2003 CHRYSLER CARAVAN engine

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.
There is no need to remove the radiator cap at any
timeexceptfor the following purposes:
(1) Check and adjust coolant freeze point.
(2) Refill system with new coolant.
(3) Conducting service procedures.
(4) Checking for vacuum leaks.
WARNING: IF VEHICLE HAS BEEN RUN RECENTLY,
WAIT 15 MINUTES BEFORE REMOVING CAP. THEN
PLACE A SHOP TOWEL OVER THE CAP AND WITH-
OUT PUSHING DOWN ROTATE COUNTERCLOCK-
WISE TO THE FIRST STOP. ALLOW FLUIDS TO
ESCAPE THROUGH THE OVERFLOW TUBE AND
WHEN THE SYSTEM STOPS PUSHING COOLANT
AND STEAM INTO THE CRS TANK AND PRESSURE
DROPS PUSH DOWN AND REMOVE THE CAP COM-
PLETELY. SQUEEZING THE RADIATOR INLET HOSE
WITH A SHOP TOWEL (TO CHECK PRESSURE)
BEFORE AND AFTER TURNING TO THE FIRST
STOP IS RECOMMENDED.
CLEANING
Use only a mild soap to clean the pressure cap.
INSPECTION
Hold the cap in your hand,top side up(Fig. 20).
The vent valve at the bottom of the cap should open.
If the rubber gasket has swollen, preventing the
valve from opening, replace the cap.Hold the cleaned cap in your hand,upside down.
If any light can be seen between vent valve and the
rubber gasket, replace the cap.Do not use a
replacement cap that has a spring to hold the
vent shut.
A replacement cap must be of the type designed for
coolant reserve systems. This design ensures coolant
return to the radiator.
RADIATOR FAN
DESCRIPTION
The dual radiator fans are mounted to the back
side of the radiator (Fig. 21). The radiator fan consist
of the fan blade, electric motor and a support shroud
which are all serviced as an assembly.
Fig. 20 Cooling System Pressure Cap
1 - OVERFLOW NIPPLE
2 - MAIN SPRING
3 - GASKET RETAINER
4 - STAINLESS-STEEL SWIVEL TOP
5 - RUBBER SEALS
6 - VENT VALVE
7 - RADIATOR
8 - FILLER NECK
7 - 28 ENGINERS
RADIATOR PRESSURE CAP (Continued)
ProCarManuals.com

OPERATION
RADIATOR FAN OPERATION CHART
COOLANT TEMPERATURE A/C PRESSURE TRANSAXLE OIL
TEMPERATURE
Fan
Operation
Speeds:Initial Max Initial Max Initial Max
Fan On: 104ÉC
(220ÉF)110ÉC
(230ÉF) Fan
Speed
Duty-Cycles
(Ramps-up)
from 30% to
99%1,724 Kpa
(250 psi)2,068 Kpa
(300 psi) Fan
Speed
Duty-Cycles
(Ramps-up)
from 30% to
99%96ÉC (204ÉF) 111ÉC (232ÉF)
Fan Speed
Duty Cycles
(Ramps-up)
from 30% to
99%
Fan Off: 101ÉC
(214ÉF)Fan Speed
Duty-Cycles
(Ramps-
down) from
99% to 30%1,710 Kpa
(248 psi)Fan Speed
Duty-Cycles
(Ramps-
down) from
99% to 30%89ÉC (192ÉF) Fan Speed
Duty Cycles
(Ramps-down)
from 99% to
30%
DIAGNOSIS AND TESTING - RADIATOR FAN MOTOR
RADIATOR FAN DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
NOISY RADIATOR FAN 1. Fan blade loose. 1. Replace fan assembly. (Refer to
7 - COOLING/ENGINE/RADIATOR
FAN - REMOVAL)
2. Fan blade striking a surrounding
object.2. Locate point of fan blade contact
and repair as necessary.
3. Air obstructions at radiator or A/C
condenser.3. Remove obstructions and/or
clean debris.
4. Electric fan motor defective. 4. Replace fan assembly. (Refer to
7 - COOLING/ENGINE/RADIATOR
FAN - REMOVAL)
ELECTRIC FAN MOTOR DOES
NOT OPERATE1. Fan relay, powertrain control
module (PCM), coolant temperature
sensor, or wiring defective.1. (Refer to Appropriate Diagnostic
Information) Repair as necessary.
2. Defective A/C pressure
transducer.2. (Refer to Appropriate Diagnostic
Information) Repair as necessary.
ELECTRIC RADIATOR FAN
OPERATES ALL THE TIME1. Fan relay, powertrain control
module (PCM), coolant temperature
sensor or wiring defective.1. (Refer to Appropriate Diagnostic
Information) Repair as necessary.
2. Check for low coolant level. 2. Add coolant as necessary.
3. Defective A/C pressure
transducer.3. (Refer to Appropriate Diagnostic
Information) Repair as necessary.
RSENGINE7-29
RADIATOR FAN (Continued)
ProCarManuals.com

