2002 CHRYSLER TOWN AND COUNTRY Hoses

RADIATOR FAN RELAY
DESCRIPTION
The low and high speed fan relays are mounted to
the upper radiator support above the charge air
cooler (Fig. 25).
OPERATION
The cooling system uses two fans. Both fans oper-
ate at two different speeds, low and high. Depending
on engine coolant temperature and A/C system high
side pressure, the fans operate at either low or high.
The ignition switch supplies voltage to the coil side of
the relay. When the ECM grounds the coil side of the
relay, the contacts close and the battery supplies
power to the fans.
COOLANT SYSTEM HOSES
REMOVAL
REMOVAL - UPPER RADIATOR HOSE
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.(1) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(2) Drain cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(3) Remove upper radiator hose (Fig. 26).
REMOVAL - LOWER RADIATOR HOSE
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.
(1) Drain cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(2) Remove lower radiator hose (Fig. 26).
Fig. 25 RELAY LOCATIONS
1 - GLOW PLUG RELAY
2 - UPPER RADIATOR SUPPORT
3 - CHARGE AIR COOLER OUTLET HOSE
4 - RADIATOR FAN RELAYS
5 - UPPER RADIATOR HOSE
6 - EGR SOLENOID
Fig. 26 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-29
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REMOVAL - COOLANT BYPASS HOSE
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.
(1) Drain cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(2) Remove the coolant bypass hose (Fig. 26).
INSTALLATION
INSTALLATION - UPPER RADIATOR HOSE
(1) Install upper radiator hose (Fig. 26).(2) Refill cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(3) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
INSTALLATION - LOWER RADIATOR HOSE
(1) Install lower radiator hose (Fig. 26).
(2) Refill cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
INSTALLATION - COOLANT BYPASS HOSE
(1) Install cooling system bypass hose (Fig. 26).
(2) Refill cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
7a - 30 ENGINERG
COOLANT SYSTEM HOSES (Continued)
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OPERATION
The Transmission Control Module (TCM) first
senses that the speed control is set. If the set speed
is exceeded by more than 4 mph (6.5 km/hr) and the
throttle is closed, the TCM causes the transaxle to
downshift to THIRD gear. After downshifting, the
automatic speed control resumes normal operation.
To ensure that an upshift is appropriate after the set
speed is reached, the TCM waits until the speed con-
trol system opens the throttle at least 6 degrees
before upshifting to OVERDRIVE again.
If the driver applies the brakes, canceling auto-
matic speed control operation with the transaxle still
in THIRD gear, the TCM maintains this gear until
the driver opens the throttle at least 6 degrees to
avoid an inappropriate upshift. The upshift is also
delayed for 2.5 seconds after reaching the 6 degrees
throttle opening in anticipation that the driver might
open the throttle enough to require THIRD gear.
This will avoid unnecessary and disturbing transmis-
sion cycling. If the automatic speed control RESUME
feature is used after braking, the upshift is delayed
until the set speed is achieved to reduce cycling and
provide better response.
DIAGNOSIS AND TESTING - ROAD TEST
Perform a vehicle road test to verify reports of
speed control system malfunction. The road test
should include attention to the speedometer. Speed-
ometer operation should be smooth and without flut-
ter at all speeds.
Flutter in the speedometer indicates a problem
which might cause surging in the speed control sys-tem. The cause of any speedometer problems should
be corrected before proceeding. Refer to the Instru-
ment Cluster for speedometer diagnosis.
If a road test verifies an inoperative system, and
the speedometer operates properly, check for:
²A Diagnostic Trouble Code (DTC). If a DTC
exists, conduct tests per the Powertrain Diagnostic
Procedures manual.
²A misadjusted brake (stop) lamp switch. This
could also cause an intermittent problem.
²Loose or corroded electrical connections at the
servo. Corrosion should be removed from electrical
terminals and a light coating of Mopar Multipurpose
Grease, or equivalent, applied.
²Leaking vacuum reservoir.
