2002 CHRYSLER CARAVAN battery

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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STANDARD PROCEDURE
STANDARD PROCEDURE - COOLANT SERVICE
For engine coolant recommended service schedule,
(Refer to LUBRICATION & MAINTENANCE/MAIN-
TENANCE SCHEDULES - DESCRIPTION).
STANDARD PROCEDURE - ADDING
ADDITIONAL COOLANT
The pressure/vent cap should not be removed
from the coolant recovery pressure container
when the engine is hot.When additional coolant is
needed to maintain this level, it should be added to
the coolant recovery pressure container (Fig. 1). Use
only 50/50 mix of ethylene glycol type antifreeze and
distilled water. For the recommeded antifreeze/cool-
ant type (Refer to LUBRICATION & MAINTE-
NANCE/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).
STANDARD PROCEDURE - COOLANT LEVEL
CHECK
NOTE: Do not remove pressure/vent cap for routine
coolant level inspections.
The coolant reserve system provides a quick visual
method for determining the coolant level without
removing the pressure/vent cap.With the engine
cold and not running,simply observe the level of
the coolant in the coolant recovery pressure container
(Fig. 2). The coolant level should be between the MIN
and MAX marks.
STANDARD PROCEDURE - COOLING SYSTEM
FILLING
(1) Remove pressure vent cap from coolant recov-
ery pressure container.
(2) Loosen air bleed screw on the thermostat hous-
ing (Fig. 9).
(3) Slowly fill the cooling through the coolant
recovery pressure container until a steady stream of
coolant comes out of the air bleed.
(4) Tighten the air bleed screw.
Fig. 1 UNDERHOOD FLUID FILL LOCATIONS
1 - COOLANT PRESSURE/VENT CAP
2 - BRAKE MASTER CYLINDER
3 - INTELLIGENT POWER MODULE
4 - BATTERY
5 - COOLANT RECOVERY PRESSURE CONTAINER6 - OIL DIPSTICK
7 - WINDSHIELD SOLVENT RESEVOIR
8 - AIR FILTER HOUSING
9 - ENGINE OIL FILL CAP
7a - 16 ENGINERG
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(5) Continue filling coolant recovery pressure con-
tainer until level reaches the full line.
(6) Without installing the pressure/vent cap, start
and run engine at idle for a couple minutes.
(7) Recheck coolant level and fill as necessary.
(8) Install pressure/vent cap and drive vehicle for
approx. 10 km to reach normal operating tempera-
tures.
(9) Allow vehicle to cool. Check and fill coolant as
needed.
STANDARD PROCEDURE - COOLING SYSTEM
DRAINING
WARNING: DO NOT REMOVE OR LOOSEN THE
COOLANT PRESSURE/VENT 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 pressure/vent cap and
with system not under pressure, open the drain-
cock. The draincock is located on the lower right side
of radiator (Fig. 3).
(2) After the coolant recovery pressure container is
empty, then remove coolant pressure/vent cap.
COOLANT RECOVERY PRESS
CONTAINER
DESCRIPTION
The coolant recovery pressure container is
mounted in the engine compartment next to the bat-
tery. The coolant recovery pressure container is made
of plastic (Fig. 4).
OPERATION
The coolant recovery pressure container works
with the pressure/vent cap to use thermal expansion
and contraction of the coolant to keep the coolant
free of trapped air. Provides a convenient and safe
method for checking coolant level and adjusting level
at atmospheric pressure without removing the pres-
sure/vent cap. It also provides some reserve coolant
to cover deaeration, evaporation, or boiling losses.
Fig. 2 COOLANT RECOVERY PRESSURE
CONTAINER LOCATION
1 - PRESSURE/VENT CAP
2 - BRAKE MASTER CYLINDER
3 - BATTERY
4 - BATTERY SHIELD
5 - COOLANT RECOVERY PRESSURE CONTAINER RETAING
CLIP
6 - ENGINE COVER
7 - COOLANT RECOVERY PRESSURE CONTAINER
Fig. 3 DRAINCOCK LOCATION
1 - RADIATOR
2 - DRAINCOCK
3 - LOWER RADIATOR SUPPORT
4 - ELECTRIC COOLING FAN
RGENGINE7a-17
COOLANT (Continued)
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REMOVAL
(1) Drain cooling system below level of coolant
recovery pressure bottle. (Refer to 7 - COOLING/EN-
GINE/COOLANT - STANDARD PROCEDURE)
(2) Disconnect coolant bypass and overflow hoses
from coolant recovery pressure container (Fig. 6).
(3) Unclip the coolant recovery pressure container
retaining clip (Fig. 5).
(4) Raise coolant recovery pressure container from
mounting bracket and disconnect coolant hose from
bottom of container (Fig. 6).