REMOVAL
There are no repairs to be made to the fan or
shroud assembly. If the fan is warped, cracked, or
otherwise damaged, it must be replaced as an assem-
bly (Fig. 21).
(1) Remove the radiator upper crossmember. (Refer
to 23 - BODY/EXTERIOR/GRILLE OPENING REIN-
FORCEMENT - REMOVAL)
(2) Disconnect the radiator fan electrical connec-
tors.
(3) Remove radiator fan(s) retaining screw (Fig.
21).
(4) Remove the radiator fan(s) by lifting upward to
release from mounts.
INSTALLATION
(1) Install the radiator fan(s) into mounts and
attaching clips on the radiator.
(2) Install radiator fan(s) attaching screws (Fig.
21). Tighten to 5 N´m (45 in. lbs.).
(3) Connect the radiator fan(s) electrical connec-
tors.
(4) Install the radiator upper support crossmem-
ber. (Refer to 23 - BODY/EXTERIOR/GRILLE OPEN-
ING REINFORCEMENT - INSTALLATION)
(5) Install the upper radiator mounts to the cross-
member bolts, if removed. Tighten to 8 N´m (70 in.
lbs.).
(6) Install the radiator upper hose to the support
clip (2.4L engine).
RADIATOR FAN RELAY
DESCRIPTION
The radiator fan relay is a solid state type and is
located on the front bumper reinforcment (Fig. 22).
Refer to WIRING DIAGRAMS for a circuit sche-
matic.
OPERATION
The solid state radiator fan relay is controlled by
the Powertrain Control Module (PCM) by way of a
Pulse Width Modulated (PWM) signal. The relay con-
trol circuit supplies a 12 volt signal to the PCM. The
PCM then pulses the ground circuit to achieve fan on
time. The relay provides a voltage to the fan motors
which is proportional to the pulse width it receives
from the PCM. The duty cycle ranges from 30% for
low speed operation, then ramps-up to 100% for high
speed operation. This fan control system provides
infinitely variable fan speeds, allowing for improved
fan noise, A/C performance, better engine cooling,
and additional vehicle power.
To control operation of the relay, the PCM looks at
inputs from:
²Engine coolant temperature
²A/C pressure transducer
²Ambient temperature from the body controller
²Vehicle speed
²Transmission oil temperature
The PCM uses these inputs to determine when the
fan should operate and at what speed. For further
information on fan operation, (Refer to 7 - COOL-
ING/ENGINE/RADIATOR FAN - OPERATION).
REMOVAL
(1) Open hood.
(2) Disconnect and isolate the battery negative
cable.
(3) Remove the radiator crossmember to front fas-
cia closure panel.
(4) Disconnect the relay electrical connector (Fig.
22).
(5) Remove the rivet attaching the relay to the
front bumper beam (Fig. 22).
(6) Remove the relay.
INSTALLATION
CAUTION: The relay mounting location is designed
to dissipate heat. Ensure the relay is securely
attached to prevent relay ªthermalº shutdown and
relay damage, resulting in possible engine over-
heating.
(1) Position relay and install a new rivet (Fig. 22).
(2) Connect electrical connector to relay.
Fig. 21 Radiator Fans
1 - SCREWS - RADIATOR FAN ATTACHING
2 - RADIATOR FAN - RIGHT
3 - MOUNT - RIGHT RADIATOR FAN
4 - CLIPS - RADIATOR FAN LOWER
5 - MOUNT - LEFT RADIATOR FAN
6 - RADIATOR FAN - LEFT
7 - 30 ENGINERS
RADIATOR FAN (Continued)
ProCarManuals.com

