2003 CHRYSLER CARAVAN clock

INSTALLATION
(1) Carefully route master cylinder plumbing into
engine compartment as removed and position master
cylinder to dash panel hole.
(2) Rotate master cylinder 45É clockwise, insert
into dash panel hole, engaging clutch pedal bracket.
Rotate master cylinder 45É counter-clockwise, secur-
ing it to pedal bracket (Fig. 13).
(3) Install and secure grommet to dash panel.
(4) Connect pushrod to clutch pedal pin. Install
retainer clip (Fig. 13).
(5) Secure master cylinder plumbing to retainers
in engine compartment.
(6) Connect clutch master cylinder plumbing to
slave cylinder ªquick connectº fitting. An audible
ªclickº should be heard. Verify connection by pulling
outward.
(7) Connect A/C suction/discharge line to evapora-
tor junction block.
(8)Diesel models:Install wiper module assembly.
(Refer to 8 - ELECTRICAL/WIPERS/WASHERS/
WIPER MODULE - INSTALLATION)
(9) Install battery and tray.
(10) Connect battery negative cable
(11) Charge Air Conditioning system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/RE-
FRIGERANT - STANDARD PROCEDURE)
MASTER CYLINDER - LHD
REMOVAL
(1) Disconnect battery cables.
(2) Remove instrument panel lower silencer (Fig.
14).
(3) Remove knee bolster (Fig. 15).
(4) Remove clutch master cylinder pushrod
retainer clip (Fig. 16).
(5) Disconnect pushrod from clutch pedal (Fig. 16).
(6) Remove battery shield.
(7) Remove battery.
(8) Remove battery tray.
(9) Remove windshield wiper module assembly
(Refer to 8 - ELECTRICAL/WIPERS/WASHERS/
WIPER MODULE - REMOVAL).
Fig. 13 Clutch Master Cylinder at Pedal Bracket
1 - CLUTCH MASTER CYLINDER
2 - RETAINER CLIP
3 - CLUTCH PEDAL PIN
4 - PUSH RODFig. 14 Instrument Panel Lower Silencer
1 - INSTRUMENT PANEL LOWER SILENCER
Fig. 15 Knee Bolster
1 - KNEE BOLSTER
RSCLUTCH6-9
MASTER CYLINDER - RHD (Continued)
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(10) Using Tool 6638A, disconnect clutch master
cylinder ªquick connectº fitting (Fig. 17). Disengage
plumbing retainer from body stud.
(11) Remove master cylinder reservoir-to-strut
tower nuts (Fig. 18). Reposition reservoir off to side.
(12) Remove clutch master cylinder from dash
panel by rotating clockwise 45É and removing from
dash panel (Fig. 18).(13) Remove master cylinder and plumbing from
engine compartment. Use care not to bend or kink
plumbing. Note plumbing routing to aid in installa-
tion.
INSTALLATION
(1) Install master cylinder into position, while
routing plumbing as originally installed.
(2) Insert master cylinder pushrod through dash
panel (Fig. 18) and rotate 45É counter-clockwise to
secure.
(3) Connect master cylinder plumbing quick-con-
nect fitting. An audible ªclickº should be heard. Ver-
ify connection by pulling outward.
(4) Install master cylinder reservoir onto strut
tower. Install and tighten two (2) master cylinder
reservoir-to-strut tower nuts to 11 N´m (100 in. lbs.)
(Fig. 18).
(5) Install windshield wiper module assembly
(Refer to 8 - ELECTRICAL/WIPERS/WASHERS/
WIPER MODULE - INSTALLATION).
(6) Install battery tray.
(7) Install battery.
(8) Install battery shield.
(9) Connect master cylinder pushrod to clutch
pedal lever (Fig. 16). Install retainer clip.
(10) Install knee bolster and instrument panel
lower silencer (Fig. 15) (Fig. 14).
(11) Connect battery cables.
