2002 CHRYSLER CARAVAN lock

(7) Install the timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKET(S)
- INSTALLATION).
(8) Install the generator mount bracket. (Fig. 24)
(9) Install the generator.
(10) Install right engine mount bracket and engine
mount (Refer to 9 - ENGINE/ENGINE MOUNTING/
RIGHT MOUNT - INSTALLATION).
(11) Fill the cooling system (Refer to 7 - COOLING
- STANDARD PROCEDURE).
(12) Install the accessory drive belts (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(13) Lower vehicle and connect battery cable.
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.
27). It is driven by the accessory drive belt.
OPERATION
The water pump is the heart of the cooling system.
The coolant is pumped through the engine block, cyl-
inder head, heater core, and radiator.
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. 27).
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. 28). Move
pulley inward between pump housing and hub (Fig.
28).
(6) Position pulley to allow access to water pump
mounting bolts. Remove water pump mounting bolts
(Fig. 29).
(7) Remove water pump with the pulley loosely
positioned between hub and the pump body.
(8) Remove and discard the seal.
Fig. 27 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
Fig. 28 Water Pump Pulley Positioning
1 - HUB - WATER PUMP
2 - PULLEY - WATER PUMP
7 - 34 ENGINERS
WATER PUMP - 2.4L (Continued)
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(5) Rotate pump by hand to check for freedom of
movement.
(6) Install the accessory drive belt. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION)
(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. 32). 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. 33).
(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. 32).(2) Lube O-ring with coolant and install inlet tube
into the cylinder block opening (Fig. 32).
(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. 33).
(5) Install the radiator upper hose.
(6) Fill the cooling system. (Refer to 7 - COOLING
- STANDARD PROCEDURE)
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. 34).
(4) Remove the oil cooler outlet/heater return hose
from inlet tube (only if equipped with engine oil
cooler) (Fig. 35).
(5) Remove the inlet tube bolts (Fig. 36).
(6) Remove the inlet tube (Fig. 36). 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. 36).
Fig. 32 Water Pump Inlet TubeÐ2.4L Engine
1 - O-RING
2 - WATER PUMP INLET TUBE
Fig. 33 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)
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CONDITION POSSIBLE CAUSES CORRECTION
4. Has undercoating been applied to
any unnecessary components?4. Clean undercoating as
necessary.
STEAM IS COMING FROM
FRONT OF VEHICLE
NEAR GRILL AREA WHEN
WEATHER IS WET,
ENGINE IS WARMED UP
AND RUNNING, AND
VEHICLE IS STATIONARY.
TEMPERATURE GAUGE
IS IN NORMAL RANGE1. During wet weather, moisture
(snow, ice, or rain condensation) on
the radiator will evaporate when the
thermostat opens. This opening
allows heated water into the radiator.
When the moisture contacts the hot
radiator, steam may be emitted. This
usually occurs in cold weather with
no fan or airflow to blow it away.1. Occasional steam emitting
from this area is normal. No
repair is necessary.
COOLANT ODOR 1. Coolant color is not necessarily an
indication of adequate corrosion or
temperature protection. Do not rely
on coolant color for determining
condition of coolant.1. Refer to Coolant in this group
for antifreeze tests. Adjust
antifreeze-to-water ratio as
necessary.
COOLANT LEVEL
CHANGES IN COOLANT
TANK. TEMPERATURE
GAUGE IS IN NORMAL
RANGE1. Level changes are to be expected
as coolant volume fluctuates with
engine temperature. If the level in
the tank was between the HOT and
COLD marks at normal engine
operating temperature, the level
should return to within that range
after operation at elevated
temperatures.1. This a normal condition. No
repair necessary.
DIAGNOSIS AND TESTING - COOLING SYSTEM
LEAK TEST
WARNING: THE WARNING WORDS ªDO NOT OPEN
HOTº ON THE RADIATOR PRESSURE CAP IS A
SAFETY PRECAUTION. WHEN HOT, PRESSURE
BUILDS UP IN COOLING SYSTEM. TO PREVENT
SCALDING OR INJURY, THE RADIATOR CAP
SHOULD NOT BE REMOVED WHILE THE SYSTEM
IS HOT OR UNDER PRESSURE.
With engine not running, remove pressure/vent cap
from the coolant recovery pressure container and
wipe the filler neck sealing seat clean. The coolant
recovery pressure container should be full.
Attach the Cooling System Tester 7700 or equiva-
lent to the radiator, as shown in (Fig. 1) and apply
104 kPa (15 psi) pressure. If the pressure drops more
than 13.8 kPa (2 psi) in 2 minutes, inspect all points
for external leaks.
All radiator and heater hoses should be shaken
while at 104 kPa (15 psi), since some leaks occur only
while driving due to engine movement.
If there are no external leaks, after the gauge dial
shows a drop in pressure, detach the tester. Startengine and run until the thermostat opens, allowing
the coolant to expand. Reattach the cooling system
tester. If the needle on the dial fluctuates it indicates
a combustion leak, usually a head gasket leak.
