2002 CHRYSLER CARAVAN warning

WARNING: THE AIR BAG SYSTEM IS A SENSITIVE,
COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL
THE AIR BAG SYSTEM COMPONENTS YOU MUST
FIRST DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE. THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE. FAILURE TO DO SO COULD RESULT IN
ACCIDENTAL DEPLOYMENT OF THE AIR BAG AND
POSSIBLE PERSONAL INJURY. THE FASTENERS,
SCREWS, AND BOLTS, ORIGINALLY USED FOR
THE AIR BAG COMPONENTS, HAVE SPECIAL
COATINGS AND ARE SPECIFICALLY DESIGNED
FOR THE AIR BAG SYSTEM. THEY MUST NEVER
BE REPLACED WITH ANY SUBSTITUTES. ANYTIME
A NEW FASTENER IS NEEDED, REPLACE WITH
THE CORRECT FASTENERS PROVIDED IN THE
SERVICE PACKAGE OR FASTENERS LISTED IN
THE PARTS BOOKS.
WARNING: SAFETY GOGGLES SHOULD BE WORN
AT ALL TIMES WHEN WORKING ON STEERING
COLUMNS.
CAUTION: Disconnect negative (ground) cable from
the battery before servicing any column compo-
nent.
CAUTION: Do not attempt to remove the pivot pins
to disassemble the tilting mechanism. Damage will
occur.
DIAGNOSIS AND TESTING - STEERING
COLUMN
For diagnosis of conditions relating to the steering
column (Refer to 19 - STEERING - DIAGNOSIS ANDTESTING) and (Refer to 19 - STEERING - DIAGNO-
SIS AND TESTING).
REMOVAL
NOTE: Before proceeding, (Refer to 19 - STEERING/
COLUMN - WARNING).
(1) Make sure the front wheels of the vehicle are
in the STRAIGHT AHEAD position before beginning
the column removal procedure.
(2) Disconnect negative (ground) cable from the
battery and isolate cable from battery terminal.
(3) Remove the lower shroud (Refer to 19 -
STEERING/COLUMN/LOWER SHROUD - REMOV-
AL).
(4) Remove the traction off switch.
(5) Remove the upper shroud.
(6) Remove the cluster trim bezel (Refer to 23 -
BODY/INSTRUMENT PANEL/CLUSTER BEZEL -
REMOVAL).
(7) Remove the knee blocker (Refer to 23 - BODY/
INSTRUMENT PANEL/STEERING COLUMN
OPENING COVER - REMOVAL).
(8) Remove the parking brake handle link.
(9) Remove the knee blocker reinforcement (Refer
to 23 - BODY/INSTRUMENT PANEL/KNEE
BLOCKER - REMOVAL).
(10) Remove the airbag (Refer to 8 - ELECTRI-
CAL/RESTRAINTS/DRIVER AIRBAG - REMOVAL).
(11) Remove the steering wheel retaining nut.
(12) Remove the vibration damper weight.
(13) Remove the steering wheel (Refer to 19 -
STEERING/COLUMN/STEERING WHEEL -
REMOVAL). (Fig. 3)
(14) Disconnect the wiring harness connectors
from the clockspring, multi-function switch, halo
lamp, SKIM module, ignition switch and BTSI sole-
noid.
1 - CLOCKSPRING WIRING
2 - STEERING WHEEL
3 - UPPER SHROUD
4 - FIXED SHROUD
5 - SCREW
6 - STEERING COLUMN MOUNTING PLATE
7 - NUT
8 - DASH PANEL STEERING COLUMN MOUNTING BRACKET
9 - STUDS (4)
10 - STEERING COLUMN LOCKING PIN
11 - NUT/WASHER ASSEMBLY
12 - STEERING COLUMN ASSEMBLY
13 - LOWER SHROUD
14 - SCREWS
15 - STEERING WHEEL RETAINING NUT16 - STEERING WHEEL DAMPER
17 - CLOCKSPRING
18 - SCREW
19 - MULTI-FUNCTION SWITCH
20 - PINCH BOLT
21 - STEERING COLUMN COUPLER
22 - PINCH BOLT RETAINING PIN
23 - DASH PANEL
24 - SILENCER SHELL
25 - INTERMEDIATE SHAFT SHIELD AND SEAL
26 - INTERMEDIATE SHAFT
27 - ROLL PIN
28 - POWER STEERING GEAR
29 - FRONT SUSPENSION CRADLE/CROSSMEMBER
19 - 12 COLUMNRS
COLUMN (Continued)
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(3) Carefully install the ignition switch. The
switch will snap over the retaining tabs (Fig. 16) .
