2002 CHRYSLER CARAVAN tire type

CONDITION POSSIBLE CAUSES CORRECTION
2. Steering column lower bearing
spring retainer slipped on steering
column shaft.2. Replace steering column.
3. Loose steering column to
instrument panel fasteners.3. Tighten fasteners to specified torque.
STEERING WHEEL, DASH
OR VEHICLE VIBRATES
DURING LOW SPEED OR
STANDSTILL STEERING
MANEUVERS.1. Air in the fluid of the power
steering system.1. Bleed air from system following the
power steering pump initial operation
service procedure.*
2. Tires not properly inflated. 2. Inflate tires to the specified pressure.
3. Excessive engine vibration. 3. Ensure that the engine is tuned properly.
4. Loose tie rod end jam nut. 4. Tighten the inner to outer tie rod jam nut
to the specified torque.
5.Overcharged air conditioning
system.5.Check air conditioning pump head
pressure and correct as necessary.
6. Grounded engine mount. 6. Repair as necessary.
7. Loose outer tie rod. 7. Replace outer tie rod.
STEERING CATCHES,
SURGES OR STICKS IN
CERTAIN POSITIONS OR
IS DIFFICULT TO TURN.
***1. Low power steering fluid level. 1. Fill power steering fluid reservoir to
specified level and check for leaks.
2. Tires not inflated to specified
pressure.2. Inflate tires to the specified pressure.
3. Lack of lubrication in front lower
control arm ball joints.3. Lubricate ball joints if ball joints are not a
lubricated-for-life type ball joint. If ball joint
is a lubricated-for-life ball joint, replace ball
joint.
4. Worn or binding lower control arm
ball joint.4. Replace lower control arm ball joint.
5. Lack of lubrication in steering gear
outer tie rod ends.5. Lubricate tie rod ends if they are not a
lubricated-for-life type. If tie rod end is a
lubricated-for-life type, replace tie rod end.
6. Loose power steering pump drive
belt.6. Tighten the power steering pump drive
belt to specifications or replace automatic
tensioner where applicable. If drive belt is
worn or glazed, replace belt.
7. Faulty power steering pump
(Perform Power Steering Flow and
Pressure Test).7. Replace power steering pump.
8. Faulty power steering gear
(Perform Power Steering Flow and
Pressure Test).8. Replace power steering gear.
9. Excessive friction in steering
column or intermediate shaft/coupler.9. Isolate and correct condition.
10. Excessive friction in power
steering gear.10. Replace power steering gear.
19 - 6 STEERINGRS
STEERING (Continued)
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CONDITION POSSIBLE CAUSES CORRECTION
11. Worn or binding seat and bearing
in front strut assembly.11. Replace seat and bearing in front strut
assembly.
STEERING WHEEL DOES
NOT RETURN TO
CENTER POSITION.1. Tires not inflated properly. 1. Inflate tires to specified pressure.
2. Improper front wheel alignment. 2. Check and adjust wheel alignment as
necessary.
3. Lack of lubrication causing binding
in front lower control arm ball joints.3. Lubricate ball joints if ball joints are not a
lubricated for life type of ball joint, then
inspect ball joint for wear, replace lower
control arm as necessary. If ball joint is a
lubricated for life ball joint, replace lower
control arm ball joint.
4. Steering column coupling joints
misaligned.4. Realign steering column coupling joints.
5. Steering wheel rubbing.** 5. Adjust steering column shrouds to
eliminate rubbing condition.
6. Damaged, mispositioned or
unlubricated steering column coupler
to dash seal.**6. Replace, reposition, or lubricate dash
seal.
7. Binding mount bearing in front
strut assembly.7. Replace mount bearing in front strut
assembly.
8. Binding shaft bearing in steering
column.8. Replace the steering column.
9. Excessive friction in steering
column coupling.9. Replace steering column coupling.
10. Excessive friction in power
steering gear.10. Replace power steering gear.
EXCESSIVE STEERING
WHEEL KICKBACK OR
TOO MUCH STEERING
WHEEL FREE PLAY.1. Air in the fluid of the power
steering system.1. Bleed air from system following the the
power steering pump initial operation
service procedure.*
2. Power steering gear loose on
cradle/crossmember.2. Inspect power steering gear mounting
bolts. Replace as necessary. Tighten to the
specified torque.
3. Steering column coupling or
intermediate shaft worn, broken or
loose.3. Replace steering column coupling or
intermediate shaft.
