2003 CHRYSLER CARAVAN suspension

Fig. 74 REAR SUSPENSION HANGER BRACKETS - LONG WHEEL BASE
RSBODY STRUCTURE23 - 175
WELD LOCATIONS (Continued)
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Fig. 82 REAR SUSPENSION HANGER BRACKETS - SHORT WHEEL BASE
RSBODY STRUCTURE23 - 183
WELD LOCATIONS (Continued)
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Fig. 93 INNER SIDE SILLS - LONG WHEEL BASE ONLY
Fig. 94 WHEELHOUSES, SIDE SILLS, SUSPENSION BRACKETS - LONG WHEEL BASE ONLY
RSBODY STRUCTURE23 - 193
WELD LOCATIONS (Continued)
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Fig. 164 REAR SUSPENSION HANGERS - LONG WHEEL BASE SHOWN, SHORT WHEEL BASE TYPICAL
RSBODY STRUCTURE23 - 253
WELD LOCATIONS (Continued)
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Fig. 168 SUSPENSION HANGER REINFORCEMENT - LONG WHEEL BASE ONLY
23 - 256 BODY STRUCTURERS
WELD LOCATIONS (Continued)
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Fig. 174 SUSPENSION HANGER REINFORCEMENT - SHORT WHEEL BASE ONLY
23 - 262 BODY STRUCTURERS
WELD LOCATIONS (Continued)
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OPERATIONÐThe Oxygen Sensor Heater Moni-
tor begins after the ignition has been turned OFF.
The PCM sends a 5 volt bias to the oxygen sensor
every 1.6 seconds. The PCM keeps it biased for 35
ms each time. As the sensor cools down, the resis-
tance increases and the PCM reads the increase in
voltage. Once voltage has increased to a predeter-
mined amount, higher than when the test started,
the oxygen sensor is cool enough to test heater oper-
ation.
When the oxygen sensor is cool enough, the PCM
energizes the ASD relay. Voltage to the O2 sensor
begins to increase the temperature. As the sensor
temperature increases, the internal resistance
decreases. The PCM continues biasing the 5 volt sig-
nal to the sensor. Each time the signal is biased, the
PCM reads a voltage decrease. When the PCM
detects a voltage decrease of a predetermined value
for several biased pulses, the test passes.
The heater elements are tested each time the
engine is turned OFF if all the enabling conditions
are met. If the monitor fails, the PCM stores a
maturing fault and a Freeze Frame is entered. If two
consecutive tests fail, a DTC is stored. Because the
ignition is OFF, the MIL is illuminated at the begin-
ning of the next key cycle.
Enabling ConditionsÐThe following conditions
must be met for the PCM to run the oxygen sensor
heater test:
²Engine run time of at least 3 minutes
²Engine run time at a predetermined speed
and throttle opening.
²Key OFF power down
²Battery voltage of at least 10 volts
²Sufficient Oxygen Sensor cool down
Pending ConditionsÐThere are not conditions or
situations that prompt conflict or suspension of test-
ing. The oxygen sensor heater test is not run pending
resolution of MIL illumination due to oxygen sensor
failure.
SuspendÐThere are no conditions which exist for
suspending the Heater Monitor.
CATALYST MONITOR
To comply with clean air regulations, vehicles are
equipped with catalytic converters. These converters
reduce the emission of hydrocarbons, oxides of nitro-
gen and carbon monoxide.
Normal vehicle miles or engine misfire can cause a
catalyst to decay. A meltdown of the ceramic core can
cause a reduction of the exhaust passage. This can
increase vehicle emissions and deteriorate engine
performance, driveability and fuel economy.
The catalyst monitor uses dual oxygen sensors
(O2S's) to monitor the efficiency of the converter. The
dual O2S strategy is based on the fact that as a cat-alyst deteriorates, its oxygen storage capacity and its
efficiency are both reduced. By monitoring the oxy-
gen storage capacity of a catalyst, its efficiency can
be indirectly calculated. The upstream O2S is used to
detect the amount of oxygen in the exhaust gas
before the gas enters the catalytic converter. The
PCM calculates the A/F mixture from the output of
the O2S. A low voltage indicates high oxygen content
(lean mixture). A high voltage indicates a low content
of oxygen (rich mixture).
