gas type CHRYSLER CARAVAN 2005 Service Manual

DIGIT 21
Price Class
²H = Highline
²L = Lowline
²P = Premium
²S = Luxury
²X = Premium
DIGITS 22 AND 23
Body Type
²52 = Short Wheel Base
²53 = Long Wheel Base
BODY CODE PLATE LINE 2
DIGITS 1, 2 AND 3
Paint Procedure
DIGIT 4
Open Space
DIGITS 5 THROUGH 7
Primary Paint (Refer to 23 - BODY/PAINT - SPEC-
IFICATIONS).
DIGIT 8 AND 9
Open Space
DIGITS 10 THROUGH 12
Secondary Paint
DIGIT 13 AND 14
Open Space
DIGITS 15 THROUGH 18
Interior Trim Code
DIGIT 19
Open Space
DIGITS 20, 21, AND 22
Engine Code
²EDZ = 2.4L 4 cyl. 16-Valve DOHC Gasoline
(MPI)
²EGA = 3.3L 6 cyl. Gasoline (SMPI)
²EGH = 3.8L 6 cyl. Gasoline (SMPI)
²EGM = 3.3L 6 cyl. Ethanol Flexible Fuel
²ENJ = 2.5L 4 cyl. 16-Valve Turbo Diesel
DIGIT 23
Open Space
BODY CODE PLATE LINE 1
DIGITS 1, 2, AND 3
Transaxle Codes
²DGC = 31TH 3-Speed Automatic Transaxle
²DGL = 41AE/TE 4-Speed Electronic Automatic
²DDR = T850 5-Speed Manual Transaxle
DIGIT 4
Open Space
DIGIT 5
Market Code
²C = Canada
²B = International
²M = Mexico
²U = United States
DIGIT 6
Open Space
DIGITS 7 THROUGH 23
Vehicle Identification Number
²Refer to Vehicle Identification Number (VIN)
paragraph for proper breakdown of VIN code.
IF TWO BODY CODE PLATES ARE REQUIRED
The last code shown on either plate will be fol-
lowed by END. When two plates are required, the
last code space on the first plate will indicate (CTD)
When a second plate is required, the first four
spaces of each line will not be used due to overlap of
the plates.
FASTENER IDENTIFICATION
DESCRIPTION
The SAE bolt strength grades range from grade 2
to grade 8. The higher the grade number, the greater
the bolt strength. Identification is determined by the
line marks on the top of each bolt head. The actual
bolt strength grade corresponds to the number of line
marks plus 2. The most commonly used metric bolt
strength classes are 9.8 and 10.9. The metric
strength class identification number is imprinted on
the head of the bolt. The higher the class number,
the greater the bolt strength. Some metric nuts are
imprinted with a single-digit strength class on the
nut face. Refer to the Fastener Identification and
Fastener Strength Charts.
2 INTRODUCTIONRS
BODY CODE PLATE (Continued)

LUBRICATION & MAINTENANCE
TABLE OF CONTENTS
page page
INTERNATIONAL SYMBOLS
DESCRIPTION..........................1
FLUID TYPES
DESCRIPTION
DESCRIPTION - ENGINE OIL AND
LUBRICANTS.........................1
DESCRIPTION - ENGINE COOLANT........3
DESCRIPTION - FLEXIBLE FUEL ENGINE
OIL .................................3
DESCRIPTION - AUTOMATIC/MANUAL
TRANSAXLE FLUID.....................4
DESCRIPTION - FUEL REQUIREMENTS.....4
DESCRIPTION - FUEL REQUIREMENTS -
DIESEL ENGINE.......................6
DESCRIPTION - ENGINE OIL - DIESEL
ENGINES............................6
DESCRIPTION - AWD REAR DRIVELINE
MODULE FLUIDS......................6
DESCRIPTION - AWD POWER TRANSFER
UNIT FLUID...........................6FLUID CAPACITIES
SPECIFICATIONS - FLUID CAPACITIES.......6
FLUID FILL/CHECK LOCATIONS
DESCRIPTION..........................7
LUBRICATION POINTS
DESCRIPTION..........................7
MAINTENANCE SCHEDULES
DESCRIPTION
DESCRIPTION........................7
DESCRIPTION - EXPORT...............13
DESCRIPTION - DIESEL ENGINES -
EXPORT............................21
HOISTING
STANDARD PROCEDURE - HOISTING.......24
JUMP STARTING
STANDARD PROCEDURE - JUMP STARTING . 25
TOWING
STANDARD PROCEDURE - TOWING........26
INTERNATIONAL SYMBOLS
DESCRIPTION
DaimlerChrysler Corporation uses international
symbols to identify engine compartment lubricant
and fluid inspection and fill locations (Fig. 1).