Install mounting screw (Fig. 12).
(4) Install upper and lower shrouds.
(5) Install key cylinder (cylinder retaining tab will
depress only in the RUN position).
(6) Connect negative cable to battery.(7) Check for proper operation of ignition switch
and key-in warning switch.
LOCK CYLINDER HOUSING
DESCRIPTION - IGNITION INTERLOCK
All vehicles equipped with automatic transaxles
have an interlock system. The system prevents shift-
ing the vehicle out of Park unless the ignition lock
cylinder is in the Unlock, Run or Start position. In
addition, the operator cannot rotate the key to the
lock position unless the shifter is in the park posi-
tion. On vehicles equipped with floor shift refer to
the - Transaxle for Automatic Transmission Shifter/
Ignition Interlock.
REMOVAL
(1) Disconnect negative (ground) cable from the
battery and isolate cable from battery terminal.
(2) Remove the screws attaching the lower steer-
ing column cover to the instrument panel (Fig. 17),
then remove the cover from the lower instrument
panel.
Fig. 15 Ignition Switch Connectors
1 - KEY IN SWITCH
2 - PRNDL SWITCH
3 - IGNITION SWITCH
Fig. 16 Ignition Switch Installation
1 - IGNITION SWITCH
2 - ACTUATOR SHAFT
3 - RETAINING TABS
Fig. 17 Lower Steering Column Cover Attachment
1 - PARK BRAKE RELEASE HANDLE
2 - STEERING COLUMN COVER
3 - STEERING COLUMN
4 - ATTACHING CLIP
5 - ATTACHING SCREWS
6 - HOOD RELEASE LEVER
7 - ATTACHING SCREWS
RSCOLUMN19-17
IGNITION SWITCH (Continued)
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(10) Install the cluster trim bezel (Refer to 23 -
BODY/INSTRUMENT PANEL/CLUSTER BEZEL -
INSTALLATION).
(11) Install the upper and lower shrouds (Refer to
19 - STEERING/COLUMN/LOWER SHROUD -
INSTALLATION).
(12) Install the knee blocker reinforcement (Refer
to 23 - BODY/INSTRUMENT PANEL/KNEE
BLOCKER - INSTALLATION).
(13) Install the knee blocker (Refer to 23 - BODY/
INSTRUMENT PANEL/STEERING COLUMN
OPENING COVER - INSTALLATION).
SHROUD
REMOVAL
(1) Remove the three screws from the lower
shroud.
(2) Unsnap and remove the lower shroud.
(3) Lift off upper shroud from the steering column.
(Fig. 35)
INSTALLATION
(1) Install the upper shroud in place over the
steering column.
(2) Snap the lower shroud to the upper shroud.
(3) Install and tighten the three retaining screws.
Tighten the screws to 11 N´m (100 in. lbs.). (Fig. 35)
STEERING WHEEL
REMOVAL
NOTE: Before proceeding, (Refer to 19 - STEERING/
COLUMN - WARNING).(1) Rotate key cylinder to the lock position and
remove key. Rotate the steering wheel a half turn to
the left until the steering column lock engages keep-
ing the steering column in the locked position (Fig.
36).
(2) Remove the 3 bolts (one in each spoke of the
steering wheel) attaching the airbag module to the
steering wheel. Lift the airbag module from the
steering wheel.
(3) Disconnect wiring connectors from the airbag,
horn switch wire, and speed control switches (Fig.
37). Remove the wiring harness routing clip from the
airbag module studs.
Fig. 34 SHIFT LEVERFig. 35 UPPER AND LOWER SHROUDS
1 - FIXED SHROUD
2 - UPPER SHROUD
3 - CLOCKSPRING
4 - LOWER SHROUD
5 - STEERING COLUMN
Fig. 36 Steering Wheel In Locked Position
1 - STEERING WHEEL
RSCOLUMN19-23
GEAR SHIFT LEVER (Continued)
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GEAR
TABLE OF CONTENTS
page page
GEAR
DESCRIPTION.........................26
OPERATION...........................26
WARNING
WARNINGS AND CAUTIONS.............26
REMOVAL
REMOVAL - LHD GEAR.................26
REMOVAL - RHD GEAR................29INSTALLATION
INSTALLATION - LHD GEAR.............32
INSTALLATION - RHD GEAR.............33
SPECIAL TOOLS
POWER STEERING GEAR..............34
OUTER TIE ROD
REMOVAL.............................34
INSTALLATION.........................34
GEAR
DESCRIPTION
This vehicle is equipped with a rack and pinion
power steering gear (Fig. 1). It is mounted to the
underside of the front suspension cradle/crossmem-
ber.