²Loose or leaking vacuum hoses or connections.
²Defective one-way vacuum check valve.
²Secure attachment at both ends of the speed
control servo cable.
²Smooth operation of throttle linkage and throttle
body air valve.
²Conduct electrical test at PCM.
²Failed speed control servo. Do the servo vacuum
test.
CAUTION: When test probing for voltage or conti-
nuity at electrical connectors, care must be taken
not to damage connector, terminals or seals. If
these components are damaged, intermittent or
complete system failure may occur.
SPECIFICATIONS - TORQUE
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Servo Mounting Bracket Nuts 14 10.3 123.9
Servo Mounting Bracket Bolts 14 10.3 123.9
Servo Mounting Nuts 6.7 60
RSSPEED CONTROL8P-3
SPEED CONTROL (Continued)
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(2) Turn off ignition.
(3) Remove the air bag, refer to the restraint sec-
tion for more information.
(4) Remove the screw from bottom of the switch.
(5) Remove switch from steering wheel.
(6) Disconnect two-way electrical connector.
(7) Repeat for the other switch.
INSTALLATION
The speed control switches are mounted in the
steering wheel and wired through the clock spring
device under the airbag module.
WARNING: IF REMOVAL OF AIRBAG MODULE IS
NECESSARY, REFER TO THE RESTRAINT SYS-
TEMS SECTION FOR MORE INFORMATION.
(1) Connect two-way electrical connector.
(2) Install switch.
(3) Install screw for the switch.
(4) Repeat for the other switch.
(5) Install the air bag, refer to the restraint section
for more information.
(6) Install the negative battery cable.
VACUUM RESERVOIR
DESCRIPTION
The vacuum reservoir is located in the engine com-
partment. It is made of plastic.
OPERATION
The reservoir stores engine vacuum. Manifold vac-
uum is supplied from the brake booster check valve.
The speed control vacuum supply hose has a check
valve at the source (brake booster) to maintain the
highest available vacuum level in the servo, reservoir
and vacuum hoses. When engine vacuum drops, as in
climbing a grade while driving, the reservoir supplies
the vacuum needed to maintain proper speed control
operation. The vacuum reservoir cannot be repaired
and must be replaced if faulty.
REMOVAL
(1) Release hood latch and open hood.
(2) Disconnect the negative battery cable.
(3) Disconnect the vacuum line to the battery tray/
vacuum reservoir.
(4) Remove battery tray/vacuum reservoir, refer to
the Battery section for more information.
INSTALLATION
(1) Install battery tray/vacuum reservoir, refer to
the Battery section for more information.
(2) Connect vacuum line that leads to the battery
tray/vacuum reservoir.
(3) Connect the negative battery cable.
8P - 6 SPEED CONTROLRS
SWITCH (Continued)
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WIPERS/WASHERS
TABLE OF CONTENTS
page page
WIPERS/WASHERS
DESCRIPTION..........................1
OPERATION............................2
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - FRONT WIPER
SYSTEM.............................2
DIAGNOSIS AND TESTING - FRONT
WIPER/WASHER SWITCH................2
DIAGNOSIS AND TESTING - FAILED PARK
SWITCH.............................3
DIAGNOSIS AND TESTING - REAR WIPER
SYSTEM.............................5
DIAGNOSIS AND TESTING - WASHER
SYSTEM.............................5
FRONT WASHER PUMP MOTOR
REMOVAL.............................9
INSTALLATION..........................9
FRONT WIPER ARMS
STANDARD PROCEDURE - FRONT WIPER
ARM ALIGNMENT......................9
REMOVAL.............................10
INSTALLATION.........................10
FRONT WIPER MOTOR
REMOVAL.............................10
INSTALLATION.........................10
HEADLAMP WASHERS - EXPORT
DESCRIPTION.........................11
OPERATION...........................11
DIAGNOSIS AND TESTING - HEADLAMP
WASHERS - EXPORT..................11
REMOVAL.............................13
INSTALLATION.........................13
HEADLAMP WASHER HOSE - EXPORT
REMOVAL.............................13
