2002 CHRYSLER CARAVAN wheel

RELEASE SYSTEM
All models utilize a hydraulic clutch release sys-
tem, conisting of a clutch master cylinder attached to
the clutch pedal (Fig. 3), and a slave cylinder fas-
tened to the transaxle which operates the clutch
release lever (Fig. 4). When the driver depresses the
clutch pedal, the master cylinder pushrod travels
through the cylinder bore, displacing fluid through
the master cylinder plumbing. This fluid displace-
ment forces the slave cylinder piston to travel, forc-
ing the clutch release bearing into the clutch
diaphragm spring via the release lever and leverage
(Fig. 5). This releases the clamping force on the
clutch disc, allowing the engine crankshaft to rotate
independently from the transaxle input shaft.
Fig. 2 Clutch Disc and Pressure PlateÐ2.5L TD Engines
1 - FLYWHEEL
2 - DISC3 - PRESSURE PLATE
Fig. 3 Clutch Master CylinderÐTypical
6 - 2 CLUTCHRS
CLUTCH (Continued)
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SERVICE DIAGNOSIS - IMPROPER CLUTCH RELEASE
CONDITION POSSIBLE CAUSES CORRECTION
CLUTCH DISC BINDS ON
INPUT SHAFT SPLINESClutch disc hub splines damaged
during installationClean, smooth, and lubricate disc and shaft
splines. Replace modular clutch assembly,
or clutch disc, and/or input shaft if splines
are severely damaged.
Input shaft splines rough, damaged. Clean input shaft splines. Then lube.
Corrosion or rust formations on
splines of input shaft and discClean input shaft splines and disc splines,
then lube
CLUTCH DISC RUSTED
TO FLYWHEEL AND/OR
PRESSURE PLATEOccurs in vehicles stored or not
driven for extended period of time.
Also occurs after steam cleaning if
vehicle is not used for extended
period.Replace modular clutch assembly (2.4L
Gas) or clutch cover and disc (2.5L TD).
CLUTCH WILL NOT
DISENGAGE PROPERLYDisc bent, distorted during transaxle
installationReplace modular clutch assembly (2.4L
Gas) or clutch cover and disc (2.5L TD).
Clutch cover diaphragm spring
damaged during transaxle installationReplace modular clutch assembly (2.4L
Gas) or clutch cover and disc (2.5L TD).
Release fork bent, loose, or
damagedReplace fork if worn or damaged
Air in clutch hydraulic circuit. Allow system to self-bleed or replace
hydraulic components.
Leak in clutch hydraulic circuit. Replace worn/damaged/leaking hydraulic
components.
Clutch pedal requires
excessive force (high
release load).Clutch disc is worn. Replace modular clutch assembly (2.4L
models) or clutch cover and disc (2.5L TD
models).
SERVICE DIAGNOSIS - CLUTCH PEDAL NOISE
CONDITION POSSIBLE CAUSES CORRECTION
CLUTCH PEDAL
SQUEAKS WHEN
DEPRESSED TO FLOORPedal bushings worn out or
inadequate lubricationReplace or lubricate bushings at clutch
pedal pivot or master cylinder pushrod.
Clutch pedal return spring worn out Lubricate or replace return spring
CLUTCH PEDAL
SQUEAKS DURING
OPERATIONClutch release lever pivot stud has
inadequate lubricationLubricate or replace clutch release lever
DIAGNOSIS AND TESTING - DRIVE PLATE
MISALIGNMENT
Common causes of misalignment are:
²Heat warping
²Mounting drive plate on a dirty crankshaft
flange
²Incorrect bolt tightening
²Improper seating on the crankshaft shoulder²Loose crankshaft bolts
Clean the crankshaft flange before mounting the
drive plate. Dirt and grease on the flange surface
may misalign the flywheel, causing excessive runout.
Use new bolts when mounting drive plate to crank-
shaft. Tighten drive plate bolts to specified torque
only. Over-tightening can distort the drive plate hub
causing excessive runout.
RSCLUTCH6-5
CLUTCH (Continued)
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CLUTCH DISC AND PRESSURE
PLATE - 2.5L TD
REMOVAL
(1) Remove transaxle assembly. (Refer to 21 -
TRANSMISSION/TRANSAXLE/MANUAL -
REMOVAL)
(2) Remove six (6) clutch pressure plate-to-fly-
wheel bolts. Remove pressure plate and disc from fly-
wheel (Fig. 21).