FLUID TYPES
DESCRIPTION
DESCRIPTION - ENGINE OIL AND LUBRICANTS
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY. CONTACT YOUR DEALER OR GOVERN-
MENT AGENCY FOR LOCATION OF COLLECTION
CENTER IN YOUR AREA.
When service is required, DaimlerChrysler Corpo-
ration recommends that only Mopartbrand parts,
lubricants and chemicals be used. Mopartprovides
the best engineered products for servicing
DaimlerChrysler Corporation vehicles.
Only lubricants bearing designations defined by
the following organization should be used.
Fig. 1 INTERNATIONAL SYMBOLS
RSLUBRICATION & MAINTENANCE0-1

letter ªGº. Chassis lubricant is identified by the letter
ªLº. The letter following the usage letter indicates
the quality of the lubricant. The following symbols
indicate the highest quality.
SPECIALIZED LUBRICANTS AND OILS
Some maintenance or repair procedures may
require the use of specialized lubricants or oils. Con-
sult the appropriate sections in this manual for the
correct application of these lubricants.
DESCRIPTION - ENGINE COOLANT
WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL
BASE COOLANT AND IS HARMFUL IF SWAL-
LOWED OR INHALED. IF SWALLOWED, DRINK
TWO GLASSES OF WATER AND INDUCE VOMIT-
ING. IF INHALED, MOVE TO FRESH AIR AREA.
SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT
STORE IN OPEN OR UNMARKED CONTAINERS.
WASH SKIN AND CLOTHING THOROUGHLY AFTER
COMING IN CONTACT WITH ETHYLENE GLYCOL.
KEEP OUT OF REACH OF CHILDREN. DISPOSE OF
GLYCOL BASE COOLANT PROPERLY, CONTACT
YOUR DEALER OR GOVERNMENT AGENCY FOR
LOCATION OF COLLECTION CENTER IN YOUR
AREA. DO NOT OPEN A COOLING SYSTEM WHEN
THE ENGINE IS AT OPERATING TEMPERATURE OR
HOT UNDER PRESSURE, PERSONAL INJURY CAN
RESULT. AVOID RADIATOR COOLING FAN WHEN
ENGINE COMPARTMENT RELATED SERVICE IS
PERFORMED, PERSONAL INJURY CAN RESULT.
CAUTION: Use of Propylene Glycol based coolants
is not recommended, as they provide less freeze
protection and less boiling protection.
The cooling system is designed around the coolant.
The coolant must accept heat from engine metal, in
the cylinder head area near the exhaust valves and
engine block. Then coolant carries the heat to theradiator where the tube/fin radiator can transfer the
heat to the air.
The use of aluminum cylinder blocks, cylinder
heads, and water pumps requires special corrosion
protection. MopartAntifreeze/Coolant, 5
Year/100,000 Mile Formula (MS-9769), or the equiva-
lent ethylene glycol base coolant with hybrid organic
corrosion inhibitors (called HOAT, for Hybrid Organic
Additive Technology) is recommended. This coolant
offers the best engine cooling without corrosion when
mixed with 50% Ethylene Glycol and 50% distilled
water to obtain a freeze point of -37ÉC (-35ÉF). If it
loses color or becomes contaminated, drain, flush,
and replace with fresh properly mixed coolant solu-
tion.
