2002 CHRYSLER CARAVAN oil

SPECIFICATIONS
TORQUE
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
All seat belt anchor bolts 39 29 Ð
Armrest shoulder bolt 29 21 Ð
Bench seat riser bolts 48 35 Ð
Bench seat track nuts 48 35 Ð
Quad bucket seat track to cushion frame bolts 40 30 Ð
Bucket seat back pivot bolts 33 24 Ð
Center seat to seat track bolts 24 17 Ð
Child seat module screws (bench seats) 7 Ð 62
Child seat module screws (quad seats) 13.5 10 Ð
Crossmember to radiator closure panel bolts 28 21 Ð
Door check strap to door end frame 12 Ð 105
Door latch to door end frame bolts 10 Ð 89
Floor latch to seat cushion frame bolts 27 19 Ð
Front cover to seat track screws 4 Ð 32
Front door hinge to hinge pillar bolts 34 25 Ð
Front door hinge to door nuts and bolts 34 25 Ð
Front door latch striker bolts 28 21 Ð
Front/quad seat cushion bolts 28.5 21 Ð
Front seat belt retractor bolts 38 28 Ð
Front seat riser to floor nuts 60 44 Ð
Front seat track cover screws 4 Ð 35
Front seat riser to seat track nuts 81 60 Ð
Front seatback pivot bolts 54 40 Ð
Front seatback recliner nut 12 Ð 105
Front seatback assist strap screws 2.5 Ð 22
Grocery bag holder screws 2 Ð 17
Hinge to liftgate bolts 33 24 Ð
Hood latch to bolts 13.5 10 Ð
Hood latch striker bolts 13.5 10 Ð
Hood hinge to hood bolts 13.5 10 Ð
Liftgate exterior handle outer screws 20 15 Ð
Liftgate exterior handle inner bolts 40 30 Ð
Lifgate hinge to roof header bolts 33 24 Ð
Liftgate latch bolts 16 12 Ð
Liftgate latch striker bolts 28 21 Ð
Liftgate lift motor link to liftgate 28 21 Ð
Liftgate spoiler bolts 9 Ð 80
RSBODY23-11
BODY (Continued)
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DESCRIPTION N´m Ft. Lbs. In. Lbs.
Lifgate stabalizer wedge striker to D-pillar bolts 3 Ð 30
Luggage rack crossbar fasteners 4 Ð 35
Lumbar support handle screw 1 Ð 9
Pivot bolt to the body half of hood hinge 28 21 Ð
Prop assembly to lifgate bolts 28 21 Ð
Rear door glass to regulator bolt 11 8 Ð
Rear door hinge to B-pillar bolt 28 20 Ð
Rear door hinge to door bolt 28 20 Ð
Rear door latch striker 28 20 Ð
Rear latch to sliding door end frame 28 20 Ð
Rear seat back to seat cushion bolt 27 19 Ð
Recliner to seat back frame 12 9 Ð
Seatback frame upper rail 8 Ð 71
Seatback hinge bolt 48 35 Ð
Seatback hinge cover screws 2.3 Ð 20
Shoulder belt turning loop onto height adjuster 39 29 Ð
Sliding door center hinge adjusting bolt 15 Ð 130
Sliding door glass nuts 3.4 Ð 30
Sliding door latch striker 28 21 Ð
Sliding door to roller arm bracket 12 9 Ð
Storage bin track quide to seat riser 3.5 Ð 31
Support cylinders to liftgate 28 21 Ð
BODY LUBRICATION
LUBRICATION REQUIREMENTS
Body mechanisms and linkages should be
inspected, cleaned, and lubricated, as required, to
maintain ease of operation and to provide protection
against rust and wear. When performing other under
hood services, the hood latch release mechanism and
safety catch should be inspected, cleaned, and lubri-
cated. During the winter season, external door lock
cylinders should be lubricated to assure proper oper-
ation when exposed to water and ice.
Prior to the application of any lubricant, the parts
concerned should be wiped clean to remove dust and
grit. If necessary, a suitable solvent can be used to
clean the item to be lubricated. After lubricating a
component, any excess oil or grease should be
removed.
LUBRICANT APPLICATION
DOOR LOCK CYLINDERS
(1) Apply a small amount of lubricant directly into
the lock cylinder.
(2) Apply a small amount of lubricant to the key.(3) Insert key into lock cylinder and cycle the
mechanism from the locked to the unlocked position.
NOTE: Do not add more lubricant.
(4) Cycle the lock cylinder mechanism several
times to allow the lubricant to flow throughout the
cylinder.