4. Free play in steering column. 4. Check all components of the steering
column and repair or replace as required.
5. Worn lower control arm ball joints. 5. Replace lower control arm ball joints as
required.
6. Loose steering knuckle-to-ball joint
stud pinch bolt.6. Inspect pinch bolt, replace as necessary,
and tighten to specified torque.
7. Front wheel bearing loose or
worn.7. Replace hub and bearing as necessary.
8. Loose outer tie rod end. 8. Replace outer tie rod end that has
excessive free play.
RSSTEERING19-7
STEERING (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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INSTALLATION
INSTALLATION - 2.4L ENGINE
(1) Remove any used O-rings from ends of power
steering hose.
(2) Using a lint free towel, wipe clean hose ends,
power steering pump fitting and steering gear port.
(3) Install new O-ring on power steering gear end
of return hose. Lubricate O-ring using clean power
steering fluid.
CAUTION: Use care not to bend tube ends of the
power steering hoses when installing. Leaks and
restrictions may occur.
CAUTION: If a new return hose is being installed
and it does not have an insulating heat sleeve
installed, the heat shield from the original hose
must be transferred before hose installation.
(4) Route hose along rear of cradle crossmember
and start gear end of hose into gear port. Do not
tighten hose tube nut at this time.
(5) Attach hose to suspension cradle crossmember
using two routing clamps and bolts (Fig. 19). Tighten
clamp bolts to 23 N´m (200 in. lbs.) torque.
(6) Tighten return hose tube nut at power steering
gear port to 31 N´m (275 in. lbs.) torque.
(7) Install the power steering fluid cooler on the
cradle crossmember reinforcement (Fig. 23). Install
the mounting bolts and tighten to 11 N´m (100 in.
lbs.).
CAUTION: Power steering fluid hoses must remain
away from the exhaust system and must not come
in contact with any unfriendly surfaces on the vehi-
cle.
(8) Route pump end of hose over cradle crossmem-
ber toward pump avoiding tight bends or kinking.
(9) Install return hose onto power steering pump
return fitting and secure with hose clamp (Fig. 19).
Tighten the screw-type clamp to a torque of 2 N´m
(18 in. lbs.).
CAUTION: To prevent overheating of power steering
fluid return hose, protective heat shield sleeve must
cover entire rubber hose.
(10) Slide insulating heat shield up over the clamp
on the return hose and tie-strap it in place.
(11) Install front emissions vapor canister. (Refer
to 25 - EMISSIONS CONTROL/EVAPORATIVE
EMISSIONS/VAPOR CANISTER - INSTALLATION)
(12) Lower vehicle.(13) Fill and bleed the power steering system
using the Power Steering Pump Initial Operation
Procedure. (Refer to 19 - STEERING/PUMP - STAN-
DARD PROCEDURE)
(14) Inspect system for leaks.
INSTALLATION - 3.3L/3.8L ENGINE
(1) Remove any used O-rings from ends of power
steering hose.
(2) Using a lint free towel, wipe clean hose ends
and power steering gear hose port.
(3) Install a new O-ring on gear port end of power
steering fluid hose. Lubricate O-ring using clean
power steering fluid.
CAUTION: Use care not to bend tube ends of the
power steering hoses when installing. Leaks and
restrictions may occur.
CAUTION: Power steering fluid hoses must remain
away from the exhaust system and must not come
in contact with any unfriendly surfaces on the vehi-
cle.
(4) Route hose (with cooler attached) up toward
reservoir avoiding tight bends or kinking.
(5) Start steering gear end of hose into gear port.
Do not tighten hose tube nut at this time.
(6) Attach return hose tubes to suspension cradle
crossmember using routing clamp and bolt (Fig. 20).
Tighten clamp bolt to 23 N´m (200 in. lbs.) torque.
(7) Install the power steering fluid cooler on the
cradle crossmember reinforcement (Fig. 23). Install
the mounting bolts and tighten to 11 N´m (100 in.
lbs.). When installing mounting bolts, include pres-
sure hose routing clamp.
(8) Tighten hose tube nut at power steering gear
port to 31 N´m (275 in. lbs.) torque.
(9) Install front emissions vapor canister. (Refer to
25 - EMISSIONS CONTROL/EVAPORATIVE EMIS-
SIONS/VAPOR CANISTER - INSTALLATION)
(10) Lower vehicle.
