2002 CHRYSLER CARAVAN maintenance

NOTE: Before installing power steering pressure
hose on power steering pump, inspect the O-ring
on the power steering pressure hose for damage
and replace if required.
(4) Install the power steering fluid pressure hose
fitting into the pressure port of the power steering
pump (Fig. 12). Tighten the pressure line to pump
fitting tube nut to a torque of 31 N´m (275 in. lbs.).
(5) Install the power steering fluid supply hose on
the power steering pump supply fitting (Fig. 12).Be
sure hose clamp is properly reinstalled.
(6) Install the accessary drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(7) Install the splash shields below the engine
compartment.
(8) Lower the vehicle.
(9) Connect the negative (-) battery cable on the
negative battery post.
(10) Fill and bleed the power steering system
using the Power Steering Pump Initial Operation
Procedure (Refer to 19 - STEERING/PUMP - STAN-
DARD PROCEDURE).
(11) Inspect for leaks.
SPECIAL TOOLS
POWER STEERING PUMP
FLUID
STANDARD PROCEDURE - POWER STEERING
FLUID LEVEL CHECKING
WARNING: FLUID LEVEL SHOULD BE CHECKED
WITH THE ENGINE OFF TO PREVENT INJURY
FROM MOVING PARTS AND TO ENSURE ACCU-
RATE FLUID LEVEL READING.
The fluid level can be read on the exterior of the
power steering fluid reservoir. The fluid level should
be within the ªFILL RANGEº when the fluid is at
normal ambient temperature, approximately 21ÉC to
27ÉC (70ÉF to 80ÉF) (Fig. 17).
Before removing the power steering filler cap, wipe
the reservoir filler cap free of dirt and debris. Do not
overfill the power steering system.Use only
MopartATF+4 Automatic Transmission Fluid
(MS-9602) in the power steering system.For
additional information on Automatic Transmission
Fluid, (Refer to LUBRICATION & MAINTENANCE/
FLUID TYPES - DESCRIPTION).
CAUTION: Use only MoparTATF+4 Automatic Trans-
mission Fluid (MS-9602). Use of other MoparT
power steering fluids (MS5931 and MS9933) should
be avoided to ensure peak performance of the
power steering system under all operating condi-
tions.
Installer C-4063B
Puller C-4333
Fig. 17 Power Steering Fluid Reservoir
19 - 44 PUMPRS
PUMP (Continued)
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FLUID COOLER
DESCRIPTION
All models (except 2.5L Diesel) are equipped with a
cooler for the power steering system fluid. The power
steering fluid cooler is located on the front suspen-
sion cradle crossmember reinforcement (Fig. 18).
There are two different size coolers depending on
model and options. There is a standard 6-inch and an
8-inch.
OPERATION
The purpose of the power steering fluid cooler is to
keep the temperature of the power steering system
fluid from rising to a level that would affect the per-
formance of the power steering system.
The cooler used on this vehicle is referred to as a
fluid-to-air type cooler. This means that the air flow
across the tubes (and fines surrounding them) of the
cooler is used to extract the heat from the cooler
which it has absorbed from the power steering fluid
flowing through it. The cooler is placed in the power
steering fluid return line, between the steering gear
and the power steering fluid reservoir.
REMOVAL
(1) Using a siphon pump, remove as much fluid as
possible from the power steering fluid reservoir.
(2) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(3) Remove the hose clamps at the cooler and
remove the hoses from the cooler inlet and outlet
tubes.
(4) Remove the 2 bolts attaching the power steer-
ing cooler cradle crossmember reinforcement (Fig.
18). Remove the cooler.
INSTALLATION
(1) Install the power steering fluid cooler on the
cradle crossmember reinforcement (Fig. 18). Install
the mounting bolts and tighten to 11 N´m (100 in.
lbs.).
(2) Install power steering fluid hoses on the cooler.
