2002 CHRYSLER CARAVAN air condition

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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(4) Install clutch release bearing/lever assembly
into position by sliding bearing onto input bearing
retainer, and using moderate hand pressure to seat
release lever to pivot ball(s) (Fig. 11). A ªpopº sound
should be heard. Verify proper engagement by lightly
pulling outward on lever at pivot ball location, and
then actuating lever and bearing to ensure proper
operation.
MASTER CYLINDER - RHD
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove master cylinder to clutch pedal pin
retainer clip. Disengage pushrod from clutch pedal
pin (Fig. 13).
(3) Disengage master cylinder grommet from cowl
panel.
(4) Remove battery and tray.
(5)Diesel models:Remove windshield wiper mod-
ule assembly. (Refer to 8 - ELECTRICAL/WIPERS/
WASHERS/WIPER MODULE - REMOVAL)
(6) Discharge Air Conditioning system. (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING/
REFRIGERANT - STANDARD PROCEDURE)
(7) Remove suction/discharge line from evaporator
junction block.
(8) Using tool 6638A, disconnect clutch hydraulic
ªquick-connectº fitting (Fig. 12).
(9) Remove clutch master cylinder tubing from
retainers in engine compartment.
(10) Remove clutch master cylinder from dash
panel/clutch pedal bracket by rotating 45É clockwise
and pulling outward towards engine (Fig. 13).
(11) Carefully guide clutch master cylinder and
hydraulic plumbing from engine compartment.
INSTALLATION
(1) Carefully route master cylinder plumbing into
engine compartment as removed and position master
cylinder to dash panel hole.
(2) Rotate master cylinder 45É clockwise, insert
into dash panel hole, engaging clutch pedal bracket.
Fig. 10 Release Bearing-to-Lever
1 - RETAINER (2)
2 - RELEASE LEVER
3 - RELEASE BEARING
Fig. 11 Release Bearing and Lever
1 - RELEASE LEVER
2 - RELEASE BEARING
Fig. 12 Disconnect Quick-Connect Using Tool 6638A
1 - QUICK CONNECT FITTING
2 - TOOL 6638A
6 - 8 CLUTCHRS
CLUTCH RELEASE LEVER AND BEARING (Continued)
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Rotate master cylinder 45É counter-clockwise, secur-
ing it to pedal bracket (Fig. 13).
(3) Install and secure grommet to dash panel.
(4) Connect pushrod to clutch pedal pin. Install
retainer clip (Fig. 13).
(5) Secure master cylinder plumbing to retainers
in engine compartment.
(6) Connect clutch master cylinder plumbing to
slave cylinder ªquick connectº fitting. An audible
ªclickº should be heard. Verify connection by pulling
outward.
(7) Connect A/C suction/discharge line to evapora-
tor junction block.
(8)Diesel models:Install wiper module assembly.
(Refer to 8 - ELECTRICAL/WIPERS/WASHERS/
WIPER MODULE - INSTALLATION)
(9) Install battery and tray.
(10) Connect battery negative cable
(11) Charge Air Conditioning system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/RE-
FRIGERANT - STANDARD PROCEDURE)
MASTER CYLINDER - LHD
REMOVAL
(1) Disconnect battery cables.
(2) Remove instrument panel lower silencer (Fig.
14).
(3) Remove knee bolster (Fig. 15).
Fig. 13 Clutch Master Cylinder at Pedal Bracket
1 - CLUTCH MASTER CYLINDER
2 - RETAINER CLIP
3 - CLUTCH PEDAL PIN
4 - PUSH RODFig. 14 Instrument Panel Lower Silencer
1 - INSTRUMENT PANEL LOWER SILENCER
Fig. 15 Knee Bolster
1 - KNEE BOLSTER
RSCLUTCH6-9
MASTER CYLINDER - RHD (Continued)
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OPERATION
OPERATION - COOLING SYSTEM
The engine cooling systems primary purpose is to
maintain engine temperature in a range that will
provide satisfactory engine performance and emission
levels under all expected driving conditions. It also
provides hot water (coolant) for heater performance
and cooling for automatic transmission oil. It does
this by transferring heat from engine metal to cool-
ant, moving this heated coolant to the radiator, and
then transferring this heat to the ambient air.
²When engine is cold: thermostat is closed, cool-
ing system has no flow through the radiator. The
coolant bypass flows through the engine only.
²When engine is warm: thermostat is open, cool-
ing system has bypass flow and coolant flow through
radiator.
Coolant flow circuits for the 2.4L and 3.3/3.8L
engines are shown in (Fig. 2).