(3) Inspect flywheel. Resurface/replace as neces-
sary.
(4) Inspect clutch release bearing and lever.
Replace as necessary. (Refer to 6 - CLUTCH/
CLUTCH RELEASE BEARING - REMOVAL)
INSTALLATION
(1) Install clutch release bearing and lever (if
removed). (Refer to 6 - CLUTCH/CLUTCH RELEASE
BEARING - INSTALLATION)
(2) Install clutch disc and pressure plate to fly-
wheel (Fig. 21). Install clutch alignment tool, and
install and torque pressure plate-to-flywheel bolts to
28 N´m (250 in. lbs.).
(3) Install transaxle assembly. (Refer to 21 -
TRANSMISSION/TRANSAXLE/MANUAL - INSTAL-
LATION)
Fig. 21 Clutch Disc and Pressure Plate
1 - FLYWHEEL
2 - DISC3 - PRESSURE PLATE
6 - 12 CLUTCHRS
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FLYWHEEL
REMOVAL
(1) Remove transaxle assembly. (Refer to 21 -
TRANSMISSION/TRANSAXLE/MANUAL -
REMOVAL)
(2) Remove clutch pressure plate and disc. (Refer
to 6 - CLUTCH/CLUTCH DISC - REMOVAL)
(3) Remove flywheel assembly (Fig. 22).
INSTALLATION
(1) Install NEW flywheel-to-crankshaft bolts by
hand.
(2) Torque bolts in a criss-cross sequence to 25
N´m (18 ft. lbs.) (Fig. 22).
(3) Torque bolts in a criss-cross sequence an addi-
tional 60É.
(4) Install clutch pressure plate and disc. (Refer to
6 - CLUTCH/CLUTCH DISC - INSTALLATION)
(5) Install transaxle assembly. (Refer to 21 -
TRANSMISSION/TRANSAXLE/MANUAL -
INSTALLATION)
Fig. 22 Flywheel Bolt Torque Sequence
RSCLUTCH6-13
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information and location views for the various wire
harness connectors, splices and grounds.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO ELECTRICAL, RESTRAINTS
BEFORE ATTEMPTING ANY STEERING WHEEL,STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
AUDIO SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSE CORRECTION
NO AUDIO. 1. FUSE FAULTY. 1. CHECK RADIO FUSES IN FUSE BLOCK MODULE.
REPLACE FUSES, IF REQUIRED.
2. RADIO CONNECTOR
FAULTY.2. CHECK FOR LOOSE OR CORRODED RADIO CONNECTOR.
REPAIR, IF REQUIRED.
3. WIRING FAULTY. 3. CHECK FOR BATTERY VOLTAGE AT RADIO CONNECTOR.
REPAIR WIRING, IF REQUIRED.
4. GROUND FAULTY. 4. CHECK FOR CONTINUITY BETWEEN RADIO CHASSIS AND
A KNOWN GOOD GROUND. THERE SHOULD BE
CONTINUITY. REPAIR GROUND, IF REQUIRED.
5. RADIO FAULTY. 5. EXCHANGE OR REPLACE RADIO, IF REQUIRED.
6. SPEAKERS FAULTY. 6. SEE SPEAKER DIAGNOSIS, IN THIS GROUP.
NO DISPLAY. 1. FUSE FAULTY. 1. CHECK RADIO FUSES IN FUSE BLOCK MODULE.
REPLACE FUSES, IF REQUIRED.
2. RADIO CONNECTOR
FAULTY.2. CHECK FOR LOOSE OR CORRODED RADIO CONNECTOR.
REPAIR, IF REQUIRED.
3. WIRING FAULTY. 3. CHECK FOR BATTERY VOLTAGE AT RADIO CONNECTOR.
REPAIR WIRING, IF REQUIRED.
4. GROUND FAULTY. 4. CHECK FOR CONTINUITY BETWEEN RADIO CHASSIS AND
A KNOWN GOOD GROUND. THERE SHOULD BE
CONTINUITY. REPAIR GROUND, IF REQUIRED.
5. RADIO FAULTY. 5. EXCHANGE OR REPLACE RADIO, IF REQUIRED.
NO MEMORY. 1. FUSE FAULTY. 1. CHECK IGNITION-OFF DRAW FUSE. REPLACE FUSE, IF
REQUIRED.
