2003 CHRYSLER CARAVAN wheel torque

CONDITION POSSIBLE CAUSES CORRECTION
MAIN BEARING NOISE 1. Insufficient oil supply. 1. Check engine oil level.
2. Low oil pressure. 2. Check engine oil level. Inspect oil
pump relief valve and spring.
3. Thin or diluted oil. 3. Change oil to correct viscosity.
4. Thick oil 4. (a) Change engine oil and filter.
(b) Run engine to operating
temperature.
(c) Change engine oil and filter
again.
5. Excessive bearing clearance. 5. Measure bearings for correct
clearance. Repair as necessary.
6. Excessive end play. 6. Check thrust bearing for wear on
flanges.
7. Crankshaft journal out-of-round
or worn.7. Replace crankshaft or grind
journals.
8. Loose flywheel or torque
converter.8. Tighten to correct torque.
OIL PRESSURE DROP 1. Low oil level. 1. Check engine oil level.
2. Faulty oil pressure sensor/switch. 2. Replace oil pressure sensor/
switch.
3. Low oil pressure. 3. Check oil pressure sensor/switch
and main bearing oil clearance.
4. Clogged oil filter. 4. Install new oil filter.
5. Worn parts in oil pump. 5. Replace worn parts or pump.
6. Thin or diluted oil. 6. Change oil to correct viscosity.
7. Oil pump relief valve stuck. 7. Remove valve and inspect, clean,
or replace.
8. Oil pump suction tube loose. 8. Remove oil pan and install new
tube or clean, if necessary.
9. Oil pump cover warped or
cracked.9. Install new oil pump.
10. Excessive bearing clearance. 10. Measure bearings for correct
clearance.
OIL LEAKS 1. Misaligned or deteriorated
gaskets.1. Replace gasket(s).
2. Loose fastener, broken or porous
metal part.2. Tighten, repair or replace the
part.
3. Misaligned or deteriorated cup or
threaded plug.3. Replace as necessary.
RSENGINE 3.3/3.8L9-81
ENGINE 3.3/3.8L (Continued)
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VIBRATION DAMPER
REMOVAL
(1) Disconnect negative cable from battery.
(2) Raise vehicle on hoist.
(3) Remove the right front wheel and inner splash
shield.
(4) Remove the accessory drive belt. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)
(5) Remove vibration damper bolt.
(6) Insert Special Tool 8450 into crankshaft nose
(Fig. 83).
(7) Position 3-jaw puller Special Tool 1026 on
damper as shown in (Fig. 83). Turn puller forcing
screw until damper releases from crankshaft.
(8) Remove the crankshaft vibration damper.
INSTALLATION
(1) Install crankshaft vibration damper using the
forcing screw, nut, and thrust bearing/washer from
Special Tool 8452 (Fig. 84).NOTE: To minimize friction and prolong tool life,
lubricate the threads on the forcing screw of Spe-
cial Tool 8452.
(2) Position vibration damper on crankshaft.
(3) Screw Special Tool 8452 into crankshaft until
the bolt seats. Turn the nut to install damper until it
seats fully.
(4) Remove Special Tool 8452.
(5) Install vibration damper bolt. Torque bolt to 54
N´m (40 ft. lbs.).
(6) Install the accessory drive belt. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION)
(7) Install inner splash shield and right front
wheel.
(8) Connect negative cable to battery.
Fig. 83 Vibration Damper - Removal
1 - SPECIAL TOOL 8450 - INSERT
2 - SPECIAL TOOL 1026-3JAWPULLER
Fig. 84 Vibration Damper - Installation
1 - FORCING SCREW / NUT FROM SPECIAL TOOL 8452
2 - VIBRATION DAMPER
3 - THRUST BEARING / WASHER
9 - 130 ENGINE 3.3/3.8LRS
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VALVE TIMING
STANDARD PROCEDURE
STANDARD PROCEDURE - VALVE TIMING
VERIFICATION
(1) Remove front cylinder head cover and all 6
spark plugs.
(2) Rotate engine until the #2 piston is at TDC of
the compression stroke.
(3) Install a degree wheel on the crankshaft pulley.
(4) With proper adaptor, install a dial indicator
into #2 spark plug hole. Using the indicator find TDC
on the compression stroke.