WARNING: WITH TOOL IN PLACE, PRESSURE WILL
BUILD UP FAST. EXCESSIVE PRESSURE BUILT UP,
BY CONTINUOUS ENGINE OPERATION, MUST BE
RELEASED TO A SAFE PRESSURE POINT. NEVER
PERMIT PRESSURE TO EXCEED 138 kPa (20 psi).
If the needle on the dial does not fluctuate, raise
the engine rpm a few times. If an abnormal amount
of coolant or steam emits from the tailpipe, it may
indicate a coolant leak caused by a faulty head gas-
ket, cracked engine block, or cracked cylinder head.
There may be internal leaks that can be deter-
mined by removing the oil dipstick. If water globules
appear intermixed with the oil it will indicate an
internal leak in the engine. If there is an internal
leak, the engine must be disassembled for repair.
7a - 6 COOLING 2.5L TURBO DIESELRG
COOLING 2.5L TURBO DIESEL (Continued)
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DIAGNOSIS AND TESTING - ACCESSORY DRIVE BELT
CONDITION POSSIBLE CAUSES CORRECTIONS
INSUFFICIENT ACCESSORY
OUTPUT DUE TO BELT SLIPPAGE1. Belt too loose 1. (a) Replace belt (auto-tensioned
belts)
2. Faulty belt tensioner 2. Replace tensioner as necessary
3. Belt excessively glazed or worn 3. Replace belt
BELT SQUEAL WHEN
ACCELERATING ENGINE1. Belts too loose 1. Check and replace belt tensioner
if necessary
2. Belt glazed 2. Replace belt
BELT SQUEAK AT IDLE 1. Belts too loose 1. (a) Replace belt
2. Dirt or paint imbedded in belt 2. Replace belt
3. Non-uniform belt 3. Replace belt
4. Misaligned pulleys 4. Align accessories
5. Non-uniform groove or eccentric
pulley5. Replace pulley
BELT ROLLED OVER IN GROOVE
OR BELT JUMPS OFF1. Broken cord in belt 1. Replace belt
2. Belt too loose, or too tight 2. Replace belt
3. Misaligned pulleys 3. Align accessories
4. Non-uniform groove or eccentric
pulley4. Replace pulley
REMOVAL
REMOVAL-ACCESSORY DRIVE BELT
(1) Remove the power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(2) Relieve tension on belt tensioner using a suit-
able wrench (Fig. 4) and lock tensioner with a drift
punch (Fig. 5).
(3) Remove the accessory drive belt.
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove right front fender inner splash shield.
(3) Install power steering belt remover tool on
crankshaft damper (Fig. 6).
(4) Rotate engine clockwise to remove belt (Fig. 7).
RGACCESSORY DRIVE7a-11
DRIVE BELTS (Continued)
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Fig. 4 ACCESSORY DRIVE BELT REMOVAL
1 - BELT TENSIONER
2 - ACCESSORY DRIVE BELT
3 - IDLER PULLEY
4 - A/C COMPRESSOR CLUTCH
5 - CRANKSHAFT DAMPER/PULLEY
6 - WRENCH
Fig. 5 LOCKING/LOCKING BELT TENSIONER
Fig. 6 POWER STEERING BELT REMOVAL TOOL
1 - VIBRATION DAMPER
2 - POWER STEERING PULLEY
3 - POWER STEERING BELT
4 - POWER STEERING BELT REMOVER
Fig. 7 POWER STEERING BELT REMOVAL
1 - VIBRATION DAMPER
2 - POWER STEERING BELT
3 - POPWER STEERING BELT REMOVER
7a - 12 ACCESSORY DRIVERG
DRIVE BELTS (Continued)
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INSTALLATION
INSTALLATION-ACCESSORY DRIVE BELT
(1) Install the accessory drive belt in proper popsi-
tion (Fig. 8).
(2) Unlock belt tensioner by removing punch and
apply tension to accessory drive belt (Fig. 9).
(3) Install the power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
INSTALLATION-POWER STEERING BELT
(1) Install power steering belt installation tool
(Fig. 10).
(2) Install power steering belt on crankshaft and
rotate crankshaft clockwise until belt is fully
installed on crankshaft (Fig. 10).
(3) Remove installation tool from crankshaft.
(4) Install right front fender inner splash shield.
(5) Lower vehicle from hoist.
Fig. 8 ACCESSORY DRIVE BELT ROUTING
1 - GENERATOR
2 - IDLER PULLEY
3 - A/C COMPRESSOR CLUTCH
4 - POWER STEERING PUMP PULLEY
5 - POWER STEERING BELT
6 - CRANKSHAFT DAMPER/PULLEY
7 - BELT TENSIONER
8 - ACCESSORY DRIVE BELT
Fig. 9 LOCKING/UNLOCKING BELT TENSIONER
Fig. 10 POWER STEERING BELT INSTALLATION
1 - POWER STEERING BELT
2 - HOLDING HOOK
3 - POWER STEERING PUMP PULLEY
4 - VIBRATION DAMPER
5 - POWER STEERING BELT INSTALLATION TOOL
RGACCESSORY DRIVE7a-13
DRIVE BELTS (Continued)
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(5) Continue filling coolant recovery pressure con-
tainer until level reaches the full line.