Be sure hose clamps are installed on hose past
the upset bead on the power steering cooler
tubes.(3) Lower the vehicle to a point where front tires
are just off the ground.
(4) Perform Power Steering Pump Initial Opera-
tion procedure. (Refer to 19 - STEERING/PUMP -
STANDARD PROCEDURE)
HOSE - POWER STEERING
PRESSURE
REMOVAL
REMOVAL - 2.4L ENGINE
NOTE: Before proceeding, review all WARNINGS
and CAUTIONS. (Refer to 19 - STEERING/PUMP -
WARNING)(Refer to 19 - STEERING/PUMP - CAU-
TION)
(1) Remove cap from power steering fluid reser-
voir.
(2) Using a siphon pump, remove as much power
steering fluid as possible from power steering fluid
reservoir.
Fig. 18 Power Steering Cooler
1 - CRADLE CROSSMEMBER REINFORCEMENT
2 - POWER STEERING COOLER
RSPUMP19-45
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(3) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(4) Remove front emissions vapor canister. (Refer
to 25 - EMISSIONS CONTROL/EVAPORATIVE
EMISSIONS/VAPOR CANISTER - REMOVAL)
(5) Place an oil drain pan under vehicle to catch
power steering fluid.
(6) Back out pressure hose tube nut at power
steering pump pressure fitting and remove hose from
pump (Fig. 19).
(7) Remove bolt attaching right routing clamp to
front suspension cradle crossmember (Fig. 19).
Remove pressure hose from clamp.
(8) Back out pressure hose tube nut at power
steering gear and remove hose from gear (Fig. 19).
(9) Remove power steering fluid pressure hose
from vehicle.
REMOVAL - 3.3L/3.8L ENGINE
NOTE:Before proceeding, review all WARNINGS and
CAUTIONS. (Refer to 19 - STEERING/PUMP - WARNIN-
G)(Refer to 19 - STEERING/PUMP - CAUTION)
(1) Remove cap from power steering fluid reser-
voir.
(2) Using a siphon pump, remove as much power
steering fluid as possible from power steering fluid
reservoir.
(3) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(4) Remove front emissions vapor canister. (Refer
to 25 - EMISSIONS CONTROL/EVAPORATIVE
EMISSIONS/VAPOR CANISTER - REMOVAL)
(5) Remove two bolts securing pressure hose rout-
ing clamps to suspension cradle crossmember and
steel reinforcement (Fig. 20).
(6) Place an oil drain pan under vehicle to catch
draining power steering fluid.
(7) Disconnect pressure hose at power steering
gear (Fig. 20).
(8) Remove pressure hose routing bracket bolt at
engine (Fig. 21). Bolt can be accessed through hole in
cradle crossmember (Fig. 22).
(9) Disconnect pressure hose tube nut at power
steering pump (Fig. 21).
(10) Remove power steering fluid pressure hose
from vehicle.
INSTALLATION
INSTALLATION - 2.4L ENGINE
(1) Remove any used O-rings from ends of power
steering hose.
(2) Using a lint free towel, wipe clean hose ends,
power steering pump pressure outlet fitting and
steering gear port.
(3) Install new O-rings on ends of power steering
fluid pressure hose. Lubricate O-rings using clean
power steering fluid.
CAUTION: Use care not to bend tube ends of power
steering hoses when installing. Leaks and restric-
tions may occur.
CAUTION: Power steering fluid hoses must remain
away from exhaust system and must not come in
contact with any unfriendly surfaces on vehicle.
(4) Route hose up through cradle crossmember
toward power steering pump avoiding tight bends or
kinking.
(5) Install power steering pressure hose end into
pump pressure outlet fitting (Fig. 19). Thread tube
nut into outlet fitting, but do not tighten at this time.
(6) Route hose behind cradle crossmember and
start hose end into gear port. Do not tighten hose
tube nut at this time.
