRING ORDER & TIMING MARKS
| WARNING | On 3.0L V6, the firing order and the spark plug connection order on the top of the distributor do not match. Circuits internal to the distributor cap differ from the external spark plug wire connections. This is intentional and is done to avoid spark plug wires crossover. (Scheme 2) |
Firing Order & Distributor Rotation (2.5L). Scheme 1
Scheme 1: Firing Order & Distributor Rotation (2.5L)
Firing Order & Distributor Rotation (3.0L). Scheme 2
Scheme 2: Firing Order & Distributor Rotation (3.0L)
Firing Order (3.3L). Scheme 3
Scheme 3: Firing Order (3.3L)
Firing Order & Distributor Rotation (3.9L). Scheme 4
Scheme 4: Firing Order & Distributor Rotation (3.9L)
Scheme 5
Scheme 5: Firing Order & Distributor Rotation (5.2L & 5.9L)
IGNITION TIMING
Note. Always refer to Emission Control Label in engine compartment before attempting service. If manual and label differ, always use emission label specifications.
| Application | (1) Degrees BTDC |
|---|
| 2.5L |
| Caravan & Voyager | 10-14 |
| Dakota | (2) |
| 3.0L | 10-14 |
| 3.3L | (3) |
| 3.9L, 5.2L & 5.9L | (3) |
| (1) At idle. (2) See emission control information label in engine compartment. (3) Ignition timing is not adjustable. |
| (2) | See emission control information label in engine compartment. |
| (3) | Ignition timing is not adjustable. |
ELECTRONIC SPARK ADVANCE CHECK
Note. Always refer to Emission Control Label in engine compartment before attempting service. If manual and label differ, always use emission label specifications.
| Application | Man. Trans. | Auto. Trans. |
|---|
| 2.5L | 17-25 @ 2000 | 17-25 @ 2000 |
| 3.0L | N/A | 34-42 @ 2000 |
| 3.3L | N/A | N/A |
| 3.9L, 5.2L & 5.9L | N/A | N/A |
ELECTRONIC SPARK ADVANCE (Degrees BTDC @ RPM)
FUEL PUMP
| Application | Pressure - psi (kPa) |
|---|
| 2.5L | 39 (269) |
| 3.0L & 3.3L | 48 (331) |
| 3.9L & 5.2L | (2) 31 (214) |
| 5.9L | 35-45 (241-310) |
| (1) Fuel pressure taken at engine idle (no load). (2) Fuel pressure is 8-10 psi (55-69 kPa) higher with fuel pressure regulator valve vacuum line disconnected. |
| (1) | Fuel pressure taken at engine idle (no load). |
| (2) | Fuel pressure is 8-10 psi (55-69 kPa) higher with fuel pressure regulator valve vacuum line disconnected. |
FUEL PUMP REGULATED PRESSURE (1)
INJECTOR RESISTANCE
| Application | Ohms | °F (°C) |
|---|
| 3.9L, 5.2L & 5.9L | 13.3-15.7 | 68 (20) |
| All Other Models | N/A | N/A |
IDLE SPEED & MIXTURE
Note. Mixture is controlled by Powertrain Control Module (PCM). No adjustment is possible.
| Application | Man. Trans. | Auto. Trans. |
|---|
| 2.5L | 1050-1250 | 1050-1250 |
| 3.0L | N/A | 750-950 |
| 3.3L | N/A | 750-950 |
| 3.9L, 5.2L & 5.9L | N/A | N/A |
MINIMUM AIRFLOW RATE SPECIFICATIONS - 4-CYLINDER
| Application | RPM |
|---|
| 2.5L | 800-1200 |
MINIMUM AIRFLOW RATE SPECIFICATIONS - 4-CYLINDER
MINIMUM AIRFLOW RATE SPECIFICATIONS - V6
| Application | RPM |
|---|
| 3.0L | 610-910 |
| 3.3L | 575-875 |
MINIMUM AIRFLOW RATE SPECIFICATIONS - V6
THROTTLE POSITION SENSOR
| Throttle Opening (2) | Volts |
|---|
| 2.5L & 3.3L |
| Idle | 0.5 |
| WOT | 4.0 |
| 3.0L (3) |
| Idle | 0.5 |
| WOT | 3.5 |
| 3.9L, 5.2L & 5.9L |
| Idle | Greater Than 0.2 |
| WOT | Less Than 4.8 |
| (1) Voltage should increase steadily as throttle opening is increased from idle position. (2) Measure voltage at throttle position sensor center terminal. (3) Voltage specifications may vary but WOT specification should be approximately 3.0 volts higher than idle specification. |
| (1) | Voltage should increase steadily as throttle opening is increased from idle position. |
| (2) | Measure voltage at throttle position sensor center terminal. |
| (3) | Voltage specifications may vary but WOT specification should be approximately 3.0 volts higher than idle specification. |
THROTTLE POSITION SENSOR VOLTAGE TEST (1)