(11) Install return hose tube into retainer on ABS
bracket (Fig. 20). Close the bracket.
(12) Install return hose onto reservoir (Fig. 21).
Slide the hose clamp into position on fluid reservoir
and attach it.Be sure hose clamp in installed
past bead on fluid reservoir fitting.
(13) Fill and bleed power steering system using
the Power Steering Pump Initial Operation Proce-
dure. (Refer to 19 - STEERING/PUMP - STANDARD
PROCEDURE)
(14) Inspect system for leaks.
19 - 50 PUMPRS
HOSE - POWER STEERING RETURN (Continued)
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(a) Remount the tire on the rim 180 degrees
from its original location (Fig. 6). Ensure the tire
bead is properly seated.
(b) Re-measure the total runout. Mark the tire
at the high spot and record the measurement.If runout is still excessive, perform the following:
²If the new high spot is within 102 mm (4.0 inch)
of the first high spot on the tire, replace the tire.
²If the new high spot is within 102 mm (4.0 inch)
of the first high spot on the wheel, the wheel may be
out of specification. Refer to Wheel Runout above.
²If the new high spot is NOT within 102 mm (4.0
inch) of either high spot, draw an arrow on the tread
from new high spot toward the original (Fig. 7).
Break down the tire and remount it 90 degrees on
rim in that direction, then re-measure runout. This
will normally reduce the runout to an acceptable
amount.
(6) Once back together, road test the vehicle for at
least 5 miles, following the format described in Road
Test. If vibration persists, and all components tested
are within specification, the tires may have an exces-
sive radial force condition. Radial force variation can
only be checked as indicated below. If this equipment
is not available, consult with the tire manufacturer.
RADIAL FORCE VARIATION
Radial Force Variation can be checked using the
Hunter GSP 9700 Vibration Control System (Wheel
Balancer) or equivalent, if available. This type of
equipment helps to correct ride disturbances by
reducing the radial force variation of an assembly
through re-indexing of the tire to wheel.
The equipment manufacturer or DaimlerChrysler
Corporation may supply reference values as guide-
Fig. 5 Checking Lateral Runout Of Wheel
1 - MOUNTING CONE
2 - SPINDLE SHAFT
3 - WING NUT
4 - PLASTIC CUP
5 - DIAL INDICATOR
6 - WHEEL
7 - DIAL INDICATOR
Fig. 6 Remount Tire 180 Degrees
1 - VALVE STEM
2 - REFERENCE MARK
Fig. 7 Remount Tire 90 Degrees In Direction of
Arrow
1 - 2ND HIGH SPOT ON TIRE
2 - 1ST HIGH SPOT ON TIRE
22 - 4 TIRES/WHEELSRS
TIRES/WHEELS (Continued)
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lines. Radial force measurements above the reference
value may not always result in a ride disturbance,
nor do they automatically mean the assembly compo-
nents are out of specification. Do not replace compo-
nents based on radial force values alone. Balancing,
runout diagnosis, re-indexing, and subjective road
testing must be performed as outlined in previous
sections of this diagnosis and testing procedure.
Use the Radial Force equipment to identify suspect
assemblies and minimize the radial forces. After all
suspect assemblies are optimized, reinstall the
assemblies and road test the vehicle. If a disturbance
still exists and all other vibration diagnostic proce-
dures have been completed, replace one tire or one
wheel at a time, starting with the assembly having
the highest force variation. Be sure to minimize each
new assembly. Road test the vehicle following each
replacement. Continue this process until the distur-
bance is resolved.
NOTE: When using Radial Force equipment, it is
critically important to set proper tire inflation pres-
sure and ensure centering of the wheel on the
equipment spindle.
RADIAL FORCE VARIATION REFERENCE
VALUES
DESCRIPTION SPECIFICATION
Total Radial Force
Variation (RFV)Less Than 22 Lbs.   2
Lbs.
Radial First Harmonic
(R1H)Less Than 16 Lbs.   2
Lbs.
Radial Second Harmonic
(R2H)Less Than 12 Lbs.   2
Lbs.
STANDARD PROCEDURE
STANDARD PROCEDURE - TIRE AND WHEEL
BALANCE
NOTE: Balance equipment must be calibrated and
maintained per equipment manufacturer's specifica-
tions.
Wheel balancing can be accomplished with either
on-vehicle or off-vehicle equipment.
NOTE: If using on-vehicle balancing equipment, on
the driving axle, remove the opposite wheel and tire
assembly.