(5) Position the degree wheel to zero.
(6) Remove dial indicator from spark plug hole.
(7) Place a 5.08 mm (0.200 in.) spacer between the
valve stem tip of #2 intake valve and rocker arm pad.
Allow tappet to bleed down to give a solid tappet
effect.
(8) Install a dial indicator so plunger contacts the
#2 intake valve spring retainer as nearly perpendic-
ular as possible. Zero the indicator.
(9) Rotate the engine clockwise until the intake
valve has lifted .254 mm (0.010 in.).
CAUTION: Do not turn crankshaft any further clock-
wise as intake valve might bottom and result in
serious damage.
(10) Degree wheel should read 6 degrees BTDC to
6 degrees ATDC.
STANDARD PROCEDURE - MEASURING
TIMING CHAIN WEAR
NOTE: This procedure must be performed with the
timing chain cover removed (Refer to 9 - ENGINE/
VALVE TIMING/TIMING CHAIN COVER - REMOVAL).
(1) Position a scale next to timing chain so that
any movement of chain may be measured (Fig. 132).
(2) Position a torque wrench and socket on the
camshaft sprocket attaching bolt. Apply force in the
direction of crankshaft rotation to take up slack to
the following torque:
²41 N´m (30 ft. lb.) with cylinder heads installed
²20 N´m (15 ft. lb.) with cylinder heads removed
NOTE: With torque applied to the camshaft
sprocket bolt, crankshaft should not be permitted to
move. It may be necessary to block crankshaft to
prevent rotation.
(3) Holding a measuring scale along edge of chain
links (Fig. 132).(4) Apply force in the reverse direction to the fol-
lowing torque:
²41 N´m (30 ft. lb.) with cylinder heads installed
²20 N´m (15 ft. lb.) with cylinder heads removed
(5) Measure amount of sprocket/chain movement.
(6) Install a new timing chain and sprockets if
movement exceeds 3.175 mm (1/8 in.).
TIMING CHAIN COVER
REMOVAL
(1) Disconnect negative cable from battery.
(2) Drain cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(3) Raise vehicle on hoist.
(4) Drain engine oil.
(5) Remove right wheel and inner splash shield.
(6) Remove oil pan. (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - REMOVAL)
(7) Remove oil pick-up tube (Fig. 133).
(8) Remove accessory drive belt. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)
(9) Remove A/C compressor and set aside.
(10) Remove crankshaft vibration damper. (Refer
to 9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL)
(11) Remove radiator lower hose.
(12) Remove heater hose from timing chain cover
housing (Fig. 134) or water pump inlet tube (if
engine oil cooler equipped) (Fig. 135).
(13) Remove the right side engine mount. (Refer to
9 - ENGINE/ENGINE MOUNTING/RIGHT MOUNT
- REMOVAL)
(14) Remove idler pulley from engine bracket (Fig.
136).
(15) Remove the engine mount bracket (Fig. 136).
Fig. 132 Measuring Timing Chain Wear
1 - TORQUE WRENCH
RSENGINE 3.3/3.8L9 - 153
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FRAME & BUMPERS
TABLE OF CONTENTS
page page
BUMPERS
SPECIFICATIONS - TORQUE...............1
FRONT FASCIA
REMOVAL.............................1
INSTALLATION..........................1
FRONT BUMPER REINFORCEMENT
REMOVAL.............................2
INSTALLATION..........................2
REAR FASCIA
REMOVAL.............................2
INSTALLATION..........................2
REAR BUMPER REINFORCEMENT
REMOVAL.............................3
INSTALLATION..........................3
REAR FASCIA - SCUFF PAD
REMOVAL.............................3INSTALLATION..........................4
FRAME
SPECIFICATIONS
FRAME DIMENSIONS...................4
SPECIFICATIONS - TORQUE.............4
FRONT CRADLE CROSSMEMBER
DESCRIPTION
DESCRIPTION - FRONT CRADLE
CROSSMEMBER.......................9
DESCRIPTION - FRONT CRADLE
CROSSMEMBER THREAD REPAIR.........9
REMOVAL.............................9
INSTALLATION.........................11
FRONT CROSSMEMBER MOUNT BUSHINGS
REMOVAL.............................12
INSTALLATION.........................12
BUMPERS
SPECIFICATIONS - TORQUE
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Front bumper reinforcement attaching nut 54 40 Ð
Rear bumper reinforcement attaching nut 27 20 Ð
FRONT FASCIA
REMOVAL
(1) Release hood latch and open hood.