(5) Wipe all lubricant from exterior of lock cylinder
and key.
ALL OTHER BODY MECHANISMS
(1) Clean component as described above.
(2) Apply specified lubricant to all pivoting and
sliding contact areas of component.
LUBRICANT USAGE
ENGINE OIL
²Door Hinges ± Hinge Pin and Pivot Contact
Areas
²Hood Hinges ± Pivot Points
²Liftgate Hinges
23 - 12 BODYRS
BODY (Continued)
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DECKLID/HATCH/LIFTGATE/TAILGATE
TABLE OF CONTENTS
page page
EXTERIOR HANDLE
REMOVAL.............................39
INSTALLATION.........................39
HINGE
REMOVAL.............................39
INSTALLATION.........................39
LATCH
REMOVAL.............................40
INSTALLATION.........................40
LATCH STRIKER
REMOVAL.............................40
INSTALLATION.........................40
LIFTGATE
REMOVAL.............................40
INSTALLATION.........................41
LIFTGATE SPOILER
REMOVAL.............................41INSTALLATION.........................41
LOCK CYLINDER
REMOVAL.............................42
INSTALLATION.........................42
SUPPORT CYLINDER
REMOVAL.............................42
INSTALLATION.........................42
TRIM PANEL
REMOVAL.............................42
INSTALLATION.........................43
SLAM BUMPER
REMOVAL
REMOVAL...........................43
REMOVAL - LIFTGATE SIDE.............43
INSTALLATION
INSTALLATION.......................43
INSTALLATION - LIFTGATE SIDE.........43
EXTERIOR HANDLE
REMOVAL
(1) Remove liftgate trim panel. (Refer to 23 -
BODY/DECKLID/HATCH/LIFTGATE/TAILGATE/
TRIM PANEL - REMOVAL)
(2) Disconnect the exterior handle electrical con-
nectors.
(3) Remove the two outer screws and the two inner
screws.
(4) Remove the exterior handle/license plate light
assembly.
INSTALLATION
(1) Route the exterior handle electrical connector
through the door and position handle.
(2) Install the two out screws and tighten to 20
N´m (15 ft. lbs.).
(3) Install the two inner bolts and tighten to 40
N´m (30 ft. lbs.).
(4) Connect the electrical connector.
(5) Install the trim panel. (Refer to 23 - BODY/
DECKLID/HATCH/LIFTGATE/TAILGATE/TRIM
PANEL - INSTALLATION)
HINGE
REMOVAL
(1) Release liftgate latch and open liftgate.
(2) Support liftgate on a suitable lifting device in
the full open position.
(3) Apply several layers of duct tape on the outside
of to roof across the gap to the lift gate to hold the
liftgate in position.
(4) Remove bolts attaching liftgate hinge to roof
header.
(5) Disconnect VTSS switch from the body har-
ness.
(6) Remove bolts attaching hinge to liftgate (Fig.
1).
(7) Remove hinge from vehicle.
INSTALLATION
(1) If necessary, paint replacement hinge before
installation.
(2) Place hinge in position on vehicle.
(3) Align hinge to marks on liftgate.
(4) Install bolts attaching hinge to liftgate (Fig. 1)
. Tighten bolts to 33 N´m (24 ft. lbs.) torque.
RSDECKLID/HATCH/LIFTGATE/TAILGATE23-39
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(5) Disconnect rear window washer hose from
spray nozzle.
(6) Support liftgate on a suitable lifting device.
(7) Remove screws attaching support cylinders to
liftgate.
(8) Remove bolts attaching liftgate hinge to roof
header (Fig. 4).
(9) With assistance, remove liftgate from vehicle.
INSTALLATION
(1) With assistance, place liftgate in position on
vehicle.
(2) Install bolts attaching liftgate hinge to roof
header. Tighten bolts to 33 N´m (24 ft. lbs.) torque.(3) Install screws attaching support cylinders to
liftgate. Tighten bolts to 28 N´m (21 ft. lbs.) torque.
(4) Remove lifting device from under liftgate.
(5) Connect liftgate wire harness into body wire
harness.
(6) Install screws attaching wire connector to rear
header.
(7) Connect rear window washer hose onto spray
nozzle.
(8) Install liftgate upper frame molding.
(9) Verify liftgate alignment. The liftgate should
have a gap to adjacent panels and fit flush across the
gaps. The gap is;
²7 mm (0.280 in.) to the fascia,
²6 mm (0.240 in.) to the roof,
²4 mm (0.160 in.) to the aperture.