The steering column is attached to the gear
through the use of an intermediate shaft and cou-
plers. The outer ends of the power steering gear's
outer tie rods connect to the steering knuckles.
NOTE: The power steering gear should NOT be ser-
viced or adjusted unless DaimlerChrysler Corpora-
tion authorizes. If a malfunction or oil leak occurs,
the complete steering gear should be replaced.
Only the outer tie rods may be replaced separately
from the rest of the gear.
OPERATION
Turning of the steering wheel is converted into lin-
ear (side-to-side) travel through the meshing of the
helical pinion teeth with the rack teeth in the steer-
ing gear. This travel pushes and pulls the tie rods to
change the direction of the vehicle's front wheels.
Power assist steering provided by the power steer-
ing pump is controlled by an open center, rotary type
control valve which directs oil from the pump to
either side of the integral rack piston upon demand.
Road feel is controlled by the diameter of a torsion
bar which initially steers the vehicle. As required
steering effort increases, as in a turn, the torsion bar
twists, causing relative rotary motion between the
rotary valve body and the valve spool. This move-
ment directs oil behind the integral rack piston
which, in turn, builds hydraulic pressure and assists
in the turning effort.Manual steering control of the vehicle can be main-
tained if power steering assist is lost. However,
under this condition, steering effort is significantly
increased.
WARNING
WARNINGS AND CAUTIONS
WARNING: POWER STEERING FLUID, ENGINE
PARTS AND EXHAUST SYSTEM MAY BE
EXTREMELY HOT IF ENGINE HAS BEEN RUNNING.
DO NOT START ENGINE WITH ANY LOOSE OR DIS-
CONNECTED HOSES. DO NOT ALLOW HOSES TO
TOUCH HOT EXHAUST MANIFOLD OR CATALYST.
WARNING: FLUID LEVEL SHOULD BE CHECKED
WITH THE ENGINE OFF TO PREVENT PERSONAL
INJURY FROM MOVING PARTS.
CAUTION: When the system is open, cap all open
ends of the hoses, power steering pump fittings or
power steering gear ports to prevent entry of for-
eign material into the components.
REMOVAL
REMOVAL - LHD GEAR
(1) Remove cap from power steering fluid reser-
voir.
(2) Using a siphon pump, remove as much fluid as
possible from the power steering fluid reservoir.Use
care not to damage the filter mesh below the
fluid surface.
19 - 26 GEARRS
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PUMP
TABLE OF CONTENTS
page page
PUMP
DESCRIPTION
DESCRIPTION - PUMP (2.4L/3.3L/3.8L
ENGINE)............................36
DESCRIPTION - PUMP (2.5L DIESEL)......37
OPERATION...........................37
WARNING.............................37
CAUTION.............................37
STANDARD PROCEDURE - POWER
STEERING PUMP INITIAL OPERATION.....37
REMOVAL
REMOVAL - PUMP (2.4L ENGINE).........38
REMOVAL - PUMP (3.3L/3.8L ENGINE).....40
REMOVAL - PUMP (2.5L DIESEL).........41
DISASSEMBLY - PUMP (PULLEY)..........41
ASSEMBLY - PUMP (PULLEY).............42
INSTALLATION
INSTALLATION - PUMP (2.4L ENGINE).....43
INSTALLATION - PUMP (3.3L/3.8L ENGINE) . 43
INSTALLATION - PUMP (2.5L DIESEL)......43
SPECIAL TOOLS
POWER STEERING PUMP..............44
FLUID
STANDARD PROCEDURE - POWER
STEERING FLUID LEVEL CHECKING......44
FLUID COOLER
DESCRIPTION.........................45
OPERATION...........................45
REMOVAL.............................45
INSTALLATION.........................45
HOSE - POWER STEERING PRESSURE
REMOVAL
REMOVAL - 2.4L ENGINE...............45REMOVAL - 3.3L/3.8L ENGINE...........46
INSTALLATION
INSTALLATION - 2.4L ENGINE...........46
INSTALLATION - 3.3L/3.8L ENGINE........47
HOSE - POWER STEERING RETURN
REMOVAL
REMOVAL - 2.4L ENGINE...............49
REMOVAL - 3.3L/3.8L ENGINE...........49
INSTALLATION
INSTALLATION - 2.4L ENGINE...........50