(2) Remove the headlamp assemblies (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
HEADLAMP - REMOVAL).
(3) Hoist vehicle and support with safety stands.
(4) Remove the five bolts attaching bottom of fas-
cia/air dam to radiator closure panel.
(5) Remove front wheels.
(6) Remove front wheelhouse splash shields fasten-
ers as necessary to gain access to bolts attaching
front fascia to fender. (Refer to 23 - BODY/EXTERI-
OR/ WHEELHOUSE SPLASH SHIELD - REMOV-
AL).
(7) Remove the two bolts and two nuts attaching
fascia to the front fenders (Fig. 1).
(8) Disconnect fog lamp wire connectors, if neces-
sary.
(9) Lower vehicle.(10) Remove two bolts attaching the upper grille
support to the headlamp mounting panel at each side
of the grille.
(11) Remove bumper fascia from vehicle.
INSTALLATION
(1) Position front bumper fascia on vehicle.
(2) Install the two bolts attaching fascia to head-
lamp mounting panel at each side of grille.
(3) Hoist vehicle and support with safety stands.
(4) Install the two bolts and two nuts attaching
fascia to the front fenders (Fig. 1). The fascia should
be flush to fender.
(5) Install front wheelhouse splash shields fasten-
ers. (Refer to 23 - BODY/EXTERIOR/ WHEEL-
HOUSE SPLASH SHIELD - INSTALLATION).
(6) Install front wheels.
(7) Connect fog lamp wire connectors, if necessary.
(8) Install the five bolts attaching bottom of fascia
to radiator closure panel.
(9) Lower the vehicle.
RSFRAME & BUMPERS13-1
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INSTALLATION
NOTE: If cradle crossmember requires replacement.
Refer to Group 2, Suspension, to transfer suspen-
sion components and Group 19, Steering, to trans-
fer steering components.
(1) Support crossmember on suitable lifting device
(Fig. 14).
(2) Position crossmember to vehicle.
(3) Loosely install bolts attaching cradle cross-
member to front frame rails.
(4) Align crossmember to previously made marks
on frame rails.
(5) Tighten bolts attaching cradle crossmember to
frame rails.
(6) Install through bolt attaching rear engine
mount to cradle crossmember (Fig. 12) and tighten to
68 N´m (50 ft. lbs.) torque.
(7) Install the rear mount heat shield (Fig. 11).
(8) Connect lower ball joints to steering knuckles
(Refer to 2 - SUSPENSION/FRONT/LOWER BALL
JOINT - INSTALLATION)
(9) Connect stabilizer bar links to ends of stabi-
lizer bar.
(10) Install bolts attaching anti-lock brake sensor
leads to cradle crossmember.
(11) Install high pressure hose to pump.
(12) Connect return hose to metal tube.
(13) Tighten hose clamp at the cradle crossmember
coupling.
(14) Remove pinch-off pliers.
(15) Position steering so front wheels are straight
ahead.
(16) Install steering column coupling to telescoping
steering gear shaft.
(17) Install clinch bolt attaching steering column
coupling to steering gear shaft.
(18) Install steering column cover backing plate
(Refer to 23 - BODY/INSTRUMENT PANEL/STEER-
ING COLUMN COVER BACKING PLATE -
INSTALLATION)
(19) Install steering column lower cover from
instrument panel (Refer to 23 - BODY/INSTRU-
MENT PANEL/STEERING COLUMN OPENING
COVER - INSTALLATION).
(20) Connect battery negative cable.