Fig. 16 Master Cylinder Pushrod at Pedal
1 - MASTER CYLINDER PUSHROD
2 - CLUTCH/BRAKE PEDAL ASSEMBLY
3 - PUSHROD RETAINER
Fig. 17 Disconnect Quick-Connect Using Tool 6638A
1 - QUICK CONNECT FITTING
2 - TOOL 6638A
Fig. 18 Clutch Master Cylinder Removal/Installation
1 - CLUTCH MASTER CYLINDER
2 - RESERVOIR
3 - NUT (2)
6 - 10 CLUTCHRS
MASTER CYLINDER - LHD (Continued)
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MODULAR CLUTCH ASSY -
2.4L GAS
REMOVAL
(1) Remove transaxle from vehicle. (Refer to 21 -
TRANSMISSION/TRANSAXLE/MANUAL -
REMOVAL)
(2) Remove modular clutch assembly from input
shaft (Fig. 19).
INSTALLATION
(1) Install modular clutch assembly to transaxle
input shaft (Fig. 19).
(2) Install transaxle to vehicle. (Refer to 21 -
TRANSMISSION/TRANSAXLE/MANUAL - INSTAL-
LATION)
SLAVE CYLINDER
REMOVAL
(1) Raise vehicle on hoist.Diesel models:Remove
underbody splash shield.
(2) Using Tool 6638A, disconnect hydraulic clutch
circuit quick connect fitting.
(3) Remove clutch slave cylinder (Fig. 20) by lifting
nylon tab with a small screwdriver, and then
depressing cylinder inward towards case and rotating
cylinder 60É counter-clockwise.
INSTALLATION
(1) Install clutch slave cylinder into position, not-
ing orientation of different sized lugs. While depress-
ing inward, rotate slave cylinder clockwise until
nylon locating tab rests in transaxle case cutout, and
the hydraulic tube is vertical (Fig. 20).
(2) Connect ªquick-connectº connection until an
audible ªclickº is heard. Verify connection by pulling
outward on connection.
(3)Diesel models:Install underbody splash
shield.
(4) Lower vehicle.
CLUTCH DISC AND PRESSURE
PLATE - 2.5L TD
REMOVAL
(1) Remove transaxle assembly. (Refer to 21 -
TRANSMISSION/TRANSAXLE/MANUAL -
REMOVAL)
(2) Remove six (6) clutch pressure plate-to-fly-
wheel bolts. Remove pressure plate and disc from fly-
wheel (Fig. 21).
(3)
Inspect flywheel. Resurface/replace as necessary.
(4) Inspect clutch release bearing and lever.
Replace as necessary. (Refer to 6 - CLUTCH/
CLUTCH RELEASE BEARING - REMOVAL)
Fig. 19 Modular Clutch Assembly
1 - MODULAR CLUTCH ASSEMBLY
2 - INPUT SHAFT
Fig. 20 Slave Cylinder Removal/Installation
1 - MOUNTING HOLE
2 - SLAVE CYLINDER
3 - ACCESS HOLE
4 - NYLON ANTI-ROTATION TAB
RSCLUTCH6-11
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CLUTCH PEDAL INTERLOCK
SWITCH
REMOVAL
LHD
(1) Disconnect battery negative cable.
(2) Remove instrument panel lower silencer (Fig.
23).
(3) Remove knee bolster (Fig. 24).
(4) Disconnect interlock switch connector (Fig. 25).
(5) Remove interlock switch by depressing four (4)
plastic wing tabs, and sliding switch through mount-
ing bracket (Fig. 25). If difficulty is encountered gain-
ing access to and removing interlock switch,
removing the upstop switch/bracket assembly (Fig.25) allows for over-travel of the pedal, giving more
room for interlock switch access.
(6) Remove interlock switch harness from pedal
bracket at retainer. Remove switch.
RHD
(1) Disconnect battery negative cable.
(2) Remove instrument panel lower silencer (Fig.
23).
(3) Remove knee bolster (Fig. 24).
(4) Remove master cylinder to clutch pedal pin
retainer clip (Fig. 26). Disengage pushrod from clutch
pedal pin.
(5) Disconnect interlock and upstop switch connec-
tors.
(6) Disengage master cylinder grommet from dash
panel.
(7) Remove clutch master cylinder tubing from
retainers in engine compartment.
(8) Remove clutch master cylinder from dash pan-
el/clutch pedal bracket by rotating 45É clockwise and
pulling outward towards engine (Fig. 26).
(9) Remove clutch pedal bracket assembly (Fig.
27).
(10) Remove interlock switch harness from pedal
bracket at retainer. Remove switch (Fig. 28).