INSTALLATION - 3.3L/3.8L ENGINE........50
HOSE - POWER STEERING SUPPLY
REMOVAL
REMOVAL - 2.4L ENGINE...............51
REMOVAL - 3.3L/3.8L ENGINE...........51
INSTALLATION
INSTALLATION - 2.4L ENGINE...........51
INSTALLATION - 3.3L/3.8L ENGINE........51
RESERVOIR - POWER STEERING FLUID
DESCRIPTION
DESCRIPTION - 2.4L/3.3L/3.8L ENGINE....51
DESCRIPTION - 2.5L DIESEL............52
OPERATION...........................52
REMOVAL
REMOVAL - 2.4L ENGINE...............52
REMOVAL - 3.3L/3.8L ENGINE...........52
REMOVAL - 2.5L DIESEL................52
INSTALLATION
INSTALLATION - 2.4L ENGINE...........53
INSTALLATION - 3.3L/3.8L ENGINE........53
INSTALLATION - 2.5L DIESEL............53
PUMP
DESCRIPTION
DESCRIPTION - PUMP (2.4L/3.3L/3.8L
ENGINE)
Hydraulic pressure for the operation of the power
steering gear is provided by a belt driven power
steering pump. The power steering pump is mounted
on the back side of the engine on all engine applica-
tions. The pumps are different depending on the
engine option. The pump for the 2.4L engine is madeout of cast iron and steel (Fig. 1). The pump used on
the 3.3L/3.8L engine is made of aluminum (Fig. 2).
The pump for the 3.3L/3.8L engine does not have a
return fitting as the pump for the 2.4L engine does.
The power steering return hose on the 3.3L/3.8L
engine goes to the reservoir instead of the pump.
19 - 36 PUMPRS
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DESCRIPTION - PUMP (2.5L DIESEL)
Hydraulic pressure for the operation of the power
steering gear is provided by a belt driven power
steering pump. The power steering pump is mounted
front lower right corner of the engine (Fig. 13).
The pump has a supply fitting for fluid coming
from the reservoir and a pressure port for exiting
fluid that is headed for the steering gear.
OPERATION
The power steering pump is a constant displace-
ment vane type pump. The 2.4L pump has an inte-
gral fluid reservoir and there is a secondary remote
non-flow reservoir which acts only as a fluid fill and
check point. The 3.3L/3.8L pump houses very little
fluid and is therefore supplied by a remote flow
through reservoir.
WARNING
WARNING: POWER STEERING FLUID, ENGINE
PARTS AND EXHAUST SYSTEM MAY BE
EXTREMELY HOT IF ENGINE HAS BEEN RUNNING.
DO NOT START ENGINE WITH ANY LOOSE OR DIS-
CONNECTED HOSES. DO NOT ALLOW HOSES TO
TOUCH HOT EXHAUST MANIFOLD OR CATALYST.
WARNING: FLUID LEVEL SHOULD BE CHECKED
WITH THE ENGINE OFF TO PREVENT PERSONAL
INJURY FROM MOVING PARTS.
CAUTION
CAUTION: When the system is open, cap all open
ends of the hoses, power steering pump fittings or
power steering gear ports to prevent entry of for-
eign material into the components.
STANDARD PROCEDURE - POWER STEERING
PUMP INITIAL OPERATION
WARNING: FLUID LEVEL SHOULD BE CHECKED
AND ADJUSTED WITH ENGINE OFF TO PREVENT
INJURY FROM MOVING ENGINE COMPONENTS.
CAUTION: Use only MoparTAutomatic Transmis-
sion Fluid (MS-9602) in power steering system. Use
of other MoparTpower steering fluids (MS5931 and
MS9933) should be avoided to ensure peak perfor-
mance of the power steering system under all oper-
ating conditions. Do not overfill.
Read the fluid level through the side of the power
steering fluid reservoir. The fluid level should indi-
cateªFILL RANGEºwhen the fluid is at a temper-
ature of approximately 21ÉC to 27ÉC (70ÉF to 80ÉF).
(1) Wipe the filler cap and area clean, then remove
the cap.
Fig. 1 POWER STEERING PUMP (2.4L)
1 - PULLEY
2 - BRACKET
3 - PRESSURE FITTING
4 - RETURN FITTING
5 - SUPPLY FITTING
Fig. 2 POWER STEERING PUMP (3.3L/3.8L)
1 - SUPPLY FITTING
2 - PRESSURE FITTING
3 - PULLEY
RSPUMP19-37
PUMP (Continued)
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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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