LIFTGATE SPOILER
REMOVAL
(1) Remove nuts (Fig. 5).
(2) Remove spoiler from vehicle.
INSTALLATION
(1) Place liftgate spoiler in position and install
nuts.
(2) Tighten nuts to 9 N´m (80 in. lbs.) torque.
Fig. 3 LIFTGATE LATCH STRIKER
1 - LIFTGATE SILL
2 - LIFTGATE STRIKER
Fig. 4 LIFTGATE
1 - HINGE
2 - ROOF
3 - NET HOLE OR SLOT
Fig. 5 LIFTGATE SPOILER
1 - RETAINER SEALER WASHER
2 - LIFT GATE SPOILER
RSDECKLID/HATCH/LIFTGATE/TAILGATE23-41
LIFTGATE (Continued)
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PAINT CODE
DESCRIPTION
Exterior vehicle body colors are identified on the
Body Code plate. (Refer to VEHICLE DATA/VEHI-
CLE INFORMATION/BODY CODE PLATE -
DESCRIPTION). The paint code is also identified on
the Vehicle Safety Certification Label which is
located on the drivers door shut face. The first digit
of the paint code listed on the vehicle indicates the
sequence of application, i.e.: P = primary coat, Q =
secondary coat. The codes listed in the Color Code
Chart are used for manufacturing purposes.
PAINTED TOUCH-UP
DESCRIPTION
When a painted metal surface has been scratched
or chipped, it should be touched up as soon as possi-
ble to avoid corrosion. For best results, use Mopart
Scratch Filler/Primer, Touch Up Paints and Clear Top
Coat. (Refer to VEHICLE DATA/VEHICLE INFOR-
MATION/BODY CODE PLATE - DESCRIPTION).
WARNING: USE A OSHA APPROVED BREATHING
MASK WHEN SPRAYING PAINT OR SOLVENTS IN A
CONFINED AREA. PERSONAL INJURY CAN
RESULT.
TOUCH UP PROCEDURE
(1) Scrape loose paint and corrosion from inside
scratch or chip.
(2) Clean affected area with MopartTar/Road Oil
Remover, and allow to dry.
(3) Fill the inside of the scratch or chip with a coat
of filler/primer. Do not overlap primer onto good sur-
face finish. The applicator brush should be wetenough to puddle-fill the defect without running. Do
not stroke brush applicator on body surface. Allow
the filler/primer to dry hard.
(4) Cover the filler/primer with color touch up
paint. Do not overlap touch up color onto the original
color coat around the scratch or chip. Butt the new
color to the original color, if possible. Do not stroke
applicator brush on body surface. Allow touch up
paint to dry hard.
(5) On vehicles without clearcoat, the touch up
color can be lightly finesse sanded (1500 grit) and
polished with rubbing compound.
(6) On vehicles with clearcoat, apply clear top coat
to touch up paint with the same technique as
described in Step 4. Allow clear top coat to dry hard.
If desired, Step 5 can be performed on clear top coat.
WARNING: AVOID PROLONGED SKIN CONTACT
WITH PETROLEUM OR ALCOHOL ± BASED CLEAN-
ING SOLVENTS. PERSONAL INJURY CAN RESULT.
FINESSE SANDING/BUFFING &
POLISHING
DESCRIPTION
Minor acid etching, orange peel, or smudging in
clearcoat or single-stage finishes can be reduced with
light finesse sanding, hand buffing, and polishing.If
the finish has been finesse sanded in the past,
it cannot be repeated. Finesse sanding opera-
tion should be performed by a trained automo-
tive paint technician.
CAUTION: Do not remove clearcoat finish, if
equipped. Basecoat paint must retain clearcoat for
durability.
23 - 84 PAINTRS
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control rear set temp button is pressed simulta-
neously with the rear control head, then the front
control head press events shall have priority, i.e. if
the front user presses Rear Set Temp down and the
rear user presses Set Temp up, then the rear set
temp will decrease.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - A/C COOL DOWN
TEST
The heater-A/C control module can perform an A/C
cool down test, which is a test performed during the
manufacturing process to confirm that the air condi-
tioning system is performing satisfactorily. This test
can also provide a quick confirmation of air condi-
tioning system performance to the service technician.
If the test is completed satisfactorily, no further ser-
vice is required. If the test is failed, proceed to the
A/C Performance Test to confirm the a/c system is
operating properly, or use a DRBIIItscan tool to
diagnose the A/C system control and distribution sys-
tems. Refer to the appropriate diagnostic informa-
tion.