(5) Remove coolant recovery pressure bottle.
INSTALLATION
(1) Connect coolant hose at bottom of coolant
recovery pressure container (Fig. 6) and install in
mounting bracket.
(2) Connect coolant recovery pressure container
retaining clip (Fig. 5).
(3) Connect coolant bypass and overflow hoses to
coolant recovery pressure container.
(4) Refill cooling system. (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE)
Fig. 4 COOLANT RECOVERY PRESSURE
CONTAINER LOCATION
1 - PRESSURE/VENT CAP
2 - BRAKE MASTER CYLINDER
3 - BATTERY
4 - BATTERY SHIELD
5 - COOLANT RECOVERY PRESSURE CONTAINER RETAING
CLIP
6 - ENGINE COVER
7 - COOLANT RECOVERY PRESSURE CONTAINER
Fig. 5 COOLANT RECOVERY PRESSURE
CONTAINER LOCATION
1 - PRESSURE/VENT CAP
2 - BRAKE MASTER CYLINDER
3 - BATTERY
4 - BATTERY SHIELD
5 - COOLANT RECOVERY PRESSURE CONTAINER RETAING
CLIP
6 - ENGINE COVER
7 - COOLANT RECOVERY PRESSURE CONTAINER
7a - 18 ENGINERG
COOLANT RECOVERY PRESS CONTAINER (Continued)
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ENGINE COOLANT TEMP
SENSOR
DESCRIPTION
The engine coolant temperature sensor threads
into a coolant passage in the cylinder head (Fig. 7).
New sensors have sealant applied to the threads.
OPERATION
The coolant temperature (ECT) sensor is a nega-
tive temperature coefficient (NTC) thermistor (resis-
tance varies inversley with temperature). This means
at cold tempertures its resistance is high so the volt-
age signal will be high. As coolant temperture
increases, resistance decreases and the signal voltage
will be low. This allows the sensor to provide an ana-
log voltage signal to the ECM.
REMOVAL
WARNING: DO NOT REMOVE OR LOOSEN THE
COOLANT PRESSURE/VENT 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) Drain the cooling system. (Refer to 7 - COOL-
ING/ENGINE/COOLANT - STANDARD PROCE-
DURE)
(2) Disconnect coolant temperature sensor electri-
cal connector (Fig. 8).
(3) Remove coolant temperature sensor from cylin-
der head (Fig. 8).
INSTALLATION
(1) Install coolant temperature sensor in cylinder
head (Fig. 8).
(2) Connect coolant temperature sensor electrical
connector (Fig. 8).
(3) Refill the cooling system. (Refer to 7 - COOL-
ING/ENGINE/COOLANT - STANDARD PROCE-
DURE)
(4) Connect the negative battery cable.
Fig. 6 COOLANT RECOVERY PRESSURE
CONTAINER
1 - COOLANT RECOVERY PRESSURE CONTAINER
2 - COOLANT BYPASS HOSE
3 - OUTLET HOSE
4 - PRESSURE/VENT CAP
Fig. 7 COOLANT TEMPERATURE SENSOR
LOCATION
1 - EGR SOLENOID
2 - UPPER RADIATOR HOSE
3 - COOLANT TEMPERATURE SENSOR
4 - INTAKE MANIFOLD INLET
5 - INTAKE MANIFOLD/CYLINDER HEAD COVER
RGENGINE7a-19
COOLANT RECOVERY PRESS CONTAINER (Continued)
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ENGINE COOLANT
THERMOSTAT
DESCRIPTION
A pellet-type thermostat controls the operating
temperature of the engine by controlling the amount
of coolant flow to the radiator (Fig. 9).
OPERATION
The thermostat starts to open at 80ÉC (176ÉF).
Above this temperature, coolant is allowed to flow to
the radiator. This provides quicker engine warmup
and overall temperature control.
The same thermostat is used for winter and sum-
mer seasons. An engine should not be operated with-
out a thermostat, except for servicing or testing.
Operating without a thermostat causes other prob-
lems. These are: longer engine warmup time, unreli-
able warmup performance, increased exhaust
emissions and crankcase condensation. This conden-
sation can result in sludge formation.
REMOVAL
NOTE: The thermostat is not serviced separately.
The thermostat and housing must be replaced as
an assembly.
(1) Disconnect negative battery cable.
(2) Drain cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(3) Remove front wiper unit to gain access to ther-
mostat housing(Refer to 8 - ELECTRICAL/WIPERS/
WASHERS/WIPER MODULE - REMOVAL).
(4) Disconnect upper radiator hose adapter tube,
water pump hose, and EGR hose at thermostat hous-
ing.
(5) Remove both thermostat housing attaching
bolts and housing (Fig. 10).