When the upstream O2S detects a lean condition,
there is an abundance of oxygen in the exhaust gas.
A functioning converter would store this oxygen so it
can use it for the oxidation of HC and CO. As the
converter absorbs the oxygen, there will be a lack of
oxygen downstream of the converter. The output of
the downstream O2S will indicate limited activity in
this condition.
As the converter loses the ability to store oxygen,
the condition can be detected from the behavior of
the downstream O2S. When the efficiency drops, no
chemical reaction takes place. This means the con-
centration of oxygen will be the same downstream as
upstream. The output voltage of the downstream
O2S copies the voltage of the upstream sensor. The
only difference is a time lag (seen by the PCM)
between the switching of the O2S's.
To monitor the system, the number of lean-to-rich
switches of upstream and downstream O2S's is
counted. The ratio of downstream switches to
upstream switches is used to determine whether the
catalyst is operating properly. An effective catalyst
will have fewer downstream switches than it has
upstream switches i.e., a ratio closer to zero. For a
totally ineffective catalyst, this ratio will be one-to-
one, indicating that no oxidation occurs in the device.
The system must be monitored so that when cata-
lyst efficiency deteriorates and exhaust emissions
increase to over the legal limit, the MIL (check
engine lamp) will be illuminated.
Monitor OperationÐTo monitor catalyst effi-
ciency, the PCM expands the rich and lean switch
points of the heated oxygen sensor. With extended
switch points, the air/fuel mixture runs richer and
leaner to overburden the catalytic converter. Once
the test is started, the air/fuel mixture runs rich and
lean and the O2 switches are counted. A switch is
counted when an oxygen sensor signal goes from
below the lean threshold to above the rich threshold.
The number of Rear O2 sensor switches is divided by
the number of Front O2 sensor switches to determine
the switching ratio.
The test runs for 20 seconds. As catalyst efficiency
deteriorated over the life of the vehicle, the switch
rate at the downstream sensor approaches that of the
upstream sensor. If at any point during the test
25 - 4 EMISSIONS CONTROLRS
EMISSIONS CONTROL (Continued)
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EXHAUSTER - REMOVAL, REAR
QUARTER PANEL/FENDER AIR..........23-56
EXPANSION VALVE - DESCRIPTION . 24-72,24-96
EXPANSION VALVE - DIAGNOSIS AND
TESTING......................24-72,24-97
EXPANSION VALVE - INSTALLATION . 24-74,24-98
EXPANSION VALVE - OPERATION . . . 24-72,24-97
EXPANSION VALVE - REMOVAL....24-73,24-97
EXPORT - BRAKE ROTOR...............5-55
EXPORT - DESCRIPTION................5-58
EXPORT - DESCRIPTION................2-10
EXPORT - DESCRIPTION, ANTENNA
MODULE............................8A-6
EXPORT - DESCRIPTION, DIESEL
SUPPLEMENTAL HEATER - DCHA.......24-106
EXPORT - DESCRIPTION, HEADLAMP
LEVELING SWITCH...................8L-15
EXPORT - DESCRIPTION, HEADLAMP