Fig. 19 PRESSURE AND RETURN HOSES - 2.4L
1 - POWER STEERING PUMP
2 - RETURN HOSE (HEAT SLEEVE COVERED)
3 - ROUTING CLAMPS
4 - PRESSURE HOSE TUBE NUT
5 - RETURN HOSE TUBE NUT
6 - CRADLE CROSSMEMBER
7 - POWER STEERING GEAR
8 - PRESSURE HOSE
19 - 46 PUMPRS
HOSE - POWER STEERING PRESSURE (Continued)
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(10) Tighten hose tube nut at power steering gear
port to 31 N´m (275 in. lbs.) torque.
(11) Install front emissions vapor canister. (Refer
to 25 - EMISSIONS CONTROL/EVAPORATIVE
EMISSIONS/VAPOR CANISTER - INSTALLATION)
(12) Lower vehicle.
(13) Fill and bleed the power steering system
using the Power Steering Pump Initial Operation
Procedure. (Refer to 19 - STEERING/PUMP - STAN-
DARD PROCEDURE)
(14) Inspect system for leaks.
HOSE - POWER STEERING
RETURN
REMOVAL
REMOVAL - 2.4L ENGINE
NOTE: Before proceeding, review all WARNINGS
and CAUTIONS. (Refer to 19 - STEERING/PUMP -
WARNING)(Refer to 19 - STEERING/PUMP - CAU-
TION)
(1) Remove cap from power steering fluid reser-
voir.
(2) Using a siphon pump, remove as much power
steering fluid as possible from power steering fluid
reservoir.
(3) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(4) Remove front emissions vapor canister. (Refer
to 25 - EMISSIONS CONTROL/EVAPORATIVE
EMISSIONS/VAPOR CANISTER - REMOVAL)
(5) Place an oil drain pan under vehicle to catch
power steering fluid.
(6) Cut tie-strap securing insulating heat sleeve to
power steering fluid return hose near power steering
pump. Pull back heat sleeve to expose hose clamp.
(7) Remove clamp, then return hose from power
steering pump (Fig. 19).
(8) Remove 2 bolts attaching power steering cooler
to cradle crossmember reinforcement (Fig. 23).
(9) Remove bolts attaching routing clamps to front
suspension cradle crossmember (Fig. 19). Remove
return hose from clamps.
(10) Back out return hose tube nut at power steer-
ing gear and remove hose (Fig. 19).
REMOVAL - 3.3L/3.8L ENGINE
NOTE:Before proceeding, review all WARNINGS and
CAUTIONS. (Refer to 19 - STEERING/PUMP - WARNIN-
G)(Refer to 19 - STEERING/PUMP - CAUTION)
(1) Remove cap from power steering fluid reser-
voir.
(2) Using a siphon pump, remove as much power
steering fluid as possible from power steering fluid
reservoir.
(3) Place an oil drain pan under vehicle to catch
any draining power steering fluid.
(4) Remove clamp attaching return hose to power
steering fluid reservoir. Disconnect hose from reser-
voir (Fig. 21).
(5) Follow return hose downward and open
retainer at ABS bracket (Fig. 20). Remove hose tube
from retainer.
(6) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(7) Remove front emissions vapor canister. (Refer
to 25 - EMISSIONS CONTROL/EVAPORATIVE
EMISSIONS/VAPOR CANISTER - REMOVAL)
(8) Remove bolt securing return hose routing
clamp to suspension cradle crossmember (Fig. 20).
(9) Remove 2 bolts attaching power steering cooler
to cradle crossmember reinforcement (Fig. 23).
(10) Disconnect return hose at power steering gear
(Fig. 20).
(11) Remove power steering fluid return hose with
cooler from vehicle.
Fig. 23 POWER STEERING COOLER
1 - CRADLE CROSSMEMBER REINFORCEMENT
2 - POWER STEERING COOLER
RSPUMP19-49
HOSE - POWER STEERING PRESSURE (Continued)
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HOSE - POWER STEERING
SUPPLY
REMOVAL
REMOVAL - 2.4L ENGINE
(1) Remove filler cap from power steering fluid res-
ervoir.
