2002 CHRYSLER CARAVAN gas type

(11) Install wheel and tire.
(12) Tighten wheel stud nuts to 135 N´m (100 ft.
lbs.).
(13) Adjust drum brake shoes. (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/BRAKE
PADS/SHOES - ADJUSTMENTS)
(14) Remove brake pedal depressor tool.
(15) Bleed the brake system as necessary. (Refer to
5 - BRAKES - BASE - STANDARD PROCEDURE).
(16) Lower the vehicle.
WHEEL CYLINDERS
REMOVAL
(1) Using a brake pedal depressor, move and
secure brake pedal to a position past its first 1 inch
of travel. This will prevent brake fluid from draining
out of master cylinder when brake tube is remove
from wheel cylinder.
(2) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE).
(3) Remove wheel and tire assembly.
(4) Disconnect brake tube from rear of wheel cylin-
der. Cap open ends
(5) Remove brake drum.
(6) Remove brake shoes from brake support plate
(Discard if contaminated).(Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/BRAKE PADS/SHOES -
REMOVAL)
(7) Remove the 2 bolts attaching the wheel cylin-
der to the brake support plate.
(8) Remove the wheel cylinder from the brake sup-
port plate.
INSPECTION
With brake drums removed, inspect the wheel cyl-
inder boots for evidence of a brake fluid leak. Visu-
ally check the boots for cuts, tears, or heat cracks. If
any of these conditions exist, the wheel cylinders
should be completely cleaned, inspected and new
parts installed.
If a wheel cylinder is leaking and the brake lining
material is saturated with brake fluid, the brake
shoes must be replaced.
INSTALLATION
(1) Apply sealant such as Mopar Gasket-In-A-Tube
or equivalent around the wheel cylinder opening in
the brake support plate.
(2) Install wheel cylinder onto brake support.
Install and tighten the wheel cylinder to brake sup-
port plate attaching bolts to 8 N´m (75 in. lbs.)
torque.(3) Install brake tube into wheel cylinder. Tighten
tube nut to a torque of 17 N´m (145 in. lbs.) torque.
(4) Install the rear brake shoes on the brake sup-
port plate. (Refer to 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/BRAKE PADS/SHOES -
INSTALLATION).
(5) Install brake drum.
(6) Install wheel and tire. Install and tighten
wheel lug nuts to 135 N´m (100 ft. lbs.).
(7) Adjust drum brake shoes. (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/BRAKE
PADS/SHOES - ADJUSTMENTS)
(8) Remove brake pedal depressor tool.
(9) Bleed the brake system as necessary. (Refer to
5 - BRAKES - BASE - STANDARD PROCEDURE).
(10) Lower vehicle.
PARKING BRAKE
DESCRIPTION
DESCRIPTION
The parking brake system is operated by a foot
operated parking brake lever. The parking brake
lever is mounted on the body of the vehicle to the left
of the brake pedal (Fig. 105). It is a automatic-ad-
justing type lever.
Fig. 105 Parking Brake Lever (Pedal)
1 - PARK BRAKE PEDAL ASSEMBLY
2 - PARK BRAKE PEDAL
3 - CARPET
4 - FRONT PARK BRAKE CABLE
5 - SEAL
6 - FLOOR PAN
RSBRAKES - BASE5-65
SUPPORT PLATE - DRUM BRAKE (Continued)
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CLUTCH
TABLE OF CONTENTS
page page
CLUTCH
DESCRIPTION..........................1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - CLUTCH
SYSTEM.............................3
DIAGNOSIS AND TESTING - DRIVE PLATE
MISALIGNMENT.......................5
DIAGNOSIS AND TESTING - CLUTCH
COVER AND DISC RUNOUT..............6
DIAGNOSIS AND TESTING - CLUTCH
CHATTER COMPLAINTS.................6
SPECIAL TOOLS - T850 TRANSAXLE........6
CLUTCH RELEASE LEVER AND BEARING
REMOVAL.............................6
INSTALLATION..........................7
MASTER CYLINDER - RHD
REMOVAL.............................8INSTALLATION..........................8
MASTER CYLINDER - LHD
REMOVAL.............................9
INSTALLATION.........................10
MODULAR CLUTCH ASSY - 2.4L GAS
REMOVAL.............................11
INSTALLATION.........................11
SLAVE CYLINDER
REMOVAL.............................11
INSTALLATION.........................11
CLUTCH DISC AND PRESSURE PLATE - 2.5L
TD
REMOVAL.............................12
INSTALLATION.........................12
FLYWHEEL
REMOVAL.............................13
INSTALLATION.........................13
CLUTCH
DESCRIPTION
CLUTCH COMPONENTS
Models equipped with a 2.4L Gas engine utilize a
modular clutch assembly (Fig. 1). The modular clutch
consists of a single, dry-type clutch disc, a diaphragm
style clutch cover, and an integrated flywheel. The
clutch cover (pressure plate) is riveted to the fly-
wheel, and therefore can only be serviced as an
assembly.