INSTALLATION
(1) Install thermostat housing, gasket, and retain-
ing bolts (Fig. 10). Torque bolts to 27.5N´m.
(2) Connect upper radiator hose adapter tube,
water pump hose, and EGR cooler hose to thermostat
housing.
Fig. 8 COOLANT TEMPERATURE SENSOR
LOCATION
1 - EGR SOLENOID
2 - UPPER RADIATOR HOSE
3 - COOLANT TEMPERATURE SENSOR
4 - INTAKE MANIFOLD INLET
5 - INTAKE MANIFOLD/CYLINDER HEAD COVER
Fig. 9 THERMOSTAT HOUSING LOCATION
1 - CYLINDER HEAD COVER
2 - THERMOSTAT HOUSING
3 - AIR BLEED
4 - WATER PUMP
5 - WATER PUMP HOUSING TO THERMOSTAT HOUSING
BYPASS HOSE
6 - E G R VA LV E
7a - 20 ENGINERG
ENGINE COOLANT THERMOSTAT (Continued)
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(3) Install front wiper unit (Refer to 8 - ELECTRI-
CAL/WIPERS/WASHERS/WIPER MODULE -
INSTALLATION).
(4) Refill cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(5) Connect negative battery cable.
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/ENGINE/COOLANT - STANDARD PROCE-
DURE).
(4) Remove the radiator fans. (Refer to 7 - COOL-
ING/ENGINE/RADIATOR FAN - REMOVAL)
(5) Disconnect coolant bypass hose (Fig. 11).
(6) Disconnect upper and lower hoses from the
radiator (Fig. 11).
(7) Remove the A/C condenser side brackets to
radiator attaching screws (Fig. 12). Separate the con-
denser from the radiator by lifting upward to disen-
gage from lower mounts (Fig. 12). Allow the
condenser to rest in front of radiator.
Fig. 10 THERMOSTAT HOUSING ASSEMBLY
1 - THERMOSTAT HOUSING GASKET
2 - THERMOSTAT HOUSING
3 - RETAINING BOLTS
4 - CYLINDER HEAD
5 - CYLINDER HEAD COVER/INTAKE MANIFOLD
Fig. 11 UPPER AND LOWER RADIATOR HOSES
1 - COOLANT BYPASS HOSE
2 - RADIATOR ASSEMBLY
3 - UPPER RADIATOR HOSE
4 - COOLING FAN
5 - LOWER RADIATOR HOSE
6 - CHARGE AIR COOLER
7 - RADIATOR BRACKET
RGENGINE7a-21
ENGINE COOLANT THERMOSTAT (Continued)
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(8) Radiator can now be lifted free from engine
compartment.Care should be taken not to dam-
age radiator cooling fins or water tubes during
removal.
INSTALLATION
(1)Be sure the air seal is in position before
radiator is installed.Slide radiator down into posi-
tion. Seat the radiator with the rubber isolators into
the mounting holes provided, with a 10 lbs. force.
(2) Position air conditioning condenser onto the
radiator lower mounts and install upper screws (Fig.
12). Tighten fasteners to 5 N´m (45 in. lbs.).
(3) Install the radiator upper and lower hoses (Fig.
11).
(4) Connect the coolant bypass hose.
(5) Install the radiator fans. (Refer to 7 - COOL-
ING/ENGINE/RADIATOR FAN - INSTALLATION)
(6) Install the radiator upper crossmember sup-
port. (Refer to 23 - BODY/EXTERIOR/GRILLE
OPENING REINFORCEMENT - INSTALLATION)
(7) Fill the cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(8) Connect negative cable to battery.
RADIATOR DRAINCOCK
REMOVAL
CAUTION: Use of pliers on draincock is not recom-
mended. Damage may occur to radiator or drain-
cock.
NOTE: It is not necessary to remove draincock dur-
ing a routine coolant drain.
(1) Drain the cooling system (Refer to 7 - COOL-
ING/ENGINE/COOLANT - STANDARD PROCE-
DURE).
(2) Open the draincock by turning it counterclock-
wise until it stops.
(3) Turn the draincock back (clockwise) 1/8 turn.
(4) Pull the draincock (Fig. 13) from the radiator
tank.
INSTALLATION
(1) Align draincock stem to radiator tank opening.
(2) Push draincock into the radiator tank opening.
(3) Tighten the draincock by turning clockwise
until it stops.
(4) Fill the cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
Fig. 12 Radiator to A/C Condenser Mounting (left
mount shown, right similar)
1 - SCREW - A/C CONDENSER SIDE BRACKET TO RADIATOR
2 - LOWER MOUNT
3 - A/C CONDENSER
Fig. 13 Draincock
1 - RADIATOR TANK
2 - DRAINCOCK
7a - 22 ENGINERG
RADIATOR (Continued)
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