Fig. 23 Instrument Panel Lower SilencerÐLHD
Shown
1 - INSTRUMENT PANEL LOWER SILENCER
Fig. 24 Knee BolsterÐLHD Shown
1 - KNEE BOLSTER
Fig. 25 Interlock/Upstop Switch Location
1 - INTERLOCK SWITCH
2 - UPSTOP SWITCH
3 - RETAINER - UPSTOP BRACKET
4 - CONNECTORS
RSCLUTCH6-13
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INSTALLATION
LHD
(1) Install interlock switch into pedal bracket hole,
and secure harness with retainer as shown in (Fig.
28). Make sure switch wing tabs are fully expanded.
(2) Connect interlock switch connector.
(3) Install knee bolster (Fig. 24).
(4) Install instrument panel lower silencer (Fig.
23).
(5) Connect battery negative cable.
(6) Verify function of starter interlock switch.
Switch must actuate when pedal is depressed.
RHD
(1) Install interlock switch to pedal bracket assem-
bly as shown in (Fig. 28). Secure connector with
retainer to hole in bracket.
(2) Install clutch pedal bracket assembly into posi-
tion. Install pedal bracket mounting nuts and torque
to 28 N´m (250 in. lbs.).
(3) Connect interlock and upstop switch connec-
tors.
(4) Install clutch master cylinder into position and
rotate 45É counter-clockwise to secure to pedal
bracket (Fig. 26). Secure dash panel grommet and
secure hydraulic pluming into dash panel retainers.
(5) Connect master cylinder pushrod to clutch
pedal pin and secure with retainer clip (Fig. 26).
(6) Install knee bolster (Fig. 24).
Fig. 26 Clutch Master Cylinder at Pedal Bracket
1 - CLUTCH MASTER CYLINDER
2 - RETAINER CLIP
3 - CLUTCH PEDAL PIN
4 - PUSH ROD
Fig. 27 Clutch Pedal/Bracket Assembly
1 - CLUTCH PEDAL/BRACKET ASSY.
2 - NUT (4)
Fig. 28 Clutch Pedal Interlock Switch
1 - CLUTCH INTERLOCK SWITCH
2 - CLUTCH PEDAL/BRACKET ASSY.
6 - 14 CLUTCHRS
CLUTCH PEDAL INTERLOCK SWITCH (Continued)
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(3) Position a wrench on the belt tensioner lug
(Fig. 2).
(4) Release belt tension by rotating the tensioner
clockwise (Fig. 2).
(5) Remove belt.
(1) Carefully return tensioner to its relaxed posi-
tion.
POWER STEERING PUMP
(1) From top of the vehicle, loosen locking nuts (1)
and (2) (Fig. 3).
(2) From under the vehicle, loosen the pivot bolt
(3). Loosen adjusting bolt (4) until belt can be
removed.
CLEANING
Clean all foreign debris from belt pulley grooves.
The belt pulleys must be free of oil, grease, and cool-
ants before installing the drive belt.
INSPECTION
Belt replacement under any or all of the following
conditions is required:
²Excessive wear
²Frayed cords
²Severe glazing
Poly-V Belt system may develop minor cracks
across the ribbed side (due to reverse bending). These
minor cracks are considered normal and acceptable.
Parallel cracks are not (Fig. 4).
NOTE: Do not use any type of belt dressing or
restorer on Poly-V Belts.
Fig. 2 A/C & GENERATOR BELT TENSION RELEASE
1 - BELT TENSIONER
2 - WRENCH
Fig. 3 Power Steering Pump Belt
1 - REAR LOCKING NUT
2 - FRONT LOCKING NUT
3 - PIVOT BOLT
4 - ADJUSTING BOLT
Fig. 4 Drive Belt Wear Pattern
1 - NORMAL CRACKS - BELT OK
2 - NOT NORMAL CRACKS - REPLACE BELT
RSACCESSORY DRIVE7-9
DRIVE BELTS - 2.4L (Continued)
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INSTALLATION
GENERATOR AND AIR CONDITIONING BELT
(1) Install belt onto all pulleys except for the
crankshaft (Fig. 5).
(2) Rotate belt tensioner clockwise until belt can
be installed onto the crankshaft pulley (Fig. 2).