(6) Without installing the pressure/vent cap, start
and run engine at idle for a couple minutes.
(7) Recheck coolant level and fill as necessary.
(8) Install pressure/vent cap and drive vehicle for
approx. 10 km to reach normal operating tempera-
tures.
(9) Allow vehicle to cool. Check and fill coolant as
needed.
STANDARD PROCEDURE - COOLING SYSTEM
DRAINING
WARNING: DO NOT REMOVE OR LOOSEN THE
COOLANT PRESSURE/VENT CAP, CYLINDER
BLOCK DRAIN PLUGS, OR THE DRAINCOCK WHEN
THE SYSTEM IS HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM THE COOLANT
CAN OCCUR.(1)Without removing pressure/vent cap and
with system not under pressure, open the drain-
cock. The draincock is located on the lower right side
of radiator (Fig. 3).
(2) After the coolant recovery pressure container is
empty, then remove coolant pressure/vent cap.
COOLANT RECOVERY PRESS
CONTAINER
DESCRIPTION
The coolant recovery pressure container is
mounted in the engine compartment next to the bat-
tery. The coolant recovery pressure container is made
of plastic (Fig. 4).
OPERATION
The coolant recovery pressure container works
with the pressure/vent cap to use thermal expansion
and contraction of the coolant to keep the coolant
free of trapped air. Provides a convenient and safe
method for checking coolant level and adjusting level
at atmospheric pressure without removing the pres-
sure/vent cap. It also provides some reserve coolant
to cover deaeration, evaporation, or boiling losses.
Fig. 2 COOLANT RECOVERY PRESSURE
CONTAINER LOCATION
1 - PRESSURE/VENT CAP
2 - BRAKE MASTER CYLINDER
3 - BATTERY
4 - BATTERY SHIELD
5 - COOLANT RECOVERY PRESSURE CONTAINER RETAING
CLIP
6 - ENGINE COVER
7 - COOLANT RECOVERY PRESSURE CONTAINER
Fig. 3 DRAINCOCK LOCATION
1 - RADIATOR
2 - DRAINCOCK
3 - LOWER RADIATOR SUPPORT
4 - ELECTRIC COOLING FAN
RGENGINE7a-17
COOLANT (Continued)
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ENGINE COOLANT TEMP
SENSOR
DESCRIPTION
The engine coolant temperature sensor threads
into a coolant passage in the cylinder head (Fig. 7).
New sensors have sealant applied to the threads.
OPERATION
The coolant temperature (ECT) sensor is a nega-
tive temperature coefficient (NTC) thermistor (resis-
tance varies inversley with temperature). This means
at cold tempertures its resistance is high so the volt-
age signal will be high. As coolant temperture
increases, resistance decreases and the signal voltage
will be low. This allows the sensor to provide an ana-
log voltage signal to the ECM.
REMOVAL
WARNING: DO NOT REMOVE OR LOOSEN THE
COOLANT PRESSURE/VENT CAP, CYLINDER
BLOCK DRAIN PLUGS, OR THE DRAINCOCK WHEN
THE SYSTEM IS HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM THE COOLANT
CAN OCCUR.(1) Drain the cooling system. (Refer to 7 - COOL-
ING/ENGINE/COOLANT - STANDARD PROCE-
DURE)
(2) Disconnect coolant temperature sensor electri-
cal connector (Fig. 8).
(3) Remove coolant temperature sensor from cylin-
der head (Fig. 8).
INSTALLATION
(1) Install coolant temperature sensor in cylinder
head (Fig. 8).
(2) Connect coolant temperature sensor electrical
connector (Fig. 8).
(3) Refill the cooling system. (Refer to 7 - COOL-
ING/ENGINE/COOLANT - STANDARD PROCE-
DURE)
(4) Connect the negative battery cable.
Fig. 6 COOLANT RECOVERY PRESSURE
CONTAINER
1 - COOLANT RECOVERY PRESSURE CONTAINER
2 - COOLANT BYPASS HOSE
3 - OUTLET HOSE
4 - PRESSURE/VENT CAP
Fig. 7 COOLANT TEMPERATURE SENSOR
LOCATION
1 - EGR SOLENOID
2 - UPPER RADIATOR HOSE
3 - COOLANT TEMPERATURE SENSOR
4 - INTAKE MANIFOLD INLET
5 - INTAKE MANIFOLD/CYLINDER HEAD COVER
RGENGINE7a-19
COOLANT RECOVERY PRESS CONTAINER (Continued)
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