MANUAL TEMPERATURE CONTROL
The front blower speed and rear blower speed (if
equipped with rear HVAC) must be set to High and
the evaporator temperature sensor must be greater
than 55É F or the test will fail immediately. The test
is activated by depressing the A/C and PWR buttons
simultaneously and holding them depressed for no
less than five seconds. The PWR and A/C LEDs will
blink on and off until the test is complete. If the
LEDs stop blinking before two minutes, then the cool
down test has been completed successfully. If the two
minutes expire without the expansion valve temper-
ature reaching 20É F less than the outside air tem-
perature, then the cool down test has been failed and
further A/C system diagnosis is required. If the test
is failed, the LEDs will continue to blink until the
vehicle has been driven for greater than (8 miles).
AUTOMATIC TEMPERATURE CONTROL
The ambient air temperature in the room where
the vehicle will be tested must be a minimum of 21É
C (70ÉF) for this test. The test is activated by
depressing the A/C and PWR buttons simultaneously
and holding them depressed for no less than four sec-
onds. The snowflake icon and the DELAY text in the
ATC display will blink on and off alternately until
the test is complete. If the snowflake icon and the
DELAY text stop blinking before two minutes, then
the cool down test has been completed successfully. If
the two minutes expire without the evaporator tem-perature reaching 20É F less than the evaporator ini-
tial temperature, then the cool down test has been
failed and further A/C system diagnosis is required.
If the test is failed, the snowflake icon and the
DELAY text will continue to blink across ignition
cycles until the vehicle has been driven for greater
than (8 miles).
DIAGNOSIS AND TESTING - A/C
PERFORMANCE TEST
An air conditioning performance test is the best
way to determine whether the system is performing
up to standard. This test also provides valuable clues
as to the possible cause of trouble with the air con-
ditioning system. The ambient air temperature in the
location where the vehicle will be tested must be a
minimum of 21É C (70ÉF) for this test.
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - WARNING - A/C PLUMBING)
and (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - CAUTION - A/C PLUMBING).
NOTE: When connecting the service equipment
coupling to the line fitting, verify that the valve of
the coupling is fully closed. This will reduce the
amount of effort required to make the connection.
(1) Connect a tachometer to monitor the engine
speed.
(2) Remove the caps from the refrigerant system
service ports and attach a manifold gauge set to
monitor the refrigerant system pressures.
(3) Set the heater-air conditioner controls so that
the compressor is engaged, the air within the vehicle
is being recirculated, the output air is directed
through the panel outlets, the temperature control is
in the full cool position, and the blower motor is oper-
ating at its highest speed.
(4) Start the engine and allow the engine to oper-
ate for about five minutes or until it reaches normal
operating temperature. Then hold the engine speed
at 1000 rpm with the compressor clutch engaged. If
the compressor clutch does not engage, proceed with
diagnosis of the compressor clutch coil. (Refer to 24 -
HEATING & AIR CONDITIONING/CONTROLS -
FRONT/COMPRESSOR CLUTCH COIL - DIAGNO-
SIS AND TESTING).
(5) Close all the vehicle windows and doors.
(6) Insert a thermometer in the left center panel
outlet and operate the engine for five minutes.
RSHEATING & AIR CONDITIONING24-5
HEATING & AIR CONDITIONING (Continued)
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If coolant flow is verified and the heater floor out-
let temperature is insufficient, a mechanical problem
may exist.
POSSIBLE LOCATION OR CAUSE OF INSUFFICIENT HEAT
²Obstructed cowl air intake.
²Obstructed heater system outlets.
²Blend-air door not functioning properly.TEMPERATURE CONTROL
If heater floor outlet temperature cannot be
adjusted with the heater-A/C control temperature
control lever, one of the following could require ser-
vice:
²Blend-air door binding.
²Faulty blend-air door motor.
²Improper engine coolant temperature.
²Faulty heater-A/C control.