2. RADIO CONNECTOR
FAULTY.2. CHECK FOR LOOSE OR CORRODED RADIO CONNECTOR.
REPAIR, IF REQUIRED.
3. WIRING FAULTY. 3. CHECK FOR BATTERY VOLTAGE AT RADIO CONNECTOR.
REPAIR WIRING, IF REQUIRED.
4. GROUND FAULTY. 4. CHECK FOR CONTINUITY BETWEEN RADIO CHASSIS AND
A KNOWN GOOD GROUND. THERE SHOULD BE
CONTINUITY. REPAIR GROUND, IF REQUIRED.
5. RADIO FAULTY. 5. EXCHANGE OR REPLACE RADIO, IF REQUIRED.
POOR RADIO
RECEPTION.1. ANTENNA FAULTY. 1. SEE ANTENNA DIAGNOSIS, IN THIS GROUP. REPAIR OR
REPLACE ANTENNA, IF REQUIRED.
8A - 2 AUDIORS
AUDIO (Continued)
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ANTENNA BODY AND CABLE
DESCRIPTION
All models use a fixed-length stainless steel rod-
type antenna mast, installed at the right front fender
of the vehicle. The antenna mast is connected to the
center wire of the coaxial antenna cable, and is not
grounded to any part of the vehicle.
OPERATION
To minimize static, the antenna base must have a
good ground. The coaxial antenna cable shield (the
outer wire mesh of the cable) is grounded to the
antenna base and the radio chassis.
The antenna coaxial cable has an additional dis-
connect, located near the right end of the instrument
panel. This additional disconnect allows the instru-
ment panel assembly to be removed and installed
without removing the radio.
The factory-installed Electronically Tuned Radios
(ETRs) automatically compensate for radio antenna
trim. Therefore, no antenna trimmer adjustment is
required or possible when replacing the receiver or
the antenna.
DIAGNOSIS AND TESTING - ANTENNA BODY
AND CABLE
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO ELECTRICAL, RESTRAINTS
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
The ohmmeter test lead connections for each test
are shown in (Fig. 1).
TEST 1
Test 1 determines of the antenna mast is insulated
from the base. Proceed as follows:
(1) Unplug the antenna coaxial cable from the
radio chassis and isolate. Remove the antenna mast.
(2) Connect an ohmmeter test lead to the inside
center of the antenna base. Connect the other test
lead to a metallic portion on the outside of the
antenna base. Check for continuity.
(3) There should be no continuity. If continuity is
found, replace the faulty or damaged antenna base
and cable assembly.
TEST 2
Test 2 checks the antenna for an open circuit as
follows:(1) Unplug the antenna coaxial cable connector
from the radio chassis. Remove the antenna mast.
The painted mast prevents measurement directly
through the mast.
(2) Connect an ohmmeter test lead to the inside
center of the antenna base. Connect the other test
lead to the center pin of the antenna coaxial cable
connector.
(3) Continuity should exist (the ohmmeter should
only register a fraction of an ohm). High or infinite
resistance indicates damage to the base and cable
assembly. Replace the faulty base and cable if
required.
TEST 3
Test 3 checks the condition of the ground between
the antenna base and the vehicle body as follows:
(1) Connect one ohmmeter test lead to the fender
on an exposed metal area (paint and e-coat must be
penetrated to obtain continuity). Connect the other
test lead to the outer crimp on the antenna coaxial
cable connector.
(2) The resistance should be less than (1) ohm.
(3) If the resistance is more than (1) ohm, clean
and/or tighten the antenna base to the fender mount-
ing hardware.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove glove box from instrument panel,
(Refer to 23 - BODY/INSTRUMENT PANEL/GLOVE
BOX - REMOVAL).
Fig. 1 Antenna Test Points
8A - 4 AUDIORS
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(3) Disconnect antenna cable connector from exten-
sion cable (Fig. 2).
(4) Remove right kick trim panel.
(5) Disengage rubber grommet insulator from door
hinge pillar.
(6) Pull antenna cable through hinge pillar into
opening between door hinges.
(7) Hoist and support vehicle on safety stands.
(8) Remove front wheel.
(9) Remove front wheelhouse splash shield. (Refer
to 23 - BODY/EXTERIOR/LF WHEELHOUSE
SPLASH SHIELD - REMOVAL).
