2002 CHRYSLER CARAVAN Service Manual

drain bolt airbag auxiliary battery power steering fluid wiring diagram key fob

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Page 1537 of 2399

CHRYSLER CARAVAN 2002 Service Manual (17) Lower the vehicle to a level were the interior
of vehicle is accessible (keeping tires off the ground).
(18) With the wheels pointed approximately
STRAIGHT-AHEAD, align the intermediate shaft
wit

Page 1538 of 2399

CHRYSLER CARAVAN 2002 Service Manual (1) Install outer tie rod onto inner tie rod.
(2) Do not tighten jam nut.(3) Install tie rod end into the steering knuckle.
Start tie rod end to steering knuckle attaching nut
onto stud of tie rod end

Page 1539 of 2399

CHRYSLER CARAVAN 2002 Service Manual 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...........................

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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Page 1540 of 2399

CHRYSLER CARAVAN 2002 Service Manual 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

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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Page 1541 of 2399

CHRYSLER CARAVAN 2002 Service Manual (2) Fill the fluid reservoir to the proper level and
let the fluid settle for at least two (2) minutes.
(3) Start the engine and let run for a few seconds,
then turn the engine off.
(4) Add fluid if n

(2) Fill the fluid reservoir to the proper level and
let the fluid settle for at least two (2) minutes.
(3) Start the engine and let run for a few seconds,
then turn the engine off.
(4) Add fluid if necessary. Repeat the above steps
until the fluid level remains constant after running
the engine.
(5) Raise the front wheels off the ground.
(6) Start the engine.
(7) Slowly turn the steering wheel right and left,
lightly contacting the wheel stops.
(8) Add fluid if necessary.
(9) Lower the vehicle, then turn the steering wheel
slowly from lock-to-lock.
(10) Stop the engine. Check the fluid level and
refill as required.
(11) If the fluid is extremely foamy, allow the vehi-
cle to stabilize a few minutes, then repeat the above
procedure.
REMOVAL
REMOVAL - PUMP (2.4L ENGINE)
(1) Remove the (-) negative battery cable from the
battery and isolate cable.
(2) Remove the cap from the power steering fluid
reservoir.
(3) Using a siphon pump, remove as much power
steering fluid as possible from the power steering
fluid reservoir.
(4) Raise the vehicle on jack stands or centered on
a frame contact type hoist. See Hoisting in Lubrica-
tion and Maintenance.
(5) Disconnect the oxygen sensor wiring harness
from the vehicle wiring harness at the rear engine
mount bracket.
NOTE: The exhaust system needs to be removed
from the engine to allow for an area to remove the
power steering pump from the vehicle.
(6) Remove the four bolts and flag nuts securing
the catalytic converter from the exhaust manifold
(Fig. 3).(7) Disconnect all the exhaust system isolators/
hangers from the brackets on the exhaust system (2
at the mufflers and 1 at the resonator) (Fig. 4).
(8) Remove the exhaust system by moving it as far
rearward, then lowering the front below the cross-
member and out of the vehicle.
(9) Remove the power steering fluid supply hose
from the fitting on the power steering pump. Drain
off excess power steering fluid from hose.
(10) Move the heat sleeve on the power steering
return hose to expose the hose connection at the
pump (Fig. 5). Remove the hose from the power
steering Pump. Allow the remaining power steering
fluid to drain from the power steering pump and res-
ervoir through the removed return hose.
(11) Remove the power steering fluid pressure line
from the power steering pump (Fig. 6). Drain excess
power steering fluid from tube.
(12) Remove the fasteners, then the accessory
drive splash shield.
Fig. 3 Catalytic Converter to Exhaust Manifold
1 - CATALYTIC CONVERTER
2 - BOLT
3 - GASKET
4 - FLAG NUT
19 - 38 PUMPRS
PUMP (Continued)
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Page 1542 of 2399

CHRYSLER CARAVAN 2002 Service Manual Fig. 4 Exhaust System - Typical (All Vehicles)
1 - CATALYTIC CONVERTER 4 - SUPPORT - RESONATOR
2 - BAND CLAMP 5 - RESONATOR
3 - SUPPORTS - MUFFLER 6 - MUFFLER
Fig. 5 Pressure And Return Hoses - 2.4L
1

Page 1543 of 2399

CHRYSLER CARAVAN 2002 Service Manual (13) Remove the adjuster nut attaching rear of
power steering pump to the cast mounting bracket.
(Fig. 7)
(14) Remove the front adjuster nut and the lower
pivot bolt (Fig. 8) attaching power steering

Page 1544 of 2399

CHRYSLER CARAVAN 2002 Service Manual (12) Remove the pump (with pulley) through the
engine compartment rocking it over the aluminum
bracket.
REMOVAL - PUMP (2.5L DIESEL)
(1) Remove the negative (-) battery cable from the
battery and isol

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