INSTALLATION.........................13HEADLAMP WASHER PUMP MOTOR - EXPORT
REMOVAL.............................13
INSTALLATION.........................14
REAR WASHER PUMP MOTOR
REMOVAL.............................14
INSTALLATION.........................15
REAR WIPER ARM
REMOVAL.............................15
INSTALLATION.........................15
REAR WIPER MOTOR
REMOVAL.............................16
INSTALLATION.........................16
REAR WIPER/WASHER SWITCH
DESCRIPTION.........................16
OPERATION...........................16
WASHER FLUID LEVEL SWITCH
REMOVAL.............................16
INSTALLATION.........................17
WASHER HOSES
REMOVAL.............................17
INSTALLATION.........................17
WASHER RESERVOIR
REMOVAL.............................18
INSTALLATION.........................18
WIPER BLADES
REMOVAL.............................18
CLEANING............................19
INSTALLATION.........................19
WIPER LINKAGE
REMOVAL.............................19
INSTALLATION.........................19
WIPER MODULE
REMOVAL.............................19
INSTALLATION.........................20
WIPERS/WASHERS
DESCRIPTION
FRONT WIPER/WASHER SYSTEM
The windshield wipers can be operated with the
windshield wiper switch when the ignition switch is
in the RUN or ACCESSORY positions. The wind-
shield wiper system is protected by a 30 amp fuse (9)
located in the Power Distribution Center (PDC) partof the Integrated Power Module (IPM) in the engine
compartment. The wiper/washer switch is integral to
the multi-function switch. It is a resistive MUX
switch that sends inputs to the BCM to operate the
wiper/washer system.REAR WIPER/WASHER SYSTEM
The rear windshield wiper and washers can be
operated when the ignition switch is in the RUN or
ACCESSORY positions.
RSWIPERS/WASHERS8R-1
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(9) Drain washer fluid from the reservoir and into
a suitable clean container. This can be done by dis-
connecting the windshield washer hose from the
front (outboard) washer pump and allowing the
washer fluid to drain into a container through a tem-
porary jumper hose connected to the front washer
pump.
(10) Disconnect the rear washer pump hose from
washer pump.
(11) Disconnect the high pressure headlamp
washer pump hose by pressing down firmly on latch
and pulling hose off.
(12) Disconnect the electrical body harness connec-
tors to the washer pump motors and the fluid level
sensor. Slide the red lock on the connector to the
release position, then, depress the black tab and pull
the connector off the pump or sensor.
(13) Remove the two reservoir mounting screws.
(14) Disconnect the reservoir from the body mount
by raising the reservoir upward slightly and then
down so that the reservoir filler neck and front
washer hose pull through the opening in the front
fender side shield.
(15) Remove pump from reservoir by pulling pump
up and away from reservoir cavity and out of mount-
ing grommet. Do not damage reservoir/pump sealing
surface or puncture reservoir during removal.
(16) Remove pump grommet and discard.
INSTALLATION
(1) Use new grommet when installing a new pump
assembly.
(2) Assure pump upper retention tab is pressed
into reservoir slot and assure the pump is aligned to
and fully seated in the reservoir cavity.
(3) Push filler neck and front washer hose through
the opening in the front fender side shield. Connect
the reservoir to the body mount by lowering the res-
ervoir down.
(4) Install the two reservoir mounting screws.
Torque screws to 8.5 - 11.3 N´m (75 - 100 in. lbs.).
(5) Connect the electrical body harness connectors
to the washer pump motors and the fluid level sen-
sor. Slide the red lock on the connector to the closed
or locked position.
(6) Connect front and rear washer pump hoses and
assure that they are properly routed to prevent
pinching and possible inoperative washers.
(7) Connect the high pressure headlamp washer
hose by firmly pushing hose onto inlet until a snap is
heard.