SPECIFICATIONS - HEATER-A/C SYSTEM
ITEM DESCRIPTION NOTES
Vehicle RS - Caravan, Town & Country, Voyager
System R134a with expansion valve(s)
Compressor Nippondenso - 10S20 ND-8 PAG Oil
Freeze±up Control evaporator temperature sensor expansion valve mounted - input
to heater-A/C control module
Low PSI Control liquid line mounted - input to
Powertrain Control Module (PCM)
- PCM opens compressor clutch
relay < 29.4 psi
High PSI Control pressure transducer liquid line mounted - input to
PCM - PCM opens compressor
clutch relay > 450 psi
pressure relief valve compressor mounted - opens >
495 psi
Control Head single zone, dual zone, and three zone
Manual Temperature Control (MTC) - or three
zone Automatic Temperature Control (ATC)PCI data bus messaging - ATC
uses three infrared temperature
sensors - two front/one rear
Mode Door electric actuator Control head driven
Blend Air Door electric actuator
Fresh/Recirc Door electric actuator
Blower Motor control head switch resistor and relay with MTC,
power module and relay with ATC
Cooling Fans pulse width modulated variable speed PCM control through solid state
fan relay
Clutch
Clutch Control PCM PCM control through compressor
clutch relay
Clutch Coil Draw 2.2 amps @ 12V   0.5amps@ 70É F
Compressor Clutch Air Gap 0.0209- 0.0359
Diagnostics DRBIIITscan tool
RSHEATING & AIR CONDITIONING24-7
HEATING & AIR CONDITIONING (Continued)
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CONTROLS - FRONT
TABLE OF CONTENTS
page page
A/C HEATER CONTROL
STANDARD PROCEDURE - HEATER-A/C
CONTROL CALIBRATION................8
REMOVAL.............................9
INSTALLATION..........................9
A/C PRESSURE TRANSDUCER
DESCRIPTION - A/C PRESSURE
TRANSDUCER.......................10
OPERATION...........................10
DIAGNOSIS AND TESTING - A/C PRESSURE
TRANSDUCER.......................10
REMOVAL.............................11
INSTALLATION.........................11
BLEND DOOR ACTUATOR
DESCRIPTION.........................11
OPERATION...........................11
REMOVAL.............................12
INSTALLATION.........................12
BLOWER MOTOR RELAY
DESCRIPTION.........................13
OPERATION...........................13
DIAGNOSIS AND TESTING - BLOWER
MOTOR RELAY.......................14
REMOVAL.............................14
INSTALLATION.........................14
BLOWER MOTOR RESISTOR
DESCRIPTION.........................15
OPERATION...........................15
DIAGNOSIS AND TESTING - BLOWER
MOTOR RESISTOR....................15
REMOVAL.............................16
INSTALLATION.........................16
COMPRESSOR CLUTCH
DESCRIPTION.........................16
OPERATION...........................17
STANDARD PROCEDURE
STANDARD PROCEDURE - COMPRESSOR
CLUTCH AIR GAP.....................17STANDARD PROCEDURE - COMPRESSOR
CLUTCH BREAK-IN....................17
REMOVAL.............................17
INSPECTION - COMPRESSOR CLUTCH/COIL . 18
INSTALLATION.........................19
COMPRESSOR CLUTCH COIL
DIAGNOSIS AND TESTING - COMPRESSOR
CLUTCH COIL........................20
COMPRESSOR CLUTCH RELAY
DESCRIPTION.........................21
OPERATION...........................21
DIAGNOSIS AND TESTING - COMPRESSOR
CLUTCH RELAY......................22
REMOVAL.............................22
INSTALLATION.........................22
EVAPORATOR TEMPERATURE SENSOR
DESCRIPTION.........................22
OPERATION...........................23
REMOVAL.............................23
INSTALLATION.........................23
INFRARED TEMPERATURE SENSOR
DESCRIPTION.........................24
OPERATION...........................24
MODE DOOR ACTUATOR
DESCRIPTION.........................24
OPERATION...........................25
REMOVAL.............................25
INSTALLATION.........................25
POWER MODULE
DESCRIPTION.........................26
OPERATION...........................26
REMOVAL.............................26
INSTALLATION.........................27
RECIRCULATION DOOR ACTUATOR
DESCRIPTION.........................27
OPERATION...........................27
REMOVAL.............................28
INSTALLATION.........................28
A/C HEATER CONTROL
STANDARD PROCEDURE - HEATER-A/C
CONTROL CALIBRATION
The heater-A/C control module must be recali-
brated each time an actuator motor or the control
module is replaced. If the vehicle is so equipped, the
calibration procedure also includes rear HVAC posi-
tions for each actuator motor.(1) Turn the ignition switch to the On position.
(2) Simultaneously depress and hold the Power
and Recirculation buttons on the heater-A/C control
for at least five seconds. The manual heater-A/C con-
trol power Light Emitting Diode (LED) and Recircu-
lation LED, or the Automatic Temperature Control
(ATC) heater-A/C control Delay and Recirculation
graphics will begin to flash when the calibration pro-
cedure has begun.
24 - 8 CONTROLS - FRONTRS
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