Models equipped with the 2.5L Turbo Diesel engine
utilize a conventional clutch system (Fig. 2). This
system consists of a flywheel, clutch disc, and clutch
cover (pressure plate), which is fastened to the fly-
wheel, capturing the clutch disc within. Each compo-
nent is individually serviceable, however it ishighly
recommended that the clutch cover and disc be
replaced as a set.
Fig. 1 Modular Clutch AssemblyÐ2.4L Gas Engines
1 - MODULAR CLUTCH ASSEMBLY
RSCLUTCH6-1
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DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - CLUTCH SYSTEM
Clutch problem diagnosis will generally require a
road test to determine the type of fault. Componentinspection will then determine the problem after road
testing.
Drive the vehicle at normal speeds during road
test. Shift the transaxle through all gear ranges and
observe clutch action. If chatter, grab, slip, or
improper release is experienced, remove and inspect
the clutch components. If the problem is noise or
hard shifting, further diagnosis may be needed. The
transaxle or other driveline components may actually
be at fault.
SERVICE DIAGNOSIS - CLUTCH GRAB/CHATTER
CONDITION POSSIBLE CAUSES CORRECTION
CLUTCH DISC FACING
COVERED WITH OIL OR
GREASEOil leak at engine rear main or
transaxle input shaft seal.Correct leak and replace modular clutch
assembly (2.4L Gas) or clutch cover and
disc (2.5L TD).
Too much grease applied to splines
of disc and input shaft.Apply lighter coating of grease to splines.
NO FAULT FOUND WITH
CLUTCH
COMPONENTSProblem actually related to
suspension or driveline component.Further diagnosis required. Check
engine/transmission mounts, suspension
attaching parts and other driveline
components as needed.
Engine related problems. Check EFI and ignition systems.
PARTIAL ENGAGEMENT
OF CLUTCH DISCClutch cover, spring, or release
fingers bent, distorted (rough
handling, improper assembly).Replace modular clutch assembly (2.4L
Gas) or clutch cover and disc (2.5L TD).
Fig. 4 Slave Cylinder Removal/Installation
1 - MOUNTING HOLE
2 - SLAVE CYLINDER
3 - ACCESS HOLE
4 - NYLON ANTI-ROTATION TAB
Fig. 5 Release Bearing and Lever
1 - RELEASE LEVER
2 - RELEASE BEARING
RSCLUTCH6-3
CLUTCH (Continued)
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DIAGNOSIS AND TESTING - COOLING SYSTEM
AERATION
Low coolant level in a cross flow radiator will
equalize in both tanks with engine off. With engine
at running and at operating temperature, the high
pressure inlet tank runs full and the low pressure
outlet tank drops, resulting in cooling system aera-
tion. Aeration will draw air into the water pump
resulting in the following:
²High reading shown on the temperature gauge.
²Loss of coolant flow through the heater core.
²Corrosion in the cooling system.
²Water pump seal may run dry, increasing the
risk of premature seal failure.
²Combustion gas leaks into the coolant can also
cause the above problems.
DIAGNOSIS AND TESTING - COOLING SYSTEM
DEAERATION
Air can only be removed from the system by gath-
ering under the pressure cap. On the next heat up it
will be pushed past the pressure cap into the coolant
recovery bottle by thermal expansion of the coolant.
It then escapes to the atmosphere in the coolant
recovery bottle and is replaced with coolant on cool
down.
To effectively deaerate the system, multiple ther-
mal cycles of the system may be required.
NOTE: Deaeration does not occur at engine idleÐ
higher engine speeds are required. Normal driving
will deaerate cooling system.
STANDARD PROCEDURE
STANDARD PROCEDURE - COOLING SYSTEM
DRAINING
WARNING: DO NOT REMOVE OR LOOSEN THE
COOLANT PRESSURE 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 radiator pressure cap
and with system not under pressure, open the
draincock. The draincock is located on the lower left
side of radiator (Fig. 5).
(2) After the coolant recovery/reserve container is
empty, then remove coolant pressure cap (Fig. 6).