(8) Connect the left right front wheelhouse splash
shield and move aside (Refer to 23 - BODY/EXTERI-
OR/WHEELHOUSE SPLASH SHIELD - INSTALLA-
TION).(9) Install the right front wheel and tire assembly
(Refer to 22 - TIRES/WHEELS - INSTALLATION).
(10) lower vehicle from hoist or jack stands.
(11) Install the filler tube screw. Torque screw to
8.5 - 11.3 N´m (75 - 100 in. lbs.).
(12) Connect the washer hose to the hose clip
located on the front fender side shield.
(13) Connect the washer hose at the in-line con-
nector forward of the cowl grille.
(14) Install the engine fresh air housing inside the
engine compartment (Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER HOUSING -
INSTALLATION).
(15) Connect the battery negative cable.
(16) Verify vehicle and system operation.
REAR WASHER PUMP MOTOR
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the engine fresh air housing inside the
engine compartment (Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER HOUSING -
REMOVAL).
(3) Disconnect the washer hose at the in-line con-
nector forward of the cowl grille so that the in-line
connector remains with the washer hose from the
fresh air plenum.
(4) Disconnect the washer hose from the hose clip
located on the front fender side shield.
(5) Remove the filler tube screw.
(6) Hoist and support vehicle on hoist or jack
stands.
(7) Remove the right front wheel and tire assembly
(Refer to 22 - TIRES/WHEELS - REMOVAL).
(8) Disconnect the left right front wheelhouse
splash shield and move aside (Refer to 23 - BODY/
EXTERIOR/WHEELHOUSE SPLASH SHIELD -
REMOVAL).
(9) Drain washer fluid from the reservoir and into
a suitable clean container. This can be done by dis-
connecting the windshield washer hose from the
front (outboard) washer pump and allowing the
washer fluid to drain into a container through a tem-
porary jumper hose connected to the front washer
pump.
(10) Disconnect the electrical body harness connec-
tors to the washer pump motors and the fluid level
sensor. Slide the red lock on the connector to the
release position, then, depress the black tab and pull
the connector off the pump or sensor.
(11) Remove the two reservoir mounting screws.
8R - 14 WIPERS/WASHERSRS
HEADLAMP WASHER PUMP MOTOR - EXPORT (Continued)
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(6) Hoist and support vehicle on hoist or jack
stands.
(7) Remove the right front wheel and tire assembly
(Refer to 22 - TIRES/WHEELS - REMOVAL).
(8) Disconnect the left right front wheelhouse
splash shield and move aside (Refer to 23 - BODY/
EXTERIOR/WHEELHOUSE SPLASH SHIELD -
REMOVAL).
(9) Drain washer fluid from the reservoir and into
a suitable clean container. This can be done by dis-
connecting the windshield washer hose from the
front (outboard) washer pump and allowing the
washer fluid to drain into a container through a tem-
porary jumper hose connected to the front washer
pump.
(10) Disconnect the electrical body harness connec-
tors to the washer pump motors and the fluid level
sensor. Slide the red lock on the connector to the
release position, then, depress the black tab and pull
the connector off the pump or sensor.
(11) Remove the two reservoir mounting screws.
(12) Disconnect the reservoir from the body mount
by raising the reservoir upward slightly and then
down so that the reservoir filler neck and front
washer hose pull through the opening in the front
fender side shield.
(13) Remove the sensor from reservoir by using a
side foot to gently pry the sensor from the body of
the reservoir. Do not damage the reservoir/sensor
sealing surface or puncture reservoir during removal.
CAUTION: To avoid damage to the sensor, assure
the reservoir is in an upright position before remov-
ing the sensor from the reservoir. Do not rotate the
sensor during removal.
INSTALLATION
(1) Use a new grommet when installing a new sen-
sor assembly.
(2) Assure that the flat of the sensor is aligned
under the ridge of the reservoir and that the sensor
connector is facing down in the fully seated position.
This will allow for proper operation of the sensor
float switch.
