2003 CHRYSLER CARAVAN radiator

SPECIFICATIONS
TORQUE
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
All seat belt anchor bolts 39 29 Ð
Armrest shoulder bolt 29 21 Ð
Bench seat riser bolts 48 35 Ð
Bench seat track nuts 48 35 Ð
Quad bucket seat track to cushion frame bolts 40 30 Ð
Bucket seat back pivot bolts 33 24 Ð
Center seat to seat track bolts 24 17 Ð
Child seat module screws (bench seats) 7 Ð 62
Child seat module screws (quad seats) 13.5 10 Ð
Crossmember to radiator closure panel bolts 28 21 Ð
Door check strap to door end frame 12 Ð 105
Door latch to door end frame bolts 10 Ð 89
Floor latch to seat cushion frame bolts 27 19 Ð
Front cover to seat track screws 4 Ð 32
Front door hinge to hinge pillar bolts 34 25 Ð
Front door hinge to door nuts and bolts 34 25 Ð
Front door latch striker bolts 28 21 Ð
Front/quad seat cushion bolts 28.5 21 Ð
Front seat belt retractor bolts 38 28 Ð
Front seat riser to floor nuts 60 44 Ð
Front seat track cover screws 4 Ð 35
Front seat riser to seat track nuts 81 60 Ð
Front seatback pivot bolts 54 40 Ð
Front seatback recliner nut 12 Ð 105
Front seatback assist strap screws 2.5 Ð 22
Grocery bag holder screws 2 Ð 17
Hinge to liftgate bolts 33 24 Ð
Hood latch to bolts 13.5 10 Ð
Hood latch striker bolts 13.5 10 Ð
Hood hinge to hood bolts 13.5 10 Ð
Liftgate exterior handle outer screws 20 15 Ð
Liftgate exterior handle inner bolts 40 30 Ð
Lifgate hinge to roof header bolts 33 24 Ð
Liftgate latch bolts 16 12 Ð
Liftgate latch striker bolts 28 21 Ð
Liftgate lift motor link to liftgate 28 21 Ð
Liftgate spoiler bolts 9 Ð 80
Lifgate stabilizer wedge striker to D-pillar bolts 3 Ð 30
RSBODY23-11
BODY (Continued)
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(7) Remove fuel filler housing and lockout link
from vehicle.
(8) Disengage clip holding link to fuel fill door
(Fig. 13).
(9) Remove link from fuel fill door.
INSTALLATION
(1) Insert link into clip on fuel fill door.
(2) Engage clip to hold link to fuel fill door.
(3) Insert lockout link through grommet in panel
between inner and outer quarter panel.
(4) Close fuel fill door.
(5) Install fuel filler housing to outer quarter
panel.(6) Verify that all clips on fuel filler housing are
fully engaged to outer quarter panel.
(7) Engage fuel filler lockout link into clip on fuel
fill blocker latch arm.
(8) Install water shield patch covering access hole
in C-pillar.
(9) Install left quarter trim panel.
GRILLE OPENING
REINFORCEMENT
REMOVAL
(1) Release hood latch and open hood.
(2) Remove bolts attaching hood latch to cross-
member and position latch out of the way.
(3) Remove radiator sight shield.
(4) Remove engine air inlet resonator.
(5) Remove hood cable.
(6) Remove hood prop rod.
(7) Remove screw attaching coolant recovery bottle
to crossmember.
(8) Remove bolts attaching radiator isolators to
crossmember.
(9) Remove bolts attaching ends of crossmember to
radiator closure panel (Fig. 14).
(10) Lift crossmember upward and away from
radiator closure panel.
(11) Remove crossmember from vehicle.
INSTALLATION
(1) Place radiator closure panel crossmember in
position on vehicle.
(2) Insert ends of crossmember between layered
metal sections of radiator closure panel at each side
of radiator.
Fig. 12 FUEL FILLER LOCKOUT LINK AT LATCH
ARM
1 - FUEL FILLER LOCKOUT LINK
2 - C-PILLAR
3 - FUEL FILLER BLOCKER LATCH ARM
4 - PLASTIC LINK CLIP
5 - INNER QUARTER PANEL
Fig. 13 FUEL FILLER LOCKOUT LINK
1 - FUEL FILLER LOCKOUT LINK
2 - FUEL FILLER OPENING
3 - QUARTER PANELFig. 14 RADIATOR CLOSURE PANEL
CROSSMEMBER
1 - RADIATOR CLOSURE PANEL CROSSMEMBER
2 - FRONT FASCIA
RSEXTERIOR23-53
FUEL FILL DOOR BLOCKER LOCKOUT LINK (Continued)
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(3) Align with paint breaks around bolt heads.
(4) Install bolts attaching ends of crossmember to
radiator closure panel (Fig. 14). Tighten bolts to 19
N´m (14 ft. lbs.) torque.
(5) Install bolts attaching radiator isolators to
crossmember.
(6) Install screw attaching coolant recovery bottle
to crossmember.
(7) Install bolt attaching air cleaner housing to
crossmember.
(8) Install engine air inlet resonator.
(9) Install radiator sight shield.
(10) Install hood prop rod.
(11) Align hood latch by placing latch over net
pierce tabs. If alignment is required, flatten tabs.
(12) Install bolts attaching hood latch to cross-
member. Tighten bolts to 13.5 N´m (10 ft. lbs.)
torque.
(13) Verify hood latch operation and hood align-
ment.
FRONT WHEELHOUSE
SPLASH SHIELD
REMOVAL
(1) Hoist and support vehicle on safety stands.
(Refer to LUBRICATION & MAINTENANCE/HOIST-
ING - STANDARD PROCEDURE).
(2) Remove front wheel.
(3) Remove push pin fasteners attaching splash
shield to frame rail forward of suspension.
(4) Remove push pin fasteners attaching splash
shield to frame rail rearward of suspension.
(5) Remove screws attaching wheelhouse splash
shield to front fender and front bumper fascia.
(6) Remove splash shield from vehicle (Fig. 15).
INSTALLATION
(1) Place splash shield in position on vehicle (Fig.
15).
(2) Install push pin fasteners attaching splash
shield to frame rail forward of suspension.
(3) Install push pin fasteners attaching splash
shield to frame rail rearward of suspension.
(4) Install screws attaching wheelhouse splash
shield to front fender.
(5) Install front wheel.
(6) Lower vehicle.
LUGGAGE RACK RISER
REMOVAL
(1) Remove two fasteners from the front riser.
Gently pull up on the luggage rack side rail and
detach the riser snap to remove riser from the rail
(Fig. 16).
(2) Repeat for the opposite side, if necessary.
(3) Remove front riser(s) from vehicle (Fig. 17).
Fig. 15 FRONT WHEELHOUSE SPLASH SHIELD
1 - FRONT FENDER WHEELHOUSE SPLASH SHIELD
2 - PUSH PIN FASTENERS
3 - ACCESSORY DRIVE SPLASH SHIELD
4 - SCREWS
Fig. 16 LUGGAGE RACK RISER COVER
1 - FRONT RISER COVER
2 - LOCK TABS
3 - LUGGAGE RACK SIDE RAIL
4 - FRONT RISER
23 - 54 EXTERIORRS
GRILLE OPENING REINFORCEMENT (Continued)
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INSTALLATION
(1) Place hood in position on vehicle. With assis-
tance from a helper at the opposite side of the vehicle
to support the hood, install bottom bolts attaching
hood to hinge finger tight.
(2) Install top bolts attaching hood to hinge finger
tight.
(3) Position bolts at marks and tighten. Tighten
bolts to 13.5 N´m (120 in. lbs.) torque. The hood
should be aligned to 4 mm (0.160 in.) gap to the front
fenders and flush across the top surfaces along fend-
ers.
(4) Verify hood operation and alignment.
LATCH
REMOVAL
(1) Release hood latch and open hood.
(2) Remove bolts attaching hood latch to radiator
closure panel crossmember (Fig. 3).
(3) Remove hood latch from crossmember.
(4) Disconnect hood release cable from hood latch
(Fig. 4).
(5) Remove hood latch from vehicle.
INSTALLATION
(1) Position hood latch on vehicle.
(2) Connect hood release cable from hood latch.
(3) Position hood latch on crossmember.
(4) Align hood latch by placing latch over net
pierced tabs. If alignment is required, flatten or
grind tabs.
(5) Verify hood operation and alignment. Adjust as
necessary.(6) Tighten attaching bolts to 13.5 N´m (10 ft. lbs.)
torque.
LATCH RELEASE CABLE
REMOVAL
(1) Remove hood latch.
(2) Disengage cable end from hood latch locking
mechanism.
(3) Slide cable case end sideways in keyhole slot of
hood latch while pinching barb on cable case closed.
(4) Remove cable from latch (Fig. 4).
(5) Remove hood release handle from instrument
panel.
(6) Disengage rubber grommet cable insulator
from hole in dash panel.
(7) Attach a suitable length of mechanic's wire to
latch end of cable to assist cable installation.
Fig. 2 HOOD
1 - HOOD
2 - HOOD LATCH STRIKER
3 - HOOD HALF OF HOOD HINGE
Fig. 3 HOOD LATCH
1 - HOOD RELEASE CABLE
2 - HOOD LATCH
3 - RADIATOR CLOSURE PANEL CROSSMEMBER
Fig. 4 HOOD
1 - RELEASE CABLE CASE
2 - HOOD LATCH
3 - RELEASE CABLE END
23 - 60 HOODRS
HOOD (Continued)
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(8) Route cable back from latch through engine
compartment toward dash panel near power brake
booster (Fig. 5).
(9) Remove attaching clips from cable case.
(10) From inside vehicle, pull cable through dash
panel until mechanic's wire is exposed.
(11) Disconnect cable from mechanic's wire.
(12) Remove hood release cable from vehicle.
INSTALLATION
(1) Place hood release cable in position under
instrument panel.
(2) Attach latch end of hood release cable to
mechanic's wire protruding through dash panel.
(3) Route cable forward through engine compart-
ment toward latch by pulling on mechanic's wire
(Fig. 5).(4) Disconnect mechanic's wire from cable.
(5) Engage rubber grommet cable insulator into
hole in dash panel.
(6) Install hood release handle into instrument
panel.
(7) Place cable in position on latch.
(8) Slide cable case end sideways into keyhole slot
of hood latch.
(9) Engage cable end into hood latch locking mech-
anism.
(10) Install hood latch.
(11) Install attaching clips to cable case and install
clips into original holes in strut tower, fender, head-
lamp area, and radiator closure panel crossmember.
LATCH STRIKER
REMOVAL
(1) Release hood latch and open hood.
(2) Remove bolts attaching striker to inside of
hood.
(3) Remove hood latch striker from vehicle.
INSTALLATION
(1) Position hood latch striker on vehicle.
(2) Install bolts attaching hood latch striker to
hood.
(3) Align hood latch striker to engage smoothly
into hood latch.
(4) Verify hood operation and alignment. Adjust as
necessary.
(5) Tighten attaching bolts to 13.5 N´m (10 ft. lbs.)
torque.Fig. 5 HOOD RELEASE CABLE ROUTING
1 - GROMMET
2 - HOOD RELEASE CABLE
3 - RADIATOR CLOSURE PANEL CROSSMEMBER
RSHOOD23-61
LATCH RELEASE CABLE (Continued)
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WELD LOCATIONS
SPECIFICATIONS - WELD LOCATIONS
INDEX
DESCRIPTION FIGURE
FRONT FENDER SHIELD - RIGHT 62
FRONT FENDER SHIELD - LEFT 63
STRUT TOWER AND REINFORCEMENTS - RIGHT 64
SUSPENSION RETAINERS AND REINFORCEMENTS - RIGHT 65
STRUT TOWER AND REINFORCEMENTS - LEFT 66
SUSPENSION RETAINERS AND REINFORCEMENTS - LEFT 67
FLOOR PAN REINFORCEMENTS - SIDE RAILS 68
REAR SUSPENSION BRACKETS 69
FLOOR PAN CROSS MEMBERS 70
SEAT REINFORCEMENTS - LONG WHEEL BASE ONLY 71
STRIKER REINFORCEMENTS - LONG WHEEL BASE ONLY 72
FUEL TANK MOUNTING/REAR SEAT AND SUSPENSION 73
REAR SUSPENSION HANGER BRACKETS - LONG WHEEL BASE 74
FRONT SEAT CROSS MEMBER 75
FLOOR PAN SIDE RAIL REINFORCEMENT 76
SILL BULKHEAD REINFORCEMENTS 77
FLOOR PAN CROSS MEMBER REINFORCEMENTS 78
FRONT SEAT CROSS MEMBER 79
SEAT REINFORCEMENT CROSS MEMBERS - SHORT WHEEL BASE 80
CENTER CONSOLE REINFORCEMENT - SHORT WHEEL BASE 81
REAR SUSPENSION HANGER BRACKETS - SHORT WHEEL BASE 82
LOWER LIFTGATE PANEL LATCH REINFORCEMENT 83
ENGINE MOUNTING PLATE AND TOW BRACKET 84
HEADLAMP MOUNTING PLATE 85
LOWER RADIATOR CROSS MEMBER BRACKETS 86
CROSS MEMBER EXTENSIONS 87
JACK MOUNTING BRACKET - LONG WHEEL BASE SHOWN, SHORT SIMILAR 88
FRONT SEAT CROSS MEMBER - LONG WHEELBASE ONLY 89
FRONT SEAT CROSS MEMBER - ALL WHEEL DRIVE ONLY 90
FUEL TANK SUPPORT CROSS MEMBERS - LONG WHEEL BASE ONLY 91
REAR SUPPORT AND TIRE STOWAGE CROSS MEMBERS - LONG WHEEL BASE
ONLY92
INNER SIDE SILLS - LONG WHEEL BASE ONLY 93
WHEELHOUSES, SIDE SILLS, SUSPENSION BRACKETS - LONG WHEEL BASE ONLY 94
REAR SEAT REINFORCEMENTS - SHORT WHEEL BASE ONLY 95
FUEL TANK SUPPORT AND TIRE STOWAGE - SHORT WHEEL BASE ONLY 96
INNER SIDE SILLS - SHORT WHEEL BASE ONLY 97
RSBODY STRUCTURE23 - 161
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Fig. 86 LOWER RADIATOR CROSS MEMBER BRACKETS
RSBODY STRUCTURE23 - 187
WELD LOCATIONS (Continued)
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Performance Temperature and Pressure
Ambient Temperature 21É C
(70É F)27É C
(80É F)32É C
(90É F)38É C
(100É F)43É C
(110É F)
Left Center Panel
Outlet Discharge Air
Temperature1to8ÉC
(34 to 46É F)3to9ÉC
(37 to 49É F)4 to 10ÉC
(39 to 50É F)6to11ÉC
(43 to 52É F)7 to 18É C
(45 to 65É F)
Discharge Pressure
(High Side Service
Port)1034 to 1724
kPa
(150 to 250
psi)1517 to 2275
kPa
(220 to 330
psi)1999 to 2620
kPa
(290 to 380
psi)2068 to 2965
kPa
(300 to 430
psi)2275 to 3421
kPa
(330 to 450 psi)
Suction Pressure (Low
Side Service Port)103 to 207 kPa
(15 to 30 psi)117 to 221 kPa
(17 to 32 psi)138 to 241 kPa
(20 to 35 psi)172 to 269 kPa
(25 to 39 psi)207 to 345 kPa
(30 to 50 psi)
DIAGNOSIS AND TESTING - HEATER
PERFORMANCE TEST
PRE-DIAGNOSTIC PREPARATIONS
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING FRONT - WARNING - HEATER PLUMB-
ING).
Check the coolant level, drive belt tension, radiator
air flow, and cooling fan operation. Start the engine
and allow it to warm up to normal temperature.
MAXIMUM HEATER OUTPUT: TEST AND ACTION
Engine coolant is provided to the heater system by
two 16 mm (5/8 inch inside diameter) heater hoses.
With the engine idling at normal running tempera-
ture, set the heater-A/C controls as follows. Temper-
ature control to full Heat, Mode control to Floor,
Blower control to the highest speed setting. Using a
test thermometer, check the air temperature coming
from the center floor outlets and compare this read-
ing to the Temperature Reference table.
TEMPERATURE REFERENCE
AMBIENT
TEMPERATUREMINIMUM FLOOR
OUTLET
TEMPERATURE
CELSIUS FAHRENHEIT CELSIUS FAHRENHEIT
15.5É 60É 62.2É 144É
21.1É 70É 63.8É 147É
26.6É 80É 65.5É 150É
32.2É 90É 67.2É 153ÉIf the floor outlet air temperature is insufficient,
check that the cooling system is operating to specifi-
cations. (Refer to 7 - COOLING/ENGINE - DIAGNO-
SIS AND TESTING). Both heater hoses should be
HOT to the touch (the coolant return hose should be
slightly cooler than the supply hose). If the coolant
return hose is much cooler than the supply hose,
locate and repair the engine coolant flow obstruction
in heater system.
POSSIBLE LOCATIONS OR CAUSE OF OBSTRUCTED
COOLANT FLOW
²Pinched or kinked heater hoses.
²Improper heater hose routing.
²Plugged heater hoses or supply and return ports
at cooling system connections.
²Plugged heater core.
²Air locked heater core.
²Restrictor in backwards.
If coolant flow is verified and the heater floor out-
let temperature is insufficient, a mechanical problem
may exist.
POSSIBLE LOCATION OR CAUSE OF INSUFFICIENT HEAT
²Obstructed cowl air intake.
²Obstructed heater system outlets.
²Blend-air door not functioning properly.
TEMPERATURE CONTROL
If heater floor outlet temperature cannot be
adjusted with the heater-A/C control temperature
control lever, one of the following could require ser-
vice:
²Blend-air door binding.
²Faulty blend-air door motor.
²Improper engine coolant temperature.
²Faulty heater-A/C control.
24 - 6 HEATING & AIR CONDITIONINGRS
HEATING & AIR CONDITIONING (Continued)
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