(3) Remove the cylinder block drain plug(s).
STANDARD PROCEDURE - COOLING SYSTEM
FILLING
Remove radiator pressure cap (Fig. 6) and fill sys-
tem, using a 50/50 mix of MopartAntifreeze/Coolant,
5 Year/100,000 Mile Formula and distilled water.
Continue filling system until full.Be careful not
to spill coolant on drive belts or the generator.
Fill coolant recovery/reserve container (Fig. 6) to at
least the MAX mark with 50/50 solution. It may be
necessary to add coolant to the recovery/reserve con-
tainer after three or four warm up/cool down cycles
to maintain coolant level between the MAX and MIN
mark. This will allow trapped air to be removed from
the system.
STANDARD PROCEDURE - ADDING
ADDITIONAL COOLANT
The radiator cap should not be removed.
When additional coolant is needed to maintain this
level, it should be added to the coolant recovery/re-
serve container (Fig. 6). Use only 50/50 mix of ethyl-
ene glycol type antifreeze and distilled water. For the
recommeded antifreeze/coolant type (Refer to LUBRI-
CATION & MAINTENANCE/FLUID TYPES -
DESCRIPTION).
CAUTION: Do not use well water, or suspect water
supply in cooling system. A 50/50 ethylene glycol
and distilled water mix is recommended. For the
recommeded antifreeze/coolant type (Refer to
LUBRICATION & MAINTENANCE/FLUID TYPES -
DESCRIPTION).
Fig. 5 Draincock Location
1 - LEFT SIDE FRAME RAIL
2 - DRAINCOCK
7 - 4 COOLINGRS
COOLING (Continued)
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(6) Fill cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
ENGINE COOLANT
THERMOSTAT
DESCRIPTION
The engine cooling thermostats are a wax pellet
driven, reverse poppet choke type. The thermostat is
mounted in a housing on the coolant outlet of the
engine (Fig. 8) or (Fig. 10).
OPERATION
The engine cooling thermostat is a wax pellet
driven, reverse poppet choke type. The thermostat is
designed to provide the fastest warm up possible by
preventing leakage through it and to guarantee a
minimum engine operating temperature of 88 to
93ÉC (192 to 199ÉF). The thermostat also will auto-
matically reach wide open so it will not restrict flow
to the radiator as temperature of the coolant rises in
hot weather to around 104ÉC (220ÉF). Above this
temperature the coolant temperature is controlled by
the radiator, fan, and ambient temperature, not the
thermostat.
The thermostat is operated by a wax filled con-
tainer (pellet) which is sealed. When heated coolantreaches a predetermined temperature, the wax
expands enough to overcome the closing spring and
water pump pressure, which forces the valve to open.
DIAGNOSIS AND TESTING - ENGINE COOLANT
THERMOSTAT
The thermostat is operated by a wax filled cham-
ber (pellet) which is sealed. When heated coolant
reaches a predetermined temperature the wax pellet
expands enough to overcome the closing spring and
water pump pressure, which forces the valve to open.
Coolant leakage into the pellet will cause a thermo-
stat to fail open. Do not attempt to free up a thermo-
stat with a screwdriver.
Thermostat diagnostics is included in powertrain
control module's (PCM) programing for on-board
diagnosis. The malfunction indicator light (MIL) will
illuminate and a diagnostic trouble code (DTC) will
be set when an ªopen too soonº condition occurs. Do
not change a thermostat for lack of heater perfor-
mance or temperature gauge position, unless a DTC
is present. For other probable causes, (Refer to 7 -
COOLING/ENGINE - DIAGNOSIS AND TESTING).
Thermostat failing shut is the normal long term
mode of failure, and normally, only on high mileage
vehicles. The temperature gauge will indicate this
(Refer to 7 - COOLING/ENGINE - DIAGNOSIS AND
TESTING).
ENGINE COOLANT
THERMOSTAT - 2.4L
REMOVAL
(1) Drain cooling system below the thermostat
level. (Refer to 7 - COOLING - STANDARD PROCE-
DURE)
(2) Remove radiator upper hose from the coolant
outlet housing (Fig. 7).
(3) Remove coolant outlet housing bolts and hous-
ing (Fig. 8).
(4) Remove thermostat. Discard gasket and clean
both gasket sealing surfaces.
INSTALLATION
(1) Place a new gasket (dipped in clean water) on
the coolant outlet connector surface. Position thermo-
stat with air bleed at the 12 o'clock position in ther-
mostat housing (Fig. 8).