Fig. 12 REAR MOUNT
1 - BOLT
2 - REAR MOUNT BRACKET
3 - THROUGH BOLT
4 - REAR MOUNT
Fig. 13 CRADLE CROSSMEMBER MOUNT
1 - CROSSMEMBER MOUNT
2 - BRAKE HOSE MOUNT
3 - STEERING TIE ROD
4 - FRONT CROSSMEMBER
5 - FRAME RAIL
RSFRAME & BUMPERS13-11
FRONT CRADLE CROSSMEMBER (Continued)
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STEERING
TABLE OF CONTENTS
page page
STEERING
DESCRIPTION - POWER STEERING SYSTEM . . 1
OPERATION - POWER STEERING SYSTEM . . . 1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - POWER
STEERING SYSTEM FLOW AND
PRESSURE TEST......................1
DIAGNOSIS AND TESTING - STEERING
SYSTEM DIAGNOSIS CHARTS............3SPECIFICATIONS
POWER STEERING FASTENER TORQUE . . . 9
SPECIAL TOOLS
POWER STEERING....................9
COLUMN..............................10
GEAR.................................26
PUMP.................................36
STEERING
DESCRIPTION - POWER STEERING SYSTEM
This vehicle comes with power steering as stan-
dard equipment. The power steering system consists
of these major components:
²POWER STEERING PUMP
²POWER STEERING GEAR
²POWER STEERING FLUID
²POWER STEERING FLUID COOLER
²POWER STEERING FLUID RESERVOIR
²POWER STEERING FLUID SUPPLY HOSE
²POWER STEERING FLUID PRESSURE HOSE
²POWER STEERING FLUID RETURN HOSE
For information on the first two components, refer
to their respective sections within this service man-
ual group. Information on all other components can
be found in POWER STEERING PUMP.
OPERATION - POWER STEERING SYSTEM
Turning of the steering wheel is converted into lin-
ear (side-to-side) travel through the meshing of the
helical pinion teeth with the rack teeth within the
steering gear. The lateral travel pushes and pulls the
tie rods to change the direction of the vehicle's front
wheels.
Power assist steering is provided by a belt driven
rotary type pump. It directs fluid through power
steering fluid hoses to the power steering gear where
it is used to assist the driver's turning effort.
Manual steering control of the vehicle can be main-
tained if power steering assist is lost. However,
under this condition, steering effort is significantly
increased.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - POWER STEERING
SYSTEM FLOW AND PRESSURE TEST
ALL ENGINES
The following procedure is to be used to test the
operation of the power steering system on this vehi-
cle. This test will provide the flow rate of the power
steering pump along with the maximum relief pres-
sure. This test is to be performed to determine if the
power steering pump or power steering gear is not
functioning properly. The following flow and pressure
test is performed using the Power Steering Analyzer
Kit, Special Tool 6815 (Fig. 1), hoses, Special Tools
6905 and 6959, and fittings from adapter kit, Special
Tool 6893.
Fig. 1 Power Steering Analyzer With Hoses Installed
1 - OUTLET
2 - SPECIAL TOOL 6815
3 - INLET
RSSTEERING19-1
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(6) Start engine and let idle just long enough to
circulate power steering fluid through the analyzer
and hoses. Shut off engine.
(7) Check power steering fluid level and add fluid
as necessary. Start engine again and let idle until the
air is out of the fluid.
(8) Gauge should read below 300 psi (2068 kPa). If
above, inspect the hoses for restrictions and repair as
necessary. The initial pressure should be in the range
of 100-275 psi (689-1896 kPa) depending on fluid
temperature. The flow meter should read above 1.5
GPM.
CAUTION: The following test procedure involves
testing maximum pump pressure output and flow
control valve operation. Do not leave valve closed
for more than four seconds as the pump could be
damaged.
NOTE:
Power steering pump maximum pressure for
2.4L engines is 1,200 ± 1,350 psi (8,274 ± 9,308 kPa).
Power steering pump maximum pressure for all other
engines is 1,400 ± 1,500 psi (9,653 ± 10,342 kPa).
(9) Close analyzer valve fully three times and
record highest pressure indicated each time. All three
readings must be within specifications. If any of the
three power steering pump pressures are above orbelow specifications, replace pump. (Refer to 19 -
STEERING/PUMP - REMOVAL)
CAUTION: Do not force the steering to operate
against the stops for more than 4 seconds at a time
because pump damage can result.
(10) Once the pump has been verified as working
correctly, completely open the valve on the Power
Steering Analyzer. Turn the steering wheel to the
extreme left until the stop in the steering gear is
met. Hold it there for 2±4 seconds, then release it.