The green coolantMUST NOT BE MIXEDwith
the orange or magenta coolants. When replacing cool-
ant the complete system flush must be performed
before using the replacement coolant.
CAUTION: MoparTAntifreeze/Coolant, 5
Year/100,000 Mile Formula (MS-9769) may not be
mixed with any other type of antifreeze. Doing so
will reduce the corrosion protection and may result
in premature water pump seal failure. If non-HOAT
coolant is introduced into the cooling system in an
emergency, it should be replaced with the specified
coolant as soon as possible.
DESCRIPTION - FLEXIBLE FUEL ENGINE OIL
The information in this section is for Flexible Fuel
Vehicles (FFV) only. These vehicles can be identified
by the unique Fuel Filler Door Label that states
Ethanol (E-85) or Unleaded Gasoline Only. This sec-
tion only covers those subjects that are unique to
these vehicles. Please refer to the other sections of
this manual for information on features that are
common between Flexible Fuel and gasoline only
powered vehicles.
ETHANOL FUEL (E-85)
E-85 is a mixture of approximately 85% fuel etha-
nol and 15% unleaded gasoline.
WARNING: Ethanol vapors are extremely flammable
and could cause serious personal injury. Never
have any smoking materials lit in or near the vehi-
cle when removing the fuel filler tube cap (gas cap)
or filling the tank. Do not use E-85 as a cleaning
agent and never use it near an open flame.
FUEL REQUIREMENTS
The vehicle will operate on both unleaded gasoline
with an octane rating of 87, or E-85 fuel, or any mix-
ture of these two.
Fig. 4 NLGI SYMBOL
1 - WHEEL BEARINGS
2 - CHASSIS LUBRICATION
3 - CHASSIS AND WHEEL BEARINGS
RSLUBRICATION & MAINTENANCE0-3
FLUID TYPES (Continued)

For best results, a refueling pattern that alternates
between E-85 and unleaded gasoline should be
avoided. When you do switch fuels, it is recom-
mended that
²you do not switch when the fuel gauge indicates
less than 1/4 full
²you do not add less than 5 gallons when refuel-
ing
²you operate the vehicle immediately after refuel-
ing for a period of at least 5 minutes
Observing these precautions will avoid possible
hard starting and/or significant deterioration in
driveability during warm up.
FFV STARTING
The characteristics of E-85 fuel make it unsuitable
for use when ambient temperatures fall below 0ÉF. In
the range of 0ÉF to 32ÉF, you may experience an
increase in the time it takes for your engine to start,
and a deterioration in driveability (sags and/or hesi-
tations) until the engine is fully warmed up.
Engine Operating on E-85 Fuel
If vehicle operates on E-85 fuel either full or part-
time, use only MopartFlexible Fuel 5W-30 engine oil
or an equivalent that meets DaimlerChrysler Stan-
dard MS-9214. Equivalent commercial Flexible Fuel
engine oils may be labeled as Multi-Fuel, Variable
Fuel, Flexible Fuel, etc. These engine oils may be
satisfactory if they meet the DaimlerChrysler Stan-
dard.
SAE 5W-30 engine oil is preferred for use in Flex-
ible Fuel engines.
CAUTION: If Flexible Fuel engine oil is not used
when using E-85 fuel, engine wear or damage may
result.
CRUISING RANGE
Because E-85 fuel contains less energy per gallon
than gasoline, you will experience an increase in fuel
consumption. You can expect your MPG and your
driving range to decrease by about 30% compared to
gasoline operation.
DESCRIPTION - AUTOMATIC/MANUAL
TRANSAXLE FLUID
NOTE: Refer to the maintenance schedules for the
recommended maintenance (fluid/filter change)
intervals for these transaxles.