WASHERS..........................8R-10
EXPORT - DESCRIPTION, POWER
FOLDAWAY MIRROR SWITCH..........8N-48
EXPORT - DESCRIPTION, QUARTER
GLASS INTEGRAL ANTENNA.............8A-9
EXPORT - DESCRIPTION, REAR FOG
LAMP..............................8L-22
EXPORT - DIAGNOSIS AND TESTING,
ANTENNA MODULE....................8A-7
EXPORT - DIAGNOSIS AND TESTING,
HEADLAMP LEVELING MOTOR..........8L-14
EXPORT - DIAGNOSIS AND TESTING,
HEADLAMP LEVELING SWITCH.........8L-15
EXPORT - DIAGNOSIS AND TESTING,
HEADLAMP SWITCH..................8L-16
EXPORT - DIAGNOSIS AND TESTING,
HEADLAMP WASHERS................8R-10
EXPORT - DIAGNOSIS AND TESTING,
QUARTER GLASS INTEGRAL ANTENNA....8A-9
EXPORT - INSTALLATION...............2-12
EXPORT - INSTALLATION, ANTENNA
MODULE............................8A-7
EXPORT - INSTALLATION, FRONT FOG
LAMP...............................8L-9
EXPORT - INSTALLATION, FRONT
POSITION LAMP.....................8L-10
EXPORT - INSTALLATION, HEADLAMP....8L-13
EXPORT - INSTALLATION, HEADLAMP
LEVELING MOTOR....................8L-15
EXPORT - INSTALLATION, HEADLAMP
UNIT..............................8L-20
EXPORT - INSTALLATION, HEADLAMP
WASHER HOSE......................8R-12
EXPORT - INSTALLATION, HEADLAMP
WASHER PUMP MOTOR...............8R-13
EXPORT - INSTALLATION, HEADLAMP
WASHERS..........................8R-12
EXPORT - INSTALLATION, HOOD AJAR
SWITCH............................8Q-3
EXPORT - INSTALLATION, PARK/TURN
SIGNAL LAMP.......................8L-22
EXPORT - INSTALLATION, POWER
FOLDAWAY MIRROR SWITCH..........8N-49
EXPORT - INSTALLATION, REPEATER
LAMP..............................8L-22
EXPORT - INSTALLATION, TAIL LAMP....8L-23
EXPORT - OPERATION, ANTENNA
MODULE............................8A-6
EXPORT - OPERATION, HEADLAMP
WASHERS
..........................8R-10
EXPORT - OPERATION, POWER
FOLDAWAY MIRROR SWITCH
..........8N-48
EXPORT - OPERATION, QUARTER GLASS
INTEGRAL ANTENNA
...................8A-9
EXPORT - REMOVAL
...................2-11
EXPORT - REMOVAL, ANTENNA MODULE
. . 8A-7
EXPORT - REMOVAL, FRONT FOG LAMP
. . . 8L-9
EXPORT - REMOVAL, FRONT POSITION
LAMP
..............................8L-10
EXPORT - REMOVAL, HEADLAMP
........8L-13
EXPORT - REMOVAL, HEADLAMP
LEVELING MOTOR
....................8L-14
EXPORT - REMOVAL, HEADLAMP UNIT
. . . 8L-20
EXPORT - REMOVAL, HEADLAMP
WASHER HOSE
......................8R-12
EXPORT - REMOVAL, HEADLAMP
WASHER PUMP MOTOR
...............8R-12
EXPORT - REMOVAL, HEADLAMP
WASHERS
..........................8R-12EXPORT - REMOVAL, HOOD AJAR
SWITCH............................8Q-3
EXPORT - REMOVAL, PARK/TURN
SIGNAL LAMP.......................8L-22
EXPORT - REMOVAL, POWER
FOLDAWAY MIRROR SWITCH..........8N-48
EXPORT - REMOVAL, REPEATER LAMP . . . 8L-22
EXPORT - REMOVAL, TAIL LAMP........8L-23
EXPORT - STANDARD PROCEDURE,
FRONT FOG LAMP UNIT ALIGNMENT......8L-9
EXPORT - STANDARD PROCEDURE,
HEADLAMP UNIT ALIGNMENT..........8L-17
EXTENSION - INSTALLATION,
EVAPORATOR LINE...................24-96
EXTENSION - REMOVAL, EVAPORATOR
LINE...............................24-95