It is recommended that a two-plane dynamic bal-
ancer be used when a wheel and tire assemblyrequires balancing. A static balancer should only be
used when a two-plane balancer is not available.
Balance wheel and tire assemblies dynamically and
statically to less than 0.25 (
1¤4) ounce.
For static balancing, find location of heavy spot
causing imbalance. Counter balance wheel directly
opposite the heavy spot. Determine weight required
to counterbalance the area of imbalance. Place half of
this weight on theinnerrim flange and the other
half on theouterrim flange (Fig. 8).
For dynamic balancing, the balance equipment is
designed to indicate the location and amount of
weight to be applied to both the inner and outer rim
flanges (Fig. 9).
The aluminum wheels on this vehicle use a unique
wheel weight (Fig. 10). This wheel weight is designed
to fit the contoured surface of the wheel (Fig. 10).
When balancing an aluminum wheel, this wheel
weight must be used. Do not use any other type of
wheel weight. It will not properly fit the contour of
the wheel.
Always verify the Balance. When using off-vehicle
equipment, rotate assembly 180 degrees on balance
equipment to verify balance. Variation should not be
more than 0.125 (
1¤8) ounce. If variation is more than
0.125 ounce, balancing equipment could be malfunc-
tioning.
If difficult to balance, break down the wheel and
tire assembly and check for loose debris inside tire.
Prior to disassembly, mark (index) the tire at the
valve stem. Use this mark in order to remount the
tire in its original orientation with respect to the
wheel.
STANDARD PROCEDURE - TIRE AND WHEEL
MATCH MOUNTING
Wheels and tires are match mounted at the factory.
This means that the high spot of the tire is matched
to the low spot on the wheel rim. This technique is
used to reduce runout in the wheel and tire assem-
bly. The high spot on the tire is marked with a paint
mark or a bright colored adhesive label on the out-
board sidewall. The low spot on the wheel is identi-
fied with a label on the outside of the rim and a dot
or line in the drop well area of the rim (inside where
the tire mounts). If the outside label has been
removed, the tire will have to be removed to locate
the dot or line on the inside of the rim. The tire can
then be match mounted to the tire.
Information on match mounting the tire to the
wheel can be found in Tire and Wheel Runout/Match
Mounting, items (2) through (5), within Diagnosis
And Testing - Tire And Wheel Vibration. (Refer to 22
- TIRES/WHEELS - DIAGNOSIS AND TESTING)
RSTIRES/WHEELS22-5
TIRES/WHEELS (Continued)
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(6) Retrain tire pressure sensors. (Refer to 22 -
TIRES/WHEELS/TIRE PRESSURE MONITORING/
SENSOR - STANDARD PROCEDURE)
TIRES
DESCRIPTION
DESCRIPTION - TIRE
Tires are designed and engineered for each specific
vehicle. They provide the best overall performance
for normal operation. The ride and handling charac-
teristics match the vehicle's requirements. With
proper care they will give excellent reliability, trac-
tion, skid resistance, and tread life.
Driving habits have more effect on tire life than
any other factor. Careful drivers will obtain, in most
cases, much greater mileage than severe use or care-
less drivers. A few of the driving habits which will
shorten the life of any tire are:
²Rapid acceleration
²Severe application of brakes
²High-speed driving
²Taking turns at excessive speeds
²Striking curbs and other obstacles
²Operating vehicle with over or under inflated
tire pressuresRadial ply tires are more prone to irregular tread
wear. It is important to follow the tire rotation inter-
val shown in the section on Tire Rotation. This will
help to achieve a greater tread-life potential.
TIRE IDENTIFICATION
Tire type, size, load index and speed rating are
encoded in the letters and numbers imprinted on the
side wall of the tire. Refer to the chart to decipher
the tire identification code (Fig. 22). An All Season
type tire will have eitherM+S,M&SorM-S
(indicating mud and snow traction) imprinted on the
side wall. An Extra or Light Load marking ªXLº or
ªLLº may also be listed on the sidewall. The absence
of an ªXLº or ªLLº marking infers a standard load
tire.
Consult the tire manufacturer regarding any ques-
tions on tire specifications or capabilities.
TIRE CHAINS
Refer to the owners manual supplied with the vehi-
cle to determine whether the use of tire chains is per-
mitted on this vehicle.