(2) Position the coolant outlet connector and gas-
ket over the thermostat, making sure thermostat is
seated in the thermostat housing.
(3) Position outlet connector to thermostat housing
and install bolts (Fig. 8). Tighten bolts to 28 N´m
(250 in. lbs.).
Fig. 6 Engine Coolant Temperature Sensor
1 - ENGINE COOLANT TEMPERATURE SENSOR
2 - CONNECTOR - ENGINE COOLANT SENSOR
3 - FITTING - HEATER SUPPLY
RSENGINE7-23
ENGINE COOLANT TEMPERATURE SENSOR - 3.3/3.8L (Continued)
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(3) Position a new gasket over the thermostat and
connector making sure thermostat is in proper posi-
tion and in the recess provided.
(4) Install thermostat and connector assembly to
the intake manifold (Fig. 10). Tighten bolts to 28
N´m (250 in. lbs.).
(5) Install the radiator upper hose to coolant outlet
connector (Fig. 9).
(6) Refill the cooling system to the proper level.
(Refer to 7 - COOLING - STANDARD PROCEDURE)
RADIATOR
DESCRIPTION
The radiator is a cross-flow type (horizontal tubes)
with design features that provide greater strength
along with sufficient heat transfer capabilities to
keep the engine satisfactorily cooled. The radiator
has plastic side tanks and aluminum cooling tubes.
OPERATION
The radiator functions as a heat exchanger, using
air flow across the exterior of the radiator tubes. This
heat is then transferred from the coolant and into
the passing air.
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove radiator upper crossmember support.
(Refer to 23 - BODY/EXTERIOR/GRILLE OPENING
REINFORCEMENT - REMOVAL)
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK PLUG OR THE RADIATOR DRAINCOCK
WITH THE SYSTEM HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM COOLANT CAN
OCCUR.
(3) Drain the cooling system. (Refer to 7 - COOL-
ING - STANDARD PROCEDURE)
(4) Remove the radiator fans. (Refer to 7 - COOL-
ING/ENGINE/RADIATOR FAN - REMOVAL)
(5) Disconnect coolant reserve/recovery hose.
Fig. 10 THERMOSTAT - 3.3/3.8L ENGINE
1 - COOLANT OUTLET CONNECTOR
2 - BOLT
3 - THERMOSTAT
4 - GASKET
Fig. 11 Connector Staking Material Removal
1-STAKE
2 - OUTLET CONNECTOR
Fig. 12 Thermostat Position In Outlet Connector
1 - LOCATING NOTCH
2 - THERMOSTAT
3 - COOLANT OUTLET CONNECTOR
RSENGINE7-25
ENGINE COOLANT THERMOSTAT - 3.3/3.8L (Continued)
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CLEANING
Use only a mild soap to clean the pressure cap.
INSPECTION
Hold the cap in your hand,top side up(Fig. 20).
The vent valve at the bottom of the cap should open.
If the rubber gasket has swollen, preventing the
valve from opening, replace the cap.
Hold the cleaned cap in your hand,upside down.
If any light can be seen between vent valve and the
rubber gasket, replace the cap.Do not use a
replacement cap that has a spring to hold the
vent shut.
A replacement cap must be of the type designed for
coolant reserve systems. This design ensures coolant
return to the radiator.
RADIATOR FAN
DESCRIPTION
The dual radiator fans are mounted to the back
side of the radiator (Fig. 21). The radiator fan consist
of the fan blade, electric motor and a support shroud
which are all serviced as an assembly.