Slowly release belt tensioner.
(3) Verify belt is properly routed and engaged on
all pulleys (Fig. 5).
(4) Install drive belt shield (Fig. 7) and lower vehi-
cle.
POWER STEERING PUMP
(1) Install belt over crankshaft and power steering
pump pulleys (Fig. 5).
(2) Apply an initial snug torque to pivot bolt (3)
and front locking nut (2) (Fig. 3).
(3) Tighten adjusting bolt (4) until proper belt ten-
sion is obtained (Fig. 3). For belt tension check pro-
cedure, (Refer to 7 - COOLING/ACCESSORY DRIVE/
DRIVE BELTS - STANDARD PROCEDURE -
CHECKING POWER STEERING BELT TENSION).
(4) Tighten pivot bolt (3) and front locking nut (2)
to 54 N´m (40 ft. lbs.) (Fig. 3).
(5) Tighten rear locking nut (1) to 54 N´m (40 ft.
lbs.) (Fig. 3).
ADJUSTMENTS
Satisfactory performance of the belt driven accesso-
ries depends on proper belt tension. Belt tensioning
should be performed with the aid of Special Tool
7198. Because of space limitations in the engine com-
partment, the use of this gauge may be restricted.
Raise the vehicle on a hoist and the remove the
splash shield to gain access to the drive belts, if nec-
essary. Adjust belt tension for either aNeworUsed
belt. For specifications, (Refer to 7 - COOLING/AC-
CESSORY DRIVE - SPECIFICATIONS).
BELT TENSIONER - 2.4L
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove the drive belt shield.
(3) Remove the generator/A/C drive belt. (Refer to
7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)
(4) Remove the belt tensioner (Fig. 6).
INSTALLATION
(1) Install belt tensioner and bolt (Fig. 6). Tighten
bolt to 54 N´m (40 ft. lbs.).
(2) Install generator/A/C compressor drive belt.
(Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE
BELTS - INSTALLATION)
(3) Install splash shield.
(4) Lower the vehicle.
Fig. 5 Accessory Drive Belts - 2.4L
1 - POWER STEERING PUMP PULLEY
2 - BELT TENSIONER
3 - GENERATOR PULLEY
4 - BELT - A/C AND GENERATOR
5 - A/C COMPRESSOR PULLEY
6 - CRANKSHAFT PULLEY
7 - BELT - POWER STEERING
Fig. 6 Belt Tensioner - 2.4L
1 - BELT TENSIONER
2 - GENERATOR BRACKET
3 - BOLT
7 - 10 ACCESSORY DRIVERS
DRIVE BELTS - 2.4L (Continued)
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DRIVE BELTS - 3.3/3.8L
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove the drive belt shield (Fig. 7).
WARNING: DO NOT ALLOW DRIVE BELT TEN-
SIONER TO SNAP BACK, AS DAMAGE TO TEN-
SIONER AND/OR PERSONAL INJURY COULD
RESULT.
(3) Position a wrench on the belt tensioner lug
(Fig. 8).
(4) Release belt tension by rotating the tensioner
counterclockwise (Fig. 8).(5) Remove the drive belt (Fig. 10).
(6) Carefully return tensioner to its relaxed posi-
tion.CLEANING
Clean all foreign debris from belt pulley grooves.
The belt pulleys must be free of oil, grease, and cool-
ants before installing the drive belt.
INSPECTION
Belt replacement under any or all of the following
conditions is required:
²Excessive wear
²Frayed cords
²Severe glazing
Poly-V Belt system may develop minor cracks
across the ribbed side (due to reverse bending). These
minor cracks are considered normal and acceptable.
Parallel cracks are not (Fig. 9).
NOTE: Do not use any type of belt dressing or
restorer on Poly-V Belts.
Fig. 7 Accessory Drive Belt Shield
1 - ATTACHING SCREW
2 - ATTACHING SCREWS
3 - SPLASH SHIELD
Fig. 8 DRIVE BELT TENSION RELEASE
1 - BELT TENSIONER LUG
2 - WRENCH
Fig. 9 Drive Belt Wear Pattern
1 - NORMAL CRACKS - BELT OK
2 - NOT NORMAL CRACKS - REPLACE BELT
RSACCESSORY DRIVE7-11
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