Now turn the steering wheel to the right until the
right stop is met. Hold it there for 2±4 seconds, then
release it. Record the stabilized pressure at each
position. Compare the recorded readings to the spec-
ifications. If the output pressures are not within 100
psi (689 kPa) of one another against either stop or
are below specifications, the steering gear is leaking
internally and must be replaced. (Refer to 19 -
STEERING/GEAR - REMOVAL)
DIAGNOSIS AND TESTING - STEERING
SYSTEM DIAGNOSIS CHARTS
NOTE: There are three diagnosis charts following
that cover POWER STEERING NOISE, STEERING
WHEEL FEEL, and POWER STEERING FLUID.
POWER STEERING NOISE
CONDITION POSSIBLE CAUSES CORRECTION
OBJECTIONABLE HISS
OR WHISTLE*1. Damaged or mispositioned
steering column shaft/coupling dash
panel seal.1. Reposition or replace steering column
shaft/coupling dash panel seal.
2. Noisy valve in power steering
gear.2. Replace power steering gear.
3. Mis-routed power steering hose. 3. Check routing of power steering
hoses. Ensure hoses do not come in
unwanted contact with other components
and objects.
RATTLE OR EXCESSIVE
CLUNK**1. Power steering gear loose on front
suspension crossmember.1. Inspect power steering gear mounting
bolts. Replace as necessary. Tighten to
the specified torque.
2. Front suspension crossmember
mounting fasteners loose at frame.2. Tighten the front suspension
crossmember mounting fasteners to the
specified torque.
3. Loose tie rod (outer or inner). 3. Check tie rod pivot points for wear.
Replace worn/loose parts as required.
4. Loose lower control arm mounting
bolts at front suspension
crossmember.4. Tighten control arm mounting bolts to
the specified torques.
RSSTEERING19-3
STEERING (Continued)
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CONDITION POSSIBLE CAUSES CORRECTION
5. Lower control arm pivot bushing
worn.5. Replace lower control arm pivot
bushing.
6. Loose strut assembly mounting
fasteners at tower or knuckle.6. Tighten strut assembly fasteners to the
specified torque.
7. Power steering fluid hose touching
the body of the vehicle.7. Adjust hose to proper position by
loosening, repositioning, and tightening
attachments to specified torque. Do not
bend tubing.
8. Internal power steering gear
noise.8. Replace power steering gear.
9. Damaged front suspension
crossmember.9. Replace front suspension
crossmember.
10. Stabilizer bar link ball joints
worn.10. Replace stabilizer bar link.
11. Lug nuts loose. 11. Tighten lug nuts to specifications.
12. Excessive Wheel bearing
free-play.12. Verify correct driveshaft hub nut
torque. Replace bearing if torque is okay.
POPPING NOISE 1. Worn outer tie rod. 1. Check ball joint for free-play; Replace
outer tie rod.
2. Loose inner tie rod. 2. Replace power steering gear.
CHIRP OR SQUEAL
(POWER STEERING
PUMP)1. Loose power steering pump drive
belt.1. Check and adjust power steering
pump drive belt to specifications or
replace automatic tensioner where
applicable. Replace belt if worn or
glazed.
2. Malfuctioning belt auto-tensioner 2. Replace belt auto-tensioner.
WHINE, GROWL, MOAN
OR GROAN (POWER
STEERING PUMP)***1. Low fluid level. 1. Fill power steering fluid reservoir to
proper level and check for leaks (make
sure all air is bled from the system fluid).
2. Power steering hose touching
vehicle body or frame.2. Adjust hose to proper position by
loosening, repositioning, and tightening
fitting to specified torque. Do not bend
tubing. Replace hose if damaged.
3. Extreme wear of power steering
pump internal components.3. Replace power steering pump and
flush system as necessary.
4. Extremely low ambient
temperature.4. Some noise can be expected, but will
go away as vehicle warms. Replace
pump if noise is excessive.
SUCKING AIR SOUND 1. Loose clamp on power steering
fluid return hose.1. Tighten or replace hose clamp.
2. Missing O-Ring on power steering
hose connection.2. Inspect connection and replace O-Ring
as required.
3. Low power steering fluid level. 3. Fill power steering fluid reservoir to
proper level and check for leaks.
4. Loose clamp on fluid supply hose. 4. Tighten or replace hose clamp.
19 - 4 STEERINGRS
STEERING (Continued)
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