2003 CHRYSLER CARAVAN Service Manual

audio load capacity wheel bolt torque manual transmission coolant capacity lumbar support

Page 265 of 2177

$CHRYSLER CARAVAN 2003 Service Manual SPECIAL TOOLS COOLING SYSTEM Hose Clamp Pliers 6094 Hose Clamp Pliers 8495A Cooling System Tester 7700 Coolant Refractometer 8286 DRB IIITwith PEP Module ± OT-CH6010A Belt Tension Gauge Adapter 8371$

Page 266 of 2177

CHRYSLER CARAVAN 2003 Service Manual ACCESSORY DRIVE
TABLE OF CONTENTS
page page
DRIVE BELTS
DIAGNOSIS AND TESTING - ACCESSORY
DRIVE BELT..........................7
DRIVE BELTS - 2.4L
STANDARD PROCEDURE - CHECKING
POWER STEERING BELT TEN

Page 267 of 2177

CHRYSLER CARAVAN 2003 Service Manual CONDITION POSSIBLE CAUSES CORRECTIONS
BELT ROLLED OVER IN GROOVE
OR BELT JUMPS OFF1. Broken cord in belt 1. Replace belt
2. Belt too loose, or too tight 2. (a) Replace belt (auto-tensioned
belts.)
(b)

Page 268 of 2177

CHRYSLER CARAVAN 2003 Service Manual (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-
ti

Page 269 of 2177

CHRYSLER CARAVAN 2003 Service Manual 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 cranksha

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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Page 270 of 2177

CHRYSLER CARAVAN 2003 Service Manual 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 PERSONA

Page 271 of 2177

CHRYSLER CARAVAN 2003 Service Manual INSTALLATION
(1) Route and position the drive belt onto all pul-
leys, except for the crankshaft (Fig. 10).
(2) Rotate belt tensioner counterclockwise until
belt can be installed onto the crankshaft p

Page 272 of 2177

CHRYSLER CARAVAN 2003 Service Manual ENGINE
TABLE OF CONTENTS
page page
ENGINE
DIAGNOSIS AND TESTING - ENGINE
COOLING SYSTEM....................14
CLEANING............................18
INSPECTION..........................18
COOLANT
DESC

ENGINE
TABLE OF CONTENTS
page page
ENGINE
DIAGNOSIS AND TESTING - ENGINE
COOLING SYSTEM....................14
CLEANING............................18
INSPECTION..........................18
COOLANT
DESCRIPTION - ENGINE COOLANT.........19
DIAGNOSIS AND TESTING - COOLANT
CONCENTRATION TESTING.............19
STANDARD PROCEDURE - COOLANT
SERVICE............................19
COOLANT RECOVERY CONTAINER
DESCRIPTION.........................19
OPERATION...........................19
DIAGNOSIS AND TESTING - COOLANT
RECOVERY SYSTEM..................20
REMOVAL.............................20
INSTALLATION.........................20
ENGINE BLOCK HEATER
DESCRIPTION.........................20
OPERATION...........................20
DIAGNOSIS AND TESTING - ENGINE BLOCK
HEATER TESTING.....................20
REMOVAL.............................20
INSTALLATION.........................20
ENGINE COOLANT TEMPERATURE SENSOR -
2.4L
DESCRIPTION.........................21
REMOVAL.............................21
INSTALLATION.........................21
ENGINE COOLANT TEMPERATURE SENSOR -
3.3/3.8L
DESCRIPTION.........................21
REMOVAL.............................21
INSTALLATION.........................22
ENGINE COOLANT THERMOSTAT
DESCRIPTION.........................22
OPERATION...........................22
DIAGNOSIS AND TESTING - ENGINE
COOLANT THERMOSTAT...............23
ENGINE COOLANT THERMOSTAT - 2.4L
REMOVAL.............................23
INSTALLATION.........................23
ENGINE COOLANT THERMOSTAT - 3.3/3.8L
REMOVAL.............................23
INSTALLATION.........................24
RADIATOR
REMOVAL.............................25INSTALLATION.........................25
RADIATOR DRAINCOCK
REMOVAL.............................26
INSTALLATION.........................26
RADIATOR PRESSURE CAP
DESCRIPTION.........................26
OPERATION...........................27
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - COOLING
SYSTEM PRESSURE CAP TESTING.......27
DIAGNOSIS AND TESTING - RADIATOR
CAP TO FILLER NECK SEAL.............27
CLEANING............................28
INSPECTION..........................28
RADIATOR FAN
DESCRIPTION.........................28
OPERATION...........................29
DIAGNOSIS AND TESTING - RADIATOR FAN
MOTOR .............................29
REMOVAL.............................30
INSTALLATION.........................30
RADIATOR FAN RELAY
DESCRIPTION.........................30
OPERATION...........................30
REMOVAL.............................30
INSTALLATION.........................30
WATER PUMP - 2.4L
DESCRIPTION.........................31
REMOVAL.............................31
CLEANING............................32
INSPECTION..........................32
INSTALLATION.........................32
WATER PUMP - 3.3/3.8L
DESCRIPTION.........................33
REMOVAL.............................33
CLEANING............................34
INSPECTION..........................34
INSTALLATION.........................34
WATER PUMP INLET TUBE - 2.4L
DESCRIPTION.........................35
REMOVAL.............................35
INSTALLATION.........................35
WATER PUMP INLET TUBE - 3.3/3.8L
REMOVAL.............................36
INSTALLATION.........................36
RSENGINE7-13
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