OPERATION - HOSE CLAMPS
The spring type hose clamp applies constant ten-
sion on a hose connection. To remove a spring type
hose clamp, use Special Tool 6094 or equivalent, con-
stant tension clamp pliers (Fig. 3) to compress the
hose clamp.
DIAGNOSIS AND TESTING
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.
Fig. 2 Cooling System Flow
1 - HEATER - REAR (3.3/3.8L OPTIONAL EQUIPMENT) 6 - WATER PUMP
2 - HEATER - FRONT 7 - RADIATOR
3 - ENGINE 8 - COOLANT RECOVERY/RESERVE CONTAINER
4 - THERMOSTAT 9 - COOLANT FLOW - PRESSURE CAP VACUUM
5 - ENGINE OIL COOLER (3.3/3.8L OPTIONAL EQUIPMENT) 10 - COOLANT FLOW - PRESSURE CAP RELIEF
7 - 2 COOLINGRS
COOLING (Continued)
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SPECIFICATIONS
COOLING SYSTEM CAPACITY
Engine Coolant Capacity*
2.4L 10.7 L (11.4 qts.)
3.3/3.8L (without
rear heater)12.6 L (13.4 qts.)
3.3/3.8L (with rear
heater)15.4 L (16.3 qts.)
*Includes Heater and Coolant Recovery System
ACCESSORY DRIVE BELT TENSION
ACCESSORY
DRIVE BELTTENSION
2.4L ENGINE
Air Conditioning
Compressor/
GeneratorDynamic Tensioner
Power
SteeringNew
Belt534 - 756 N
183 - 218 Hz
(120 - 170
lbs.)
Used
Belt*356 - 534 N
150 - 183 Hz
(80 - 120 lbs)
*Belt is considered used after 15 minutes of run-in
time
3.3/3.8L ENGINES
Air Conditioning
CompressorDynamic
Tensioner
Generator/Water
Pump/Power
Steering
TORQUE
DESCRIPTION N´mFt.
Lbs.In.
Lbs.
Accessory Drive Belt Tensioner
Assembly (3.3/3.8L)ÐBolt28 Ð 250
Engine Coolant Temperature
Sensor
(2.4 & 3.3/3.8L) 7 Ð 60
Generator & A/C Compressor Drive
Belt Tensioner Assembly (2.4L)Ð
Bolt54 40 Ð
Coolant Outlet Connector/
Thermostat Housing
(2.4 & 3.3/3.8L)ÐBolts 28 Ð 250
Water Pump
(2.4 & 3.3/3.8L)ÐBolts 12 Ð 105
Water Pump Inlet Tube (2.4L)Ð
Bolts12 Ð 105
Water Pump Inlet Tube (3.3/3.8L)Ð
Bolts28 Ð 250
Water Pump Pulley (3.3/3.8L)Ð
Bolts28 Ð 250
Radiator to A/C CondenserÐ
Screws5Ð45
Radiator FanÐScrews 5 Ð 45
Radiator Mounting (Upper
Bracket)ÐNuts12 Ð 105
7 - 6 COOLINGRS
COOLING (Continued)
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CONDITION POSSIBLE CAUSES CORRECTIONS
BELT ROLLED OVER IN GROOVE
OR BELT JUMPS OFF1. Broken cord in belt 1. Replace belt
2. Belt too loose, or too tight 2. (a) Replace belt (auto-tensioned
belts.)
(b) Adjust power steering belt
tension (4 cyl. engine)
3. Misaligned pulleys 3. Align accessories
4. Non-uniform groove or eccentric
pulley4. Replace pulley
DRIVE BELTS - 2.4L
STANDARD PROCEDURE - CHECKING POWER
STEERING BELT TENSION
WARNING: DO NOT CHECK BELT TENSION WITH
ENGINE RUNNING.
Accessory drive belt tension can be measured with
Special Tool 8371 ± Belt Tension Gauge Adapter, and
the DRBIIItusing the following procedures:
(1) Connect 8371 to the DRBIIItfollowing the
instructions provided with tool.
(2) Place end of microphone probe approximately
2.54 cm (1 in.) from belt at belt center span location
shown in (Fig. 3).
(3) Pluck the belt a minimum of 3 times. (Use your
finger or other suitable tool) The frequency of the
belt in hertz (Hz) will display on DRBIIItscreen.
(4) Adjust belt to obtain proper frequency (ten-
sion). Refer to ACCESSORY DRIVE BELT TENSION
CHART for belt tension specifications.