OPERATION
RADIATOR FAN OPERATION CHART
COOLANT TEMPERATURE A/C PRESSURE TRANSAXLE OIL
TEMPERATURE
Fan
Operation
Speeds:Initial Max Initial Max Initial Max
Fan On: 104ÉC
(220ÉF)110ÉC
(230ÉF) Fan
Speed
Duty-Cycles
(Ramps-up)
from 30% to
99%1,724 Kpa
(250 psi)2,068 Kpa
(300 psi) Fan
Speed
Duty-Cycles
(Ramps-up)
from 30% to
99%96ÉC (204ÉF) 111ÉC (232ÉF)
Fan Speed
Duty Cycles
(Ramps-up)
from 30% to
99%
Fan Off: 101ÉC
(214ÉF)Fan Speed
Duty-Cycles
(Ramps-
down) from
99% to 30%1,710 Kpa
(248 psi)Fan Speed
Duty-Cycles
(Ramps-
down) from
99% to 30%89ÉC (192ÉF) Fan Speed
Duty Cycles
(Ramps-down)
from 99% to
30%
Fig. 20 Cooling System Pressure Cap
1 - OVERFLOW NIPPLE
2 - MAIN SPRING
3 - GASKET RETAINER
4 - STAINLESS-STEEL SWIVEL TOP
5 - RUBBER SEALS
6 - VENT VALVE
7 - RADIATOR
8 - FILLER NECK
RSENGINE7-29
RADIATOR PRESSURE CAP (Continued)
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TRANSMISSION
TABLE OF CONTENTS
page page
TRANSMISSION
STANDARD PROCEDURE - FLUSHING
COOLERS AND TUBES.................38
TRANSMISSION OIL COOLER
DESCRIPTION.........................38
REMOVAL.............................38CLEANING............................39
INSPECTION..........................39
INSTALLATION.........................39
TRANSMISSION OIL COOLER LINES
REMOVAL.............................39
INSTALLATION.........................40
TRANSMISSION
STANDARD PROCEDURE - FLUSHING
COOLERS AND TUBES
The recommended procedure for cooler flushing is
to use Tool 6906 Cooler Flusher.
WARNING: WEAR PROTECTIVE EYEWEAR THAT
MEETS THE REQUIREMENTS OF OSHA AND ANSI
Z87.1±1968. WEAR STANDARD INDUSTRIAL RUB-
BER GLOVES. KEEP LIT CIGARETTES, SPARKS,
FLAMES, AND OTHER IGNITION SOURCES AWAY
FROM THE AREA TO PREVENT THE IGNITION OF
COMBUSTIBLE LIQUIDS AND GASES. KEEP A
CLASS (B) FIRE EXTINGUISHER IN THE AREA
WHERE THE FLUSHER WILL BE USED.
WARNING: KEEP THE AREA WELL VENTILATED.
DO NOT LET FLUSHING SOLVENT COME IN CON-
TACT WITH YOUR EYES OR SKIN: IF EYE CONTAM-
INATION OCCURS, FLUSH EYES WITH WATER FOR
15 TO 20 SECONDS. REMOVE CONTAMINATED
CLOTHING AND WASH AFFECTED SKIN WITH
SOAP AND WATER. SEEK MEDICAL ATTENTION.
(1) Remove cover plate filler plug on Tool 6906.
Fill reservoir 1/2 to 3/4 full of fresh flushing solution.
Use MopartTransmission Cooler Flush (MS-552) or
equivalent solution conforming to MS-552. Flushing
solvents are petroleum based solutions generally
used to clean automatic transmission components.
DO NOTuse solvents containing acids, water, gaso-
line, or any other corrosive liquids.
(2) Reinstall filler plug on Tool 6906.
(3) Verify pump power switch is turned OFF. Con-
nect red alligator clip to positive (+) battery post.
Connect black (-) alligator clip to a good ground.
NOTE: When flushing transmission cooler and
lines, ALWAYS reverse flush.(4) Connect the BLUE pressure line to the OUT-
LET (From) cooler line.
(5) Connect the CLEAR return line to the INLET
(To) cooler line
(6) Turn pump ON for two to three minutes to
flush cooler and lines.
(7) Turn pump OFF.
(8) Disconnect CLEAR suction line from reservoir
at cover plate. Disconnect CLEAR return line at
cover plate, and place it in a drain pan.
(9) Turn pump ON for 30 seconds to purge flush-
ing solution from cooler and lines. Turn pump OFF.
(10) Place CLEAR suction line into a one quart
container of MopartATF+4 (Automatic Transmission
FluidÐType 9602).
(11) Turn pump ON until all transmission fluid is
removed from the one quart container and lines. This
purges any residual cleaning solvent from the trans-
mission cooler and lines. Turn pump OFF.
(12) Disconnect alligator clips from battery. Recon-
nect flusher lines to cover plate, and remove flushing
adapters from cooler lines.
TRANSMISSION OIL COOLER
DESCRIPTION
The transmission oil cooler is an oil-to-air type
cooler that is mounted between the front of the radi-
ator and back side of the A/C condenser (Fig. 2). Use
only approved transmission oil cooler hoses that are
molded to fit the space available.
REMOVAL
(1) Remove the radiator. (Refer to 7 - COOLING/
ENGINE/RADIATOR - REMOVAL)
(2) Disconnect lines from oil cooler (Fig. 1).
(3) Remove oil cooler attaching screws (Fig. 2).
(4) Remove the oil cooler.
7 - 38 TRANSMISSIONRS
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