(2) Using a siphon pump, remove as much power
steering fluid as possible from the power steering
fluid reservoir.
(3) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(4) Remove hose clamp securing supply hose to
power steering pump, then remove supply hose from
pump fitting.
(5) Lower vehicle.
(6) Remove hose clamp attaching power steering
fluid supply hose to power steering fluid reservoir,
then remove supply hose.
(7) Remove the power steering fluid supply hose
from the vehicle.
REMOVAL - 3.3L/3.8L ENGINE
NOTE: Before proceeding, review all WARNINGS
and CAUTIONS. (Refer to 19 - STEERING/PUMP -
WARNING)(Refer to 19 - STEERING/PUMP - CAU-
TION)
(1) Remove cap from power steering fluid reser-
voir.
(2) Using a siphon pump, remove as much power
steering fluid as possible from power steering fluid
reservoir.
(3) Place an oil drain pan under vehicle to catch
any draining power steering fluid.
(4) Remove clamp attaching supply hose to power
steering fluid reservoir. Disconnect hose from reser-
voir (Fig. 21).
(5) Pull upward on hose routing clip releasing it
from bracket on cylinder head cover (Fig. 21).
NOTE: It may be necessary to remove air cleaner
housing to gain greater access to supply hose at
power steering pump. (Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER HOUSING -
REMOVAL)
(6) Remove clamp attaching supply hose to power
steering pump. Disconnect hose from pump and
remove from vehicle (Fig. 21).
INSTALLATION
INSTALLATION - 2.4L ENGINE
(1) Install and correctly route power steering fluid
supply hose from remote fluid reservoir to power
steering pump.
(2) Install fluid supply hose onto power steering
fluid reservoir. Install hose clamp.Be sure hose
clamp is installed past bead on fluid reservoir
fitting.
(3) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(4) Install power steering fluid supply hose on
power steering pump supply fitting. Install hose
clamp.Be sure hose clamp is installed past bead
on pump fitting.
(5) Lower vehicle.
(6) Fill and bleed power steering system using
Power Steering Pump Initial Operation Procedure.
(Refer to 19 - STEERING/PUMP - STANDARD PRO-
CEDURE)
(7) Inspect system for leaks.
INSTALLATION - 3.3L/3.8L ENGINE
(1) Install supply hose onto supply fitting on power
steering pump (Fig. 21). Slide the hose clamp into
position on fluid reservoir and attach it.Be sure
hose clamp in installed past bead on fluid res-
ervoir fitting.
(2) Align routing clip located toward center of sup-
ply hose with hole in bracket on cylinder head cover
and push into place (Fig. 21).
(3) Install supply hose onto reservoir (Fig. 21).
Slide the hose clamp into position on fluid reservoir
and attach it.Be sure hose clamp in installed
past bead on fluid reservoir fitting.
(4) Fill and bleed power steering system using
Power Steering Pump Initial Operation Procedure.
(Refer to 19 - STEERING/PUMP - STANDARD PRO-
CEDURE)
(5) Inspect system for leaks.
RESERVOIR - POWER
STEERING FLUID
DESCRIPTION
DESCRIPTION - 2.4L/3.3L/3.8L ENGINE
All vehicles use a remote mounted power steering
fluid reservoir. The power steering fluid reservoir is
mounted to the engine near the battery (Fig. 24).
RSPUMP19-51
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STANDARD PROCEDURE
STANDARD PROCEDURE - FLUID LEVEL
INSPECTION
(1) Raise vehicle on hoist.
(2) Remove PTU inspection plug (Fig. 6).
(3) Fluid level should be within 3/16º from bottom
of inspection hole. Add MopartGear and Axle Lubri-
cant 80W-90 as necessary with suitable suction gun
(Fig. 7).
(4) Install inspection plug and torque to 20 N´m
(180 in. lbs.) torque.
(5) Lower vehicle.