(3) Push filler neck and front washer hose through
the opening in the front fender side shield. Connect
the reservoir to the body mount by lowering the res-
ervoir down.
(4) Install the two reservoir mounting screws.
Torque screws to 8.5 - 11.3 N´m (75 - 100 in. lbs.).(5) Connect the electrical body harness connectors
to the washer pump motors and the fluid level sen-
sor. Slide the red lock on the connector to the closed
or locked position.
(6) Assure that washer hose is properly routed to
prevent pinching and possible inoperative washers.
(7) Connect the left right front wheelhouse splash
shield and move aside (Refer to 23 - BODY/EXTERI-
OR/WHEELHOUSE SPLASH SHIELD - INSTALLA-
TION).
(8) Install the right front wheel and tire assembly
(Refer to 22 - TIRES/WHEELS - INSTALLATION).
(9) lower vehicle from hoist or jack stands.
(10) Install the filler tube screw. Torque screw to
8.5 - 11.3 N´m (75 - 100 in. lbs.).
(11) Connect the washer hose to the hose clip
located on the front fender side shield.
(12) Connect the washer hose at the in-line con-
nector forward of the cowl grille.
(13) Install the engine fresh air housing inside the
engine compartment (Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER HOUSING -
INSTALLATION).
(14) Connect the battery negative cable.
(15) Verify system operation.
WASHER HOSES
REMOVAL
(1) Remove washer reservoir from vehicle (Refer to
8 - ELECTRICAL/WIPERS/WASHERS/WASHER
RESERVOIR - REMOVAL).
(2) Disconnect washer hose front the reservoir cav-
ity.
(3) Disconnect the washer hose from the reservoir
pump.
(4) Remove parts as necessary to replace washer
hose (engine compartment, interior components, etc.).
INSTALLATION
(1) Install parts as necessary to after replacing
washer hose (engine compartment, interior compo-
nents, etc.).
(2) Connect the washer hose to the reservoir
pump.
(3) Connect washer hose to the reservoir cavity.
(4) Install the washer reservoir into vehicle (Refer
to 8 - ELECTRICAL/WIPERS/WASHERS/WASHER
RESERVOIR - INSTALLATION).
RSWIPERS/WASHERS8R-17
WASHER FLUID LEVEL SWITCH (Continued)
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DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - PERFORMANCE
CONDITION POSSIBLE CAUSE CORRECTION
ENGINE WILL NOT START 1. Weak battery. 1. Test battery. Charge or replace
as necessary. (Refer to 8 -
ELECTRICAL/BATTERY SYSTEM -
DIAGNOSIS AND TESTING)
2. Corroded or loose battery
connections.2. Clean and tighten battery
connections. Apply a coat of light
mineral grease to terminals.
3. Faulty starter. 3. Test starting system. (Refer to 8 -
ELECTRICAL/STARTING -
DIAGNOSIS AND TESTING)
4. Faulty coil(s) or control unit. 4. Test and replace as needed.
(Refer to Appropriate Diagnostic
Information)
5. Incorrect spark plug gap. 5. Set gap. (Refer to 8 -
ELECTRICAL/IGNITION CONTROL
- SPECIFICATIONS)
6. Contamination in fuel system. 6. Clean system and replace fuel
filter.
7. Faulty fuel pump. 7. Test fuel pump and replace as
needed. (Refer to Appropriate
Diagnostic Information)
8. Incorrect engine timing. 8. Check for a skipped timing
belt/chain.
ENGINE STALLS OR IDLES
ROUGH1. Idle speed too low. 1. Test minimum air flow. (Refer to
Appropriate Diagnostic Information)
2. Incorrect fuel mixture. 2. (Refer to Appropriate Diagnostic
Information)
3. Intake manifold leakage. 3. Inspect intake manifold, manifold
gasket, and vacuum hoses.
4. Faulty ignition coil(s). 4. Test and replace as necessary.
(Refer to Appropriate Diagnostic
Information)
9 - 4 ENGINE 2.4LRS
ENGINE 2.4L (Continued)
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