NOTE: All transaxles have a common transmission
and differential sump. Filling the transaxle accom-
modates the differential as well.
TRANSMISSION FLUID
MopartATF+4 (Automatic Transmission Fluid) is
required in the 4XTE automatic and T850 manual
transaxles. Substitute fluids can induce transmission
problems and/or failure.
MopartATF+4 (Automatic Transmission Fluid)
when new is red in color. The ATF is dyed red so it
can be identified from other fluids used in the vehicle
such as engine oil or antifreeze. The red color is not
permanent and is not an indicator of fluid condition.
As the vehicle is driven, the ATF will begin to look
darker in color and may eventually become brown.
This is normal.ATF+4 also has a unique odor that
may change with age. Consequently,odor and color
cannot be used to indicate the fluid condition
or the need for a fluid change.
FLUID ADDITIVES
DaimlerChrysler strongly recommends against the
addition of any fluids to the transmission, other than
those automatic transmission fluids listed above.
Exceptions to this policy are the use of special dyes
to aid in detecting fluid leaks.
Various ªspecialº additives and supplements exist
that claim to improve shift feel and/or quality. These
additives and others also claim to improve converter
clutch operation and inhibit overheating, oxidation,
varnish, and sludge. These claims have not been sup-
ported to the satisfaction of DaimlerChrysler and
these additivesmust not be used.The use of trans-
mission ªsealersº should also be avoided, since they
may adversely affect the integrity of transmission
seals.
DESCRIPTION - FUEL REQUIREMENTS
Your engine is designed to meet all emissions reg-
ulations and provide excellent fuel economy and per-
formance when using high quality unleaded gasoline
having an octane rating of 87. The use of premium
gasoline is not recommended. The use of premium
gasoline will provide no benefit over high quality reg-
ular gasoline, and in some circumstances may result
in poorer performance.
Light spark knock at low engine speeds is not
harmful to your engine. However, continued heavy
spark knock at high speeds can cause damage and
immediate service is required. Engine damage result-
ing from operation with a heavy spark knock may
not be covered by the new vehicle warranty.
Poor quality gasoline can cause problems such as
hard starting, stalling and hesitations. If you experi-
ence these symptoms, try another brand of gasoline
before considering service for the vehicle.
Over 40 auto manufacturers world-wide have
issued and endorsed consistent gasoline specifications
(the Worldwide Fuel Charter, WWFC) to define fuel
0 - 4 LUBRICATION & MAINTENANCERS
FLUID TYPES (Continued)

properties necessary to deliver enhanced emissions,
performance and durability for your vehicle. We rec-
ommend the use of gasolines that meet the WWFC
specifications if they are available.
REFORMULATED GASOLINE
Many areas of the country require the use of
cleaner burning gasoline referred to as ªreformu-
latedº gasoline. Reformulated gasoline contain oxy-
genates, and are specifically blended to reduce
vehicle emissions and improve air quality.
We strongly support the use of reformulated gaso-
line. Properly blended reformulated gasoline will pro-
vide excellent performance and durability for the
engine and fuel system components.
GASOLINE/OXYGENATE BLENDS
Some fuel suppliers blend unleaded gasoline with
oxygenates such as 10% ethanol, MTBE, and ETBE.
Oxygenates are required in some areas of the country
during the winter months to reduce carbon monoxide
emissions. Fuels blended with these oxygenates may
be used in your vehicle.
CAUTION: DO NOT use gasoline containing METH-
ANOL. Gasoline containing methanol may damage
critical fuel system components.
MMT IN GASOLINE
MMT is a manganese-containing metallic additive
that is blended into some gasoline to increase octane.