STANDARD PROCEDURE - PTU FLUID CHANGE
NOTE: PTU Fluid should be changed upon servic-
ing the unit, or at the unit's regular scheduled inter-
val. (Refer to LUBRICATION & MAINTENANCE/
MAINTENANCE SCHEDULES - DESCRIPTION)
(1) Raise vehicle on hoist.
(2) Remove PTU inspection plug (Fig. 8).
(3) Using suitable suction gun, draw fluid from
PTU. Make sure hose contacts bottom of case to
ensure all fluid is removed.
Fig. 6 Inspection Plug
1 - INSPECTION PLUG
Fig. 7 Removing/Adding PTU Fluid
1 - SUCTION GUN
2 - INSPECTION HOLE
Fig. 8 Inspection Plug
1 - INSPECTION PLUG
RSPOWER TRANSFER UNIT21-5
POWER TRANSFER UNIT (Continued)
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FLUID
STANDARD PROCEDURE
STANDARD PROCEDURE - FLUID LEVEL AND
CONDITION CHECK
NOTE: The transmission and differential sump have
a common oil sump with a communicating opening
between the two.
FLUID LEVEL CHECK
The torque converter fills in both the P Park and N
Neutral positions. Place the selector lever in P Park
to be sure that the fluid level check is accurate.The
engine should be running at idle speed for at
least one minute, with the vehicle on level
ground. This will assure complete oil level sta-
bilization between differential and transmis-
sion.The fluid should be at normal operating
temperature (approximately 82 C. or 180 F.). The
fluid level is correct if it is in the HOT region (cross-
hatched area) on the fluid level indicator (Fig. 165).
Low fluid level can cause a variety of conditions
because it allows the pump to take in air along with
the fluid. As in any hydraulic system, air bubbles
make the fluid spongy, therefore, pressures will be
low and build up slowly.
Improper filling can also raise the fluid level too
high. When the transaxle has too much fluid, the
gears churn up foam and cause the same conditions
which occur with a low fluid level.
In either case, the air bubbles can cause overheat-
ing, fluid oxidation, and varnishing. This can inter-
fere with normal valve, clutch, and servo operation.
Foaming can also result in fluid escaping from thetransaxle dipstick where it may be mistaken for a
leak.
FLUID CONDITION
Along with fluid level, it is important to check the
condition of the fluid. MopartATF+4 (Automatic
Transmission Fluid-Type 9602) when new is red in
color. The ATF is dyed red so it can be identified from
other fluids used in the vehicle such as engine oil or
antifreeze. The red color is not permanent and is not
an indicator of fluid condition. As the vehicle is
driven, the ATF will begin to look darker in color and
may eventually become brown.This is normal.
ATF+4 also has a unique odor that may change with
age. Consequently,odor and color cannot be used
to indicate the fluid condition, or the need for a
fluid change.
After the fluid has been checked, seat the dipstick
fully to seal out water and dirt.
STANDARD PROCEDURE - FLUID AND FILTER
CHANGE
NOTE: For the recommended maintenance (fluid/fil-
ter change) intervals for this transaxle, (Refer to
LUBRICATION & MAINTENANCE/MAINTENANCE
SCHEDULES - DESCRIPTION)
NOTE: Only fluids of the type labeled MoparTATF+4
(Automatic Transmission Fluid) Type 9602 should
be used. A filter change should be made at the time
of the transmission oil change. The magnet (on the
inside of the oil pan) should also be cleaned with a
clean, dry cloth.
NOTE: If the transaxle is disassembled for any rea-
son, the fluid and filter should be changed.
FLUID/FILTER SERVICE (RECOMMENDED)
(1) Raise vehicle on a hoist. Place a drain con-
tainer with a large opening, under transaxle oil pan.
(2) Loosen pan bolts and tap the pan at one corner
to break it loose allowing fluid to drain, then remove
the oil pan.
(3) Remove oil filter-to-valve body screws (Fig.
166).