EXTENSION TRIM - INSTALLATION,
A-PILLAR LOWER....................23-73
EXTENSION TRIM - REMOVAL, A-PILLAR
LOWER............................23-73
EXTENSION TUBES - INSTALLATION,
HEATER CORE.......................24-77
EXTENSION TUBES - REMOVAL, HEATER
CORE..............................24-75
EXTERIOR - DESCRIPTION, LAMPS/
LIGHTING...........................8L-2
EXTERIOR - OPERATION, LAMPS/
LIGHTING...........................8L-3
EXTERIOR - WARNING, LAMPS/
LIGHTING...........................8L-4
EXTERIOR HANDLE - INSTALLATION.....23-22,
23-39
EXTERIOR HANDLE - REMOVAL.....23-22,23-39
EXTERIOR HANDLE SWITCH -
DESCRIPTION.......................8N-11
EXTERIOR HANDLE SWITCH -
INSTALLATION......................8N-12
EXTERIOR HANDLE SWITCH -
OPERATION.........................8N-11
EXTERIOR HANDLE SWITCH - REMOVAL . . 8N-11
EXTERIOR LAMPS, SPECIFICATIONS......8L-4
EXTERIOR NAME PLATES - ADHESIVE
ATTACHED - INSTALLATION............23-50
EXTERIOR NAME PLATES - ADHESIVE
ATTACHED - REMOVAL................23-50
EXTERIOR NAME PLATES - TAPE
ATTACHED - INSTALLATION............23-50
EXTERIOR NAME PLATES - TAPE
ATTACHED - REMOVAL................23-50
FACTOR SETTING - STANDARD
PROCEDURE, PINION............8E-15,8E-23
FAILED PARK SWITCH - DIAGNOSIS AND
TESTING............................8R-2
FAN - DESCRIPTION, RADIATOR..........7-28
FAN - INSTALLATION, RADIATOR.........7-30
FAN - OPERATION, RADIATOR...........7-29
FAN - REMOVAL, RADIATOR.............7-30
FAN MOTOR - DIAGNOSIS AND
TESTING, RADIATOR...................7-29
FAN RELAY - DESCRIPTION, RADIATOR....7-30
FAN RELAY - INSTALLATION, RADIATOR . . . 7-30
FAN RELAY - OPERATION, RADIATOR......7-30
FAN RELAY - REMOVAL, RADIATOR.......7-30
FASCIA - INSTALLATION, FRONT.........13-1
FASCIA - INSTALLATION, REAR..........13-2
FASCIA - REMOVAL, FRONT.............13-1
FASCIA - REMOVAL, REAR..............13-2
FASCIA - SCUFF PAD - INSTALLATION,
REAR...............................13-4
FASCIA - SCUFF PAD - REMOVAL, REAR . . . 13-3
FASTENER IDENTIFICATION -
DESCRIPTION......................Intro.-2
FASTENER TORQUE, SPECIFICATIONS -
ABS ................................5-79
FASTENER TORQUE, SPECIFICATIONS -
BRAKE...............................5-9
FASTENER TORQUE, SPECIFICATIONS -
FRONT SUSPENSION...................2-3
FASTENER TORQUE, SPECIFICATIONS -
POWER STEERING....................19-9
FASTENER TORQUE, SPECIFICATIONS -
REAR SUSPENSION
...................2-27
FASTENER USAGE - DESCRIPTION
......Intro.-5
FEED CIRCUIT RESISTANCE TEST -
DIAGNOSIS AND TESTING
..............8F-32
FEED CIRCUIT TEST - DIAGNOSIS AND
TESTING
...........................8F-33
FENDER - INSTALLATION, FRONT
........23-51FENDER - REMOVAL, FRONT...........23-51
FFV REPLACEMENT PARTS -
DESCRIPTION........................14-2
FILL - DIAGNOSIS AND TESTING,
VEHICLE DOES NOT..................25-16
FILL - STANDARD PROCEDURE, FLUID
DRAIN.............................21-71
FILL DOOR - INSTALLATION, FUEL.......23-51
FILL DOOR - REMOVAL, FUEL..........23-51
FILL DOOR BLOCKER LATCH -
INSTALLATION, FUEL.................23-52