Gasoline blended with MMT provide no performance
advantage beyond gasoline of the same octane num-
ber without MMT. Gasoline blended with MMT
reduce spark plug life and reduce emission system
performance in some vehicles. We recommend that
gasoline free of MMT be used in your vehicle. The
MMT content of gasoline may not be indicated on the
gasoline pump; therefore, you should ask your gaso-
line retailer whether or not his/her gasoline contains
MMT.
It is even more important to look for gasoline with-
out MMT in Canada because MMT can be used at
levels higher than allowed in the United States.
MMT is prohibited in Federal and California refor-
mulated gasoline.
SULFUR IN GASOLINE
If you live in the northeast United States, your
vehicle may have been designed to meet California
low emission standards with Cleaner-Burning Cali-
fornia reformulated gasoline with low sulfur. If such
fuels are not available in states adopting California
emission standards, your vehicles will operate satis-
factorily on fuels meeting federal specifications, but
emission control system performance may beadversely affected. Gasoline sold outside of California
is permitted to have higher sulfur levels which may
affect the performance of the vehicle's catalytic con-
verter. This may cause the Malfunction Indicator
Lamp (MIL), Check Engine or Service Engine Soon
light to illuminate. We recommend that you try a dif-
ferent brand of unleaded gasoline having lower sulfur
to determine if the problem is fuel related prior to
returning your vehicle to an authorized dealer for
service.
CAUTION: If the Malfunction Indicator Lamp (MIL),
Check Engine or Service Engine Soon light is flash-
ing, immediate service is required; see on-board
diagnostics system section.
MATERIALS ADDED TO FUEL
All gasoline sold in the United States and Canada
are required to contain effective detergent additives.
Use of additional detergents or other additives is not
needed under normal conditions.
FUEL SYSTEM CAUTIONS
CAUTION: Follow these guidelines to maintain your
vehicle's performance:
²The use of leaded gas is prohibited by Federal
law. Using leaded gasoline can impair engine perfor-
mance, damage the emission control system, and
could result in loss of warranty coverage.
²An out-of-tune engine, or certain fuel or ignition
malfunctions, can cause the catalytic converter to
overheat. If you notice a pungent burning odor or
some light smoke, your engine may be out of tune or
malfunctioning and may require immediate service.
Contact your dealer for service assistance.
²When pulling a heavy load or driving a fully
loaded vehicle when the humidity is low and the tem-
perature is high, use a premium unleaded fuel to
help prevent spark knock. If spark knock persists,
lighten the load, or engine piston damage may result.
²The use of fuel additives which are now being
sold as octane enhancers is not recommended. Most
of these products contain high concentrations of
methanol. Fuel system damage or vehicle perfor-
mance problems resulting from the use of such fuels
or additives is not the responsibility of
DaimlerChrysler Corporation and may not be covered
under the new vehicle warranty.
NOTE: Intentional tampering with emissions control
systems can result in civil penalties being assessed
against you.
RSLUBRICATION & MAINTENANCE0-5
FLUID TYPES (Continued)

DESCRIPTION - FUEL REQUIREMENTS -
DIESEL ENGINE
WARNING: DO NOT USE ALCOHOL OR GASOLINE
AS A FUEL BLENDING AGENT. THEY CAN BE
UNSTABLE UNDER CERTAIN CONDITIONS AND
HAZARDOUS OR EXPLOSIVE WHEN MIXED WITH
DIESEL FUEL.
Use good quality diesel fuel from a reputable sup-
plier. For most year-round service, number 2 diesel
fuel meeting DIN EN 590 (Class0-4)will provide
good performance. If the vehicle is exposed to
extreme cold (below -18ÉC/0ÉF) or is required to oper-
ate at colder than normal conditions for prolonged
periods, use climatize No. 2 diesel fuel or dilute the
No. 2 diesel fuel with 50% No. 1 diesel fuel as long as
it meets ASTM D 975: 1D and 2D and the quality of
lubrication behavior is in accordance with DIN EN
590. This will provide better protection from fuel gel-
ling or wax plugging of the fuel filters.