(4) Remove oil filter and gasket (Fig. 167).
(5) Install a new filter and gasket (Fig. 167).
(6) Clean the oil pan and magnet. Reinstall pan
using new MopartSilicone Rubber Adhesive Sealant.
Torque oil pan bolts to 19 N´m (165 in. lbs.).
(7) Pour four quarts of MopartATF+4 (Automatic
Transmission Fluid-Type 9602) through the dipstick
opening.
Fig. 165 Fluid Level Indicator Markings
1 - TRANSAXLE DIPSTICK
RS31TH AUTOMATIC TRANSAXLE21-99
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(6) Adjust transmission fluid level shown on the
indicator according to the chart.
(7) Check transmission for leaks.
Low fluid level can cause a variety of conditions
because it allows the pump to take in air along with
the fluid. As in any hydraulic system, air bubbles
make the fluid spongy, therefore, pressures will be
low and build up slowly.
Improper filling can also raise the fluid level too
high. When the transaxle has too much fluid, the
gears churn up foam and cause the same conditions
which occur with a low fluid level.
In either case, air bubbles can cause overheating
and/or fluid oxidation, and varnishing. This can
interfere with normal valve, clutch, and accumulator
operation. Foaming can also result in fluid escaping
from the transaxle vent where it may be mistaken
for a leak.
FLUID CONDITION
Along with fluid level, it is important to check the
condition of the fluid. When the fluid smells burned,
and is contaminated with metal or friction material
particles, a complete transaxle recondition is proba-
bly required. Be sure to examine the fluid on the dip-
stick closely. If there is any doubt about its condition,
drain out a sample for a double check.
MopartATF+4 (Automatic Transmission Fluid-
Type 9602) when new is red in color. The ATF is dyed
red so it can be identified from other fluids used in
the vehicle such as engine oil or antifreeze. The red
color is not permanent and is not an indicator of fluid
condition. As the vehicle is driven, the ATF will begin
to look darker in color and may eventually become
brown.This is normal.ATF+4 also has a unique
odor that may change with age. Consequently,odor
and color cannot be used to indicate the fluid
condition or the need for a fluid change.
After the fluid has been checked, seat the dipstick
fully to seal out water and dirt.
STANDARD PROCEDURE - FLUID AND FILTER
SERVICE
NOTE: Refer to the maintenance schedules in
LUBRICATION and MAINTENANCE, or the vehicle
owner's manual, for the recommended maintenance
(fluid/filter change) intervals for this transaxle.
NOTE: Only fluids of the type labeled MoparTATF+4
(Automatic Transmission Fluid) Type 9602 should
be used. A filter change should be made at the time
of the transmission oil change. The magnet (on the
inside of the oil pan) should also be cleaned with a
clean, dry cloth.NOTE: If the transaxle is disassembled for any rea-
son, the fluid and filter should be changed.
FLUID/FILTER SERVICE (RECOMMENDED)
(1) Raise vehicle on a hoist. Refer to LUBRICA-
TION and MAINTENANCE for proper procedures.
Place a drain container with a large opening, under
transaxle oil pan.
(2) Loosen pan bolts and tap the pan at one corner
to break it loose allowing fluid to drain, then remove
the oil pan.
(3) Install a new filter and o-ring on bottom of the
valve body (Fig. 212).
(4) Clean the oil pan and magnet. Reinstall pan
using new Mopar Silicone Adhesive sealant. Tighten
oil pan bolts to 19 N´m (165 in. lbs.).
(5) Pour four quarts of MopartATF+4 (Automatic
Transmission Fluid) Type 9602 through the dipstick
opening.
(6) Start engine and allow to idle for at least one
minute. Then, with parking and service brakes
applied, move selector lever momentarily to each
position, ending in the park or neutral position.
Fig. 212 Filter and O-Ring
1 - OIL FILTER
2 - O-RING
21 - 250 41TE AUTOMATIC TRANSAXLERS
FLUID (Continued)
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