(3) Install closure panel and attaching screws.
(4) Connect negative cable to battery.
WATER PUMP - 2.4L
DESCRIPTION
The water pump has a cast aluminum body and
housing with a stamped steel impeller. The water
pump bolts directly to the block (Fig. 23). The cylin-
der block to water pump seal is provided by a rubber
O-ring. The water pump is driven by the engine tim-
ing belt.
REMOVAL
(1) Disconnect negative cable from battery.
(2) Raise vehicle on a hoist.
(3) Remove the right inner splash shield.
(4) Remove the accessory drive belts (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(5) Drain the cooling system (Refer to 7 - COOL-
ING - STANDARD PROCEDURE).
(6) Support engine from the bottom and remove
right engine mount. (Refer to 9 - ENGINE/ENGINE
MOUNTING/RIGHT MOUNT - REMOVAL).
(7) Remove right engine mount bracket (Fig. 24).
(8) Remove the timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKET(S)
- REMOVAL).
Fig. 22 Radiator Fan Relay
1 - FRONT FASCIA
2 - FAN RELAY
3 - RIVET
4 - A/C CONDENSER (FRONT SIDE)
Fig. 23 Water Pump
1 - CYLINDER BLOCK
2 - WATER PUMP
RSENGINE7-31
RADIATOR FAN RELAY (Continued)
ProCarManuals.com

(9) Remove timing belt idler pulley.
(10) Hold camshaft sprocket with Special tool
C-4687 and adaptor C-4687-1 while removing bolt.
Remove both cam sprockets.
(11) Remove the timing belt rear cover (Refer to 9
- ENGINE/VALVE TIMING/TIMING BELT COV-
ER(S) - REMOVAL).
(12) Remove the generator and bracket (Fig. 24).
(13) Remove water pump to engine attaching
screws (Fig. 25).
CLEANING
Clean gasket mating surfaces as necessary.
INSPECTION
Replace water pump body assembly if it has any of
these defects:
(1) Cracks or damage on the body.
(2) Coolant leaks from the shaft seal, evident by
wet coolant traces on the pump body.
(3) Loose or rough turning bearing.
(4) Impeller rubs either the pump body or the
engine block.
(5) Impeller loose or damaged.
(6) Sprocket or sprocket flange loose or damaged.
INSTALLATION
(1) Install new O-ring gasket in water pump body
O-ring locating groove (Fig. 26).
CAUTION: Make sure O-ring is properly seated in
water pump groove before tightening screws. An
improperly located O-ring may be damaged and
cause a coolant leak.
(2) Assemble pump body to block and tighten
screws to 12 N´m (105 in. lbs.) (Fig. 25). Pressurize
cooling system to 103.4 Kpa (15 psi) with pressure
tester and check water pump shaft seal and O-ring
for leaks.
(3) Rotate pump by hand to check for freedom of
movement.
(4) Install the timing belt rear cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT COVER(S)
- INSTALLATION).
(5) Install camshaft sprockets and torque bolts to
101 N´m (75 ft. lbs.) while holding camshaft sprocket
with Special tool C-4687 and adaptor C-4687-1.
(6) Install timing belt idler pulley and torque
mounting bolt to 61 N´m (45 ft. lbs.).
Fig. 24 Generator Bracket
1 - BRACKET - ENGINE MOUNT 5 - BOLT
2 - BOLT 6 - TENSIONER - DRIVE BELT
3 - GENERATOR 7 - BOLT
4 - BOLT 8 - BOLT
7 - 32 ENGINERS
WATER PUMP - 2.4L (Continued)
ProCarManuals.com

(7) Install the timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKET(S)
- INSTALLATION).
(8) Install the generator mount bracket. (Fig. 24)(9) Install the generator.
(10) Install right engine mount bracket and engine
mount (Refer to 9 - ENGINE/ENGINE MOUNTING/
RIGHT MOUNT - INSTALLATION).
(11) Fill the cooling system (Refer to 7 - COOLING
- STANDARD PROCEDURE).
(12) Install the accessory drive belts (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(13) Lower vehicle and connect battery cable.
WATER PUMP - 3.3/3.8L
DESCRIPTION
The water pump has a die-cast aluminum body
and a plastic impeller. It bolts directly to the timing
chain case cover, using a rubber seal for sealing (Fig.
27). It is driven by the accessory drive belt.
REMOVAL
(1) Drain the cooling system. (Refer to 7 - COOL-
ING - STANDARD PROCEDURE)
(2) Remove the accessory drive belt shield.
(3) Remove the accessory drive belt. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)
(4) Remove water pump pulley bolts (Fig. 27).
Fig. 25 Water Pump - 2.4L
1 - CYLINDER BLOCK
2 - WATER PUMP
Fig. 26 Water Pump Body
1 - IMPELLER
2 - WATER PUMP BODY
3 - O-RING LOCATING GROOVE
Fig. 27 Water Pump - 3.3/3.8L Engine
1 - WATER PUMP
2 - PULLEY - WATER PUMP
3 - BOLT - PULLEY
4 - BOLT - WATER PUMP
5 - SEAL - WATER PUMP
RSENGINE7-33
WATER PUMP - 2.4L (Continued)
ProCarManuals.com