Diesel fuel is seldom completely free of water. To
prevent fuel system trouble, including fuel line freez-
ing in winter, drain the accumulated water from the
fuel/water separator using the fuel/water separator
drain provided. If you buy good quality fuel and follow
the cold weather advice above, fuel conditioners should
not be required in your vehicle. If available in your
area, a high cetane ªpremiumº diesel fuel may offer
improved cold starting and warm up performance.
DESCRIPTION - ENGINE OIL - DIESEL
ENGINES
Use only Diesel Engine Oil meeting standardMIL-
2104Cor API ClassificationCD or higherorCCML
D4, D5.
SAE VISCOSITY GRADE
CAUTION: Low viscosity oils must have the proper
API quality or the CCMC G5 designation.
To assure of properly formulated engine oils, it is
recommended that SAE Grade 10W-40 engine oils
that meet Chrysler material standard MS-6395, be
used in accordance to ACEA B3, B4 specification.
European Grade 10W-40 oils are also acceptable.
Oils of the SAE 5W-40 grade number are preferred
when minimum temperatures consistently fall below
-15ÉC.
DESCRIPTION - AWD REAR DRIVELINE
MODULE FLUIDS
The AWD Rear Driveline Module Assembly consists
of two subassemblies, the Overrunning Clutch Hous-
ing (front) and the Differential Carrier (rear).The recommended lubricant for the Overrunning
Clutch Housing is MopartATF+4. The recommended
lubricant for the Differential Carrier is Mopart
80W-90 Gear and Axle Lubricant.
DESCRIPTION - AWD POWER TRANSFER UNIT
FLUID
The recommended lubricant for the AWD Power
Transfer Unit is MopartGear and Axle Lubricant
80W-90.
FLUID CAPACITIES
SPECIFICATIONS - FLUID CAPACITIES
DESCRIPTION SPECIFICATION
Fuel Tank (Gas) 75 L (20 gal.)
Fuel Tank (Diesel) 75 L (20 gal.)
Engine Oil* - 2.4 L 4.7 L (5.0 qts.)
Engine Oil* - 3.3/3.8 L 4.7 L (5.0 qts.)
Engine Oil* - 2.5 L
(Diesel)6.0 L (6.3 qts.)
Cooling System** - 2.4 L 10.7 L (11.4 qts.)
Cooling System** - 2.5 L
Turbo Diesel with
Auxiliary Heater13.8 L (14.6 qts.)
Cooling System** -
3.3/3.8 L without Auxiliary
Heater12.6 L (13.4 qts.)
Cooling System** -
3.3/3.8 L with Auxiliary
Heater15.4 L (16.3 qts.)
Automatic Transaxle -
Service Fill3.8 L (4.0 qts.)
Automatic Transaxle -
4XTE Overhaul Fill9.2 L (9.7 qts.)
Manual Transaxle (T850
5-Speed)2.4-2.7 L (2.5-2.9 qts.)
AWD Power Transfer Unit 1.15 L (2.4 pts.)
Power Steering 1.2 L (2.5 pts.)
AWD Bi-directional
Overrunning Clutch0.575 L (1.22 pts.)
AWD Rear Carrier 0.7 L (1.48 pts.)
* (includes oil filter)
** (includes heater and recovery/reserve bottle)
0 - 6 LUBRICATION & MAINTENANCERS
FLUID TYPES (Continued)

SUPPORT PLATE - DRUM
BRAKE
REMOVAL
(1) Using a brake pedal depressor, move and
secure brake pedal to a position past its first 1 inch
of travel. This will prevent brake fluid from draining
out of master cylinder when brake tube is remove
from wheel cylinder.
(2) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE).
(3) Remove wheel and tire assembly.
(4) Disconnect brake tube from rear of wheel cylin-
der. Cap open ends
(5) Remove brake drum.
(6) Remove brake shoes from brake support plate.