(10) Remove antenna mast from antenna base
(Fig. 3).
(11) Remove plastic cap from the cap nut. Using
cap nut tool, remove cap nut holding antenna base to
front fender (Fig. 4).
(12) Remove antenna base from under front
fender.
INSTALLATION
(1) Install antenna base to underside of front
fender.
(2) Install cap nut holding antenna base to front
fender.
(3) Install plastic cap to the cap nut.
(4) Install antenna mast to antenna base.
(5) Install front wheelhouse splash shield.(6) Install front wheel.
(7) Lower vehicle.
(8) Push antenna cable through opening in hinge
pillar.
(9) Insert rubber grommet into door hinge pillar.
(10) Install kick panel.
Fig. 2 Antenna Cable
1 - CAP NUT
2 - ADAPTER
3 - FENDER
4 - CABLE TO RADIO (EXTENSION CABLE)
5 - A-PILLAR6 - RUBBER GROMMET
7 - ANTENNA CABLE AND BODY ASSEMBLY
8 - RUBBER GROMMET
Fig. 3 Antenna Mast
1 - ANTENNA MAST
2 - ADAPTER
3 - CAP NUT
RSAUDIO8A-5
ANTENNA BODY AND CABLE (Continued)
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NOTE: Use care when inserting CD changer so that
cable is not pinched or trapped against instrument
panel.
(3) Install screws holding CD changer.
(4) Reconnect the battery negative cable.
INSTRUMENT PANEL
ANTENNA CABLE
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO ELECTRICAL, RESTRAINTS
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove glove box (Refer to 23 - BODY/IN-
STRUMENT PANEL/GLOVE BOX - REMOVAL).
(3) Disconnect extension cable end from antenna
cable end.
(4) Disconnect cable hanger clip from HVAC unit.
(5) Remove radio as necessary to gain access to
extension cable (Refer to 8 - ELECTRICAL/AUDIO/
RADIO - REMOVAL).
(6) Disconnect extension cable from back of radio.
(7) Remove extension cable from vehicle.
INSTALLATION
(1) Install extension cable to vehicle.
(2) Connect extension cable to back of radio.
(3) Install radio (Refer to 8 - ELECTRICAL/AU-
DIO/RADIO - INSTALLATION).
(4) Connect cable hanger clip to HVAC unit.
(5) Connect extension cable end to antenna cable
end.
(6) Install glove box (Refer to 23 - BODY/INSTRU-
MENT PANEL/GLOVE BOX - INSTALLATION).
(7) Connect the battery negative cable.
QUARTER GLASS INTEGRAL
ANTENNA - EXPORT
DESCRIPTION
The quarter glass integral antenna element is
bonded to the right rear quarter glass and is replaced
with the glass assembly only (Fig. 7).
OPERATION
The integral antenna receives RF (Radio Frequen-
cies) and sends them to the antenna module for
amplification.
DIAGNOSIS AND TESTING - QUARTER GLASS
INTEGRAL ANTENNA - EXPORT
The antenna grid pattern is divided into two sepa-
rate patterns. Each terminal connects to a separate
grid pattern, one for AM and the other for FM.
For circuit descriptions and diagrams, refer to the
appropriate wiring information. The wiring informa-
tion includes wiring diagrams, proper wire and con-
nector repair procedures, details of wire harness
routing and retention, connector pin-out information
and location views for the various wire harness con-
nectors, splices and grounds. To detect breaks in the
integral antenna elements, the following procedure is
required:
(1) Disconnect the antenna module connector from
the antenna terminals on the glass.
(2) Using an ohmmeter, place a lead on one of the
terminals and check each end of the grid pattern con-
nected to this terminal for continuity. If continuity is
not present, move one lead through the grid in pro-
gression starting at the terminal with the other lead
on the terminal until continuity is lost. Repeat pro-
cedure for the other terminal. A break in the antenna
grid can be repaired using a Mopar Rear Window
Defogger Repair Kit (Part Number 4267922) or
equivalent. (Refer to 8 - ELECTRICAL/HEATED
GLASS/WINDSHIELD GRID - STANDARD PROCE-
DURE).
Fig. 7 QUARTER GLASS INTEGRAL ANTENNA
1 - REAR QUARTER GLASS
2 - ANTENNA
8A - 8 AUDIORS
CD CHANGER (Continued)
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