FILL DOOR BLOCKER LATCH -
REMOVAL, FUEL.....................23-52
FILL DOOR BLOCKER LATCH STRIKER -
INSTALLATION, FUEL.................23-52
FILL DOOR BLOCKER LATCH STRIKER -
REMOVAL, FUEL.....................23-52
FILL DOOR BLOCKER LOCKOUT LINK -
INSTALLATION, FUEL.................23-53
FILL DOOR BLOCKER LOCKOUT LINK -
REMOVAL, FUEL.....................23-52
FILL/CHECK LOCATIONS - DESCRIPTION,
FLUID...............................0-7
FILLER CAP - DESCRIPTION, FUEL.......25-12
FILLER CAP - OPERATION, FUEL........25-12
FILLER NECK SEAL - DIAGNOSIS AND
TESTING, RADIATOR CAP TO............7-27
FILLER TUBE - INSTALLATION, FUEL
TANK ..............................14-12
FILLER TUBE - REMOVAL, FUEL TANK....14-12
FILLING - STANDARD PROCEDURE,
COOLING SYSTEM.......................7-5
FILLING - STANDARD PROCEDURE,
HEATER CORE.......................24-98
FILTER - DESCRIPTION, AIR............24-39
FILTER - DESCRIPTION, OIL.............9-53
FILTER - INSTALLATION, AIR...........24-40
FILTER - INSTALLATION, FUEL...........14-4
FILTER - INSTALLATION, INLET..........14-13
FILTER - INSTALLATION, OIL.......9-139,9-53
FILTER - REMOVAL, AIR...............24-39
FILTER - REMOVAL, FUEL...............14-4
FILTER - REMOVAL, INLET.............14-13
FILTER - REMOVAL, OIL...........9-139,9-53
FILTER ADAPTER - INSTALLATION, OIL . . . 9-139
FILTER ADAPTER - REMOVAL, OIL.......9-139
FILTER CHANGE - STANDARD
PROCEDURE, ENGINE OIL..........9-137,9-53
FILTER SERVICE - STANDARD
PROCEDURE, FLUID.................21-203
FINAL DRIVE - ASSEMBLY............21-195
FINAL DRIVE - DISASSEMBLY.........21-190
FINESSE SANDING/BUFFING &
POLISHING - DESCRIPTION............23-84
FINISH - DESCRIPTION, BASE
COAT/CLEARCOAT....................23-84
FIRING ORDER, SPECIFICATIONS.........8I-3
FIRST ROW - BENCH - INSTALLATION,
SEAT BELT BUCKLE..................8O-12
FIRST ROW - BENCH - REMOVAL, SEAT
BELT BUCKLE.......................8O-12
FIRST ROW - OUTBOARD -
INSTALLATION, SEAT BELT &
RETRACTOR........................8O-13
FIRST ROW - OUTBOARD - REMOVAL,
SEAT BELT & RETRACTOR.............8O-13
FIRST ROW INBOARD - QUAD BUCKET -
INSTALLATION, SEAT BELT BUCKLE......8O-11
FIRST ROW INBOARD - QUAD BUCKET -
REMOVAL, SEAT BELT BUCKLE.........8O-11
FITTING - CONNECTING ROD............9-45
FITTING - PISTON RING................9-45
FITTING - STANDARD PROCEDURE,
MAIN BEARING......................9-123
FITTING - STANDARD PROCEDURE,
PISTON RING.......................9-121
FITTING - STANDARD PROCEDURE,
PISTON TO CYLINDER BORE............9-42
FITTING CONNECTING RODS -
STANDARD PROCEDURE...............9-116
FITTING PISTONS - STANDARD
PROCEDURE........................9-117
FITTINGS - STANDARD PROCEDURE,
QUICK-CONNECT
.....................14-13
FLANGE SEAL - INSTALLATION, INPUT
....3-45
FLANGE SEAL - INSTALLATION, OUTPUT
. . . 3-46
FLANGE SEAL - REMOVAL, INPUT
........3-44
FLANGE SEAL - REMOVAL, OUTPUT
.......3-45
12 INDEXRS
Description Group-Page Description Group-Page Description Group-Page
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