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
BRAKE PADS/SHOES - REMOVAL).
(7) Remove the 2 bolts attaching the wheel cylin-
der to the brake support plate.
(8) Remove the wheel cylinder from the brake sup-
port plate.
(9) Disconnect the park brake cable from the park
brake actuation lever.
(10) Using a suitable tool such as a 14 mm box
wrench (Fig. 92) or an aircraft type hose clamp, com-
press the flared legs on park brake cable retainer.
Then pull the park brake cable out of brake support
plate.
(11) Remove the rear hub and bearing. (Refer to 2
- SUSPENSION/REAR/HUB / BEARING -
REMOVAL)(12) Remove the rear brake support plate from the
rear axle.
INSTALLATION
(1) Install the 4 hub and bearing to axle mounting
bolts into the mounting holes in the flange of the
rear axle.
(2) Install the rear brake support plate on the 4
mounting bolts installed in the flange of the rear axle
(Fig. 93).
(3) Install the rear hub and bearing (and connect
wheel speed sensor where applicable) stopping short
of installing the brake drum. (Refer to 2 - SUSPEN-
SION/REAR/HUB / BEARING - INSTALLATION)
(4) Install the rear park brake cable into its
mounting hole in the rear brake support plate.
(5) Install the park brake cable on the park brake
actuation lever.
(6) Apply sealant such as Mopar Gasket-In-A-Tube
or equivalent around the wheel cylinder opening in
the brake support plate.
(7) Install wheel cylinder onto brake support.
Install and tighten the wheel cylinder to brake sup-
port plate attaching bolts to 8 N´m (75 in. lbs.)
torque.
(8) Install brake tube into wheel cylinder. Tighten
tube nut to a torque of 17 N´m (145 in. lbs.) torque.
(9) Install the rear brake shoes on the brake sup-
port plate. (Refer to 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/BRAKE PADS/SHOES -
INSTALLATION).
(10) Install brake drum.
(11) Install the wheel and tire assembly. Tighten
the wheel mounting nuts in proper sequence until all
nuts are torqued to half specification, then repeat the
Fig. 92 Removing Park Brake Cable From Brake
Support Plate
1 - PARK BRAKE CABLE
2 - CABLE RETAINER
3 - 14 mm BOX WRENCH
4 - BRAKE SUPPORT PLATE
Fig. 93 Brake Support Plate Mounted On Bearing
Attaching Bolts
1 - REAR BRAKE SUPPORT PLATE
2 - HUB/BEARING MOUNTING BOLTS
RSBRAKES - BASE5-61

tightening sequence to the full specified torque of 135
N´m (100 ft. lbs.).
(12) Adjust drum brake shoes. (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/BRAKE
PADS/SHOES - ADJUSTMENTS)
(13) Remove brake pedal depressor tool.
(14) Bleed the brake system as necessary. (Refer to
5 - BRAKES - BASE - STANDARD PROCEDURE).
(15) Lower the vehicle.
WHEEL CYLINDERS
REMOVAL
(1) Using a brake pedal depressor, move and
secure brake pedal to a position past its first 1 inch
of travel. This will prevent brake fluid from draining
out of master cylinder when brake tube is remove
from wheel cylinder.
(2) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE).
(3) Remove wheel and tire assembly.
(4) Disconnect brake tube from rear of wheel cylin-
der. Cap open ends
(5) Remove brake drum.
(6) Remove brake shoes from brake support plate
(Discard if contaminated).(Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/BRAKE PADS/SHOES -
REMOVAL)
(7) Remove the 2 bolts attaching the wheel cylin-
der to the brake support plate.
(8) Remove the wheel cylinder from the brake sup-
port plate.
INSPECTION
With brake drums removed, inspect the wheel cyl-
inder boots for evidence of a brake fluid leak. Visu-
ally check the boots for cuts, tears, or heat cracks. If
any of these conditions exist, the wheel cylinders
should be completely cleaned, inspected and new
parts installed.