ACCESSORY DRIVE BELT TENSION CHART -
2.4L
Accessory Drive Belt Belt Tension
Air Conditioning
Compressor/GeneratorDynamic Tensioner
Power Steering PumpNew183 - 218
Hz
Used* 150 - 183
Hz
*A belt is considered used after 15 minutes of run-in
time.
REMOVAL
GENERATOR AND AIR CONDITIONING BELT
(1) Raise vehicle on hoist.
(2) Remove the drive belt shield (Fig. 8).WARNING: DO NOT ALLOW DRIVE BELT TEN-
SIONER TO SNAP BACK, AS DAMAGE TO TEN-
SIONER AND/OR PERSONAL INJURY COULD
RESULT.
(3) Position a wrench on the belt tensioner lug
(Fig. 4).
(4) Release belt tension by rotating the tensioner
clockwise (Fig. 4).
(5) Remove belt.
(1) Carefully return tensioner to its relaxed posi-
tion.
POWER STEERING PUMP
(1) From top of the vehicle, loosen locking nuts (D)
and (F) (Fig. 5).
Fig. 3 Power Steering Belt - Center Span Location
1 - POWER STEERING BELT CENTER SPAN LOCATION
7 - 10 ACCESSORY DRIVERS
DRIVE BELTS (Continued)
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(2) From under the vehicle, loosen the pivot bolt
(E). Loosen adjusting bolt (G) until belt can be
removed.
CLEANING
Clean all foreign debris from belt pulley grooves.
The belt pulleys must be free of oil, grease, and cool-
ants before installing the drive belt.
INSPECTION
Belt replacement under any or all of the following
conditions is required:
²Excessive wear
²Frayed cords
²Severe glazing
Poly-V Belt system may develop minor cracks
across the ribbed side (due to reverse bending). These
minor cracks are considered normal and acceptable.
Parallel cracks are not (Fig. 6).
NOTE: Do not use any type of belt dressing or
restorer on Poly-V Belts.
INSTALLATION
GENERATOR AND AIR CONDITIONING BELT
(1) Install belt onto all pulleys except for the
crankshaft (Fig. 7).
(2) Rotate belt tensioner clockwise until belt can
be installed onto the crankshaft pulley (Fig. 4).
Slowly release belt tensioner.
(3) Verify belt is properly routed and engaged on
all pulleys (Fig. 7).
(4) Install drive belt shield (Fig. 8) and lower vehi-
cle.
Fig. 4 A/C & GENERATOR BELT TENSION RELEASE
1 - BELT TENSIONER
2 - WRENCH
Fig. 5 Power Steering Pump
1 - REAR LOCKING NUT
2 - ADJUSTING BOLT
3 - PIVOT BOLT
4 - FRONT LOCKING NUT
Fig. 6 Drive Belt Wear Pattern
1 - NORMAL CRACKS - BELT OK
2 - NOT NORMAL CRACKS - REPLACE BELT
RSACCESSORY DRIVE7-11
DRIVE BELTS - 2.4L (Continued)
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(5) Remove the drive belt (Fig. 11).
(6) Carefully return tensioner to its relaxed posi-
tion.
CLEANING
Clean all foreign debris from belt pulley grooves.
The belt pulleys must be free of oil, grease, and cool-
ants before installing the drive belt.
INSPECTION
Belt replacement under any or all of the following
conditions is required:
²Excessive wear
²Frayed cords
²Severe glazing
Poly-V Belt system may develop minor cracks
across the ribbed side (due to reverse bending). These
minor cracks are considered normal and acceptable.
Parallel cracks are not (Fig. 10).
NOTE: Do not use any type of belt dressing or
restorer on Poly-V Belts.
INSTALLATION
(1) Route and position the drive belt onto all pul-
leys, except for the crankshaft (Fig. 11).
(2) Rotate belt tensioner counterclockwise until
belt can be installed onto the crankshaft pulley (Fig.
9). Slowly release belt tensioner.
(3) Verify belt is properly routed and engaged on
all pulleys.
(4) Install drive belt shield (Fig. 8) and lower vehi-
cle.
Fig. 10 Drive Belt Wear Pattern
1 - NORMAL CRACKS - BELT OK
2 - NOT NORMAL CRACKS - REPLACE BELT
Fig. 11 ACCESSORY DRIVE BELT
1 - DRIVE BELT
2 - POWER STEERING PUMP PULLEY
3 - BELT TENIONER PULLEY
4 - IDLER PULLEY
5 - GENERATOR PULLEY
6 - AIR CONDITIONING COMPRESSOR PULLEY
7 - CRANKSHAFT PULLEY
8 - WATER PUMP PULLEY
RSACCESSORY DRIVE7-13
DRIVE BELTS - 3.3/3.8L (Continued)
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