DESCRIPTION - RADIAL-PLY TIRES
Radial-ply tires improve handling, tread life, ride
quality and decrease rolling resistance.
Fig. 21 Mounting Tire Using Rotating Tool Machine
1 - VALVE STEM
2 - MOUNTING END OF TOOL
3 - BEAD BREAKER (KEEP CLEAR OF SENSOR)
Fig. 22 Tire Identification (Typical)
RSTIRES/WHEELS22-13
SENSOR - TPM (Continued)
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Radial-ply tires must always be used in sets of four
and under no circumstances should they be used on
the front only. It is recommended that tires from dif-
ferent manufacturers NOT be mixed. They may be
mixed with a temporary spare tire when necessary. A
maximum speed of 80 km/h (50 mph) is recom-
mended while a temporary spare is in use.
Radial-ply tires have the same load-carrying capac-
ity as other types of tires of the same size. They also
use the same recommended inflation pressures.
DESCRIPTION - REPLACEMENT TIRES
WARNING: FAILURE TO EQUIP THE VEHICLE WITH
TIRES HAVING ADEQUATE SPEED CAPABILITY
CAN RESULT IN SUDDEN TIRE FAILURE.
It is recommended that tires equivalent to the orig-
inal equipment tires be used when replacement is
needed.
Failure to use equivalent replacement tires may
adversely affect the safety and handling of the vehi-
cle.
The original equipment tires provide a proper com-
bination of many characteristics such as:
²Ride
²Noise
²Handling
²Durability
²Tread life
²Traction
²Rolling resistance
²Speed capability
The use of tires smaller than the minimum tire
size approved for the vehicle can result in tire over-
loading and failure.
Use tires that have the approved load rating for
the vehicle and never overload them. Failure to equip
the vehicle with tires having adequate speed capabil-
ity can result in sudden tire failure and loss of vehi-
cle control.
The use of oversize tires may cause interference
with vehicle components. Under extremes of suspen-
sion and steering travel, interference with vehicle
components may cause tire damage.
DESCRIPTION - SPARE TIRE (TEMPORARY)
The temporary (convenience) spare tire is designed
for emergency use only. The original tire should be
repaired and reinstalled, or replaced with a new, at
the first opportunity.
The temporary (convenience) spare tire should be
inflated to the pressure listed on its sidewall. Do not
exceed speeds of 80 km/h (50 mph) when the tempo-
rary spare tire is in use on the vehicle. Refer to the
Owner's Manual for more details.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - TIRE NOISE
Unusual tire noise can be associated with tire and
wheel vibration or irregular tire wear. For vibration,
(Refer to 22 - TIRES/WHEELS - DIAGNOSIS AND
TESTING). For irregular tire wear, (Refer to 22 -
TIRES/WHEELS/TIRES - DIAGNOSIS AND TEST-
ING).
DIAGNOSIS AND TESTING - TIRE/VEHICLE
LEAD
Use the following Vehicle Lead Diagnosis And Cor-
rection Chart to diagnose and correct a vehicle lead
or drift problem.
DIAGNOSIS AND TESTING - TIRE WEAR
PATTERNS
Under inflation will cause wear on the shoulders of
tire. Over inflation will cause wear at the center of
tire.
Excessive camber causes the tire to run at an
angle to the road. One side of tread is then worn
more than the other (Fig. 23).
Excessive toe-in or toe-out causes wear on the
tread edges and a feathered effect across the tread
(Fig. 23).
DIAGNOSIS AND TESTING - TREAD WEAR
INDICATORS
Tread wear indicators are molded into the bottom
of the tread grooves. When tread depth is 1.6 mm
(1/16 in.), the tread wear indicators will appear as a
13 mm (1/2 in.) band (Fig. 24).
Tire replacement is necessary when indicators
appear in two or more grooves or if localized balding
occurs.
STANDARD PROCEDURE
STANDARD PROCEDURE - TIRE INFLATION
PRESSURES
The specified tire pressures have been chosen to
provide safe operation, vehicle stability, and a smooth
ride. The proper tire pressure specification can be
found on the Tire Inflation Pressure Label provided
with the vehicle (usually on the rear face of the driv-
er's door).
A quality air pressure gauge is recommended to
check tire air pressure. Tire pressure should be
checked cold once per month. Check tire pressure
more frequently when the weather temperature var-
ies widely. Tire pressure will decrease when the out-
22 - 14 TIRES/WHEELSRS
TIRES (Continued)
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