NOTE: To remove the water pump pulley, it MUST
first be positioned between water pump housing
and drive hub. The pulley can then be removed with
the water pump assembly.
(5) Rotate pulley until openings in pulley align
with water pump drive hub spokes (Fig. 28). Move
pulley inward between pump housing and hub (Fig.
28).
(6) Position pulley to allow access to water pump
mounting bolts. Remove water pump mounting bolts
(Fig. 29).
(7) Remove water pump with the pulley loosely
positioned between hub and the pump body.
(8) Remove and discard the seal.
(9) Clean seal groove and sealing surfaces on
pump and timing chain case cover. Take care not to
scratch or gouge sealing surfaces.
CLEANING
Clean gasket mating surfaces as necessary.
INSPECTION
Replace the water pump if it has any of the follow-
ing defects.
(1) Damage or cracks on the pump body.
(2) Coolant leaks; this will be evident by a wet
stream of coolant running down the pump body and
components below. A thin stain below the weep hole
reservoir slot (Fig. 30) is considered normal opera-
tion.
(3) Impeller rubs inside of chain case cover.
(4) Excessively loose or rough turning bearing.
NOTE: A weepage stain that is black, brown, or grey
is considered normal, if it is dry. If the weep
appears wet; pressure test the cooling system at
15±18 psi and observe the weep area. If weep arearemains unchanged, do not replace the water pump
for this condition. Replace the water pump, if a
steady flow of engine coolant is evident from the
weep hole/reservoir slot (Fig. 30) (shaft seal failure).
Be sure to perform a thorough analysis before
replacing water pump.
INSTALLATION
(1) Install new seal into water pump housing
groove (Fig. 31).
NOTE: The water pump pulley MUST be positioned
loosely between the pump housing and drive hub
BEFORE water pump installation.
Fig. 28 Water Pump Pulley Positioning
1 - HUB - WATER PUMP
2 - PULLEY - WATER PUMP
Fig. 29 Water Pump Bolts - 3.3/3.8L Engine (Shown
Without Pulley)
1 - WATER PUMP
2 - BOLTS
Fig. 30 Water Pump Inspection - 3.3/3.8L Engine
7 - 34 ENGINERS
WATER PUMP - 3.3/3.8L (Continued)
ProCarManuals.com

(2) Position the water pump pulley loosely between
pump housing and drive hub (Fig. 28).
(3) Install water pump and pulley to the timing
chain case cover (Fig. 27). Tighten water pump bolts
to 12 N´m (105 in. lbs.).
(4) Position pulley on water pump hub. Install
bolts and tighten to 28 N´m (250 in. lbs.) (Fig. 27).
(5) Rotate pump by hand to check for freedom of
movement.
(6) Install the accessory drive belt. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION)
(7) Install drive belt shield.
(8) Fill the cooling system. (Refer to 7 - COOLING
- STANDARD PROCEDURE)
WATER PUMP INLET TUBE -
2.4L
DESCRIPTION
The 2.4L engine uses a metal tube to connect the
engine block to the lower radiator hose and heater
return (Fig. 32). The tube has an O-ring for block to
tube sealing and bolts attach the tube to the engine
block.
REMOVAL
(1) Drain the cooling system. (Refer to 7 - COOL-
ING - STANDARD PROCEDURE)
(2) Remove radiator upper hose to access the hose
connections at the inlet tube.(3) Remove radiator lower (Fig. 7) and heater
hoses from the inlet tube (Fig. 33).
(4) Remove the two fasteners that hold the inlet
tube to the block.
(5) Rotate tube while removing the tube from the
engine block.
INSTALLATION
(1) Inspect the O-ring for damage before installing
the tube into the cylinder block (Fig. 32).
(2) Lube O-ring with coolant and install inlet tube
into the cylinder block opening (Fig. 32).
(3) Install the two inlet tube fasteners and tighten
to 12 N´m (105 in. lbs.).
(4) Connect the radiator lower hose (Fig. 7) and
heater hose to inlet tube (Fig. 33).
Fig. 31 Water Pump Seal
1 - WATER PUMP HOUSING
2 - SEAL
3 - IMPELLER
Fig. 32 Water Pump Inlet TubeÐ2.4L Engine
1 - O-RING
2 - WATER PUMP INLET TUBE
Fig. 33 Water Pump Inlet Tube Hose Connections
1 - WATER PUMP INLET TUBE
2 - HOSE - HEATER RETURN
3 - COOLANT INLET
RSENGINE7-35
WATER PUMP - 3.3/3.8L (Continued)
ProCarManuals.com