If a wheel cylinder is leaking and the brake lining
material is saturated with brake fluid, the brake
shoes must be replaced.
INSTALLATION
(1) Apply sealant such as Mopar Gasket-In-A-Tube
or equivalent around the wheel cylinder opening in
the brake support plate.
(2) Install wheel cylinder onto brake support.
Install and tighten the wheel cylinder to brake sup-
port plate attaching bolts to 8 N´m (75 in. lbs.)
torque.
(3) Install brake tube into wheel cylinder. Tighten
tube nut to a torque of 17 N´m (145 in. lbs.) torque.(4) Install the rear brake shoes on the brake sup-
port plate. (Refer to 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/BRAKE PADS/SHOES -
INSTALLATION).
(5) Install brake drum.
(6) Install wheel and tire. Install and tighten
wheel lug nuts to 135 N´m (100 ft. lbs.).
(7) Adjust drum brake shoes. (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/BRAKE
PADS/SHOES - ADJUSTMENTS)
(8) Remove brake pedal depressor tool.
(9) Bleed the brake system as necessary. (Refer to
5 - BRAKES - BASE - STANDARD PROCEDURE).
(10) Lower vehicle.
PARKING BRAKE
DESCRIPTION
DESCRIPTION
The parking brake system is operated by a foot
operated parking brake lever. The parking brake
lever is mounted on the body of the vehicle to the left
of the brake pedal (Fig. 94). It is a automatic-adjust-
ing type lever.
Vehicles without Fold-in-floor seating have four
flexible steel parking brake cables. They are:
²Front
²Intermediate
²Left rear
²Right rear
Fig. 94 Parking Brake Lever (Pedal)
1 - PARK BRAKE PEDAL ASSEMBLY
2 - PARK BRAKE PEDAL
3 - CARPET
4 - FRONT PARK BRAKE CABLE
5 - SEAL
6 - FLOOR PAN
5 - 62 BRAKES - BASERS
SUPPORT PLATE - DRUM BRAKE (Continued)

DIAGNOSIS AND TESTING - COOLING SYSTEM
AERATION
Low coolant level in a cross flow radiator will
equalize in both tanks with engine off. With engine
at running and at operating temperature, the high
pressure inlet tank runs full and the low pressure
outlet tank drops, resulting in cooling system aera-
tion. Aeration will draw air into the water pump
resulting in the following:
²High reading shown on the temperature gauge.
²Loss of coolant flow through the heater core.
²Corrosion in the cooling system.
²Water pump seal may run dry, increasing the
risk of premature seal failure.
²Combustion gas leaks into the coolant can also
cause the above problems.
DIAGNOSIS AND TESTING - COOLING SYSTEM
DEAERATION
Air can only be removed from the system by gath-
ering under the pressure cap. On the next heat up it
will be pushed past the pressure cap into the coolant
recovery bottle by thermal expansion of the coolant.
It then escapes to the atmosphere in the coolant
recovery bottle and is replaced with coolant on cool
down.
To effectively deaerate the system, multiple ther-
mal cycles of the system may be required.
NOTE: Deaeration does not occur at engine idleÐ
higher engine speeds are required. Normal driving
will deaerate cooling system.
STANDARD PROCEDURE
STANDARD PROCEDURE - COOLING SYSTEM
DRAINING
WARNING: DO NOT REMOVE OR LOOSEN THE
COOLANT PRESSURE CAP, CYLINDER BLOCK
DRAIN PLUGS, OR THE DRAINCOCK WHEN THE
SYSTEM IS HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM THE COOLANT
CAN OCCUR.
(1)Without removing radiator pressure cap
and with system not under pressure, using a
screwdriver, open the draincock. The draincock is
located on the lower left side of radiator.
(2) After the coolant recovery/reserve container is
empty, then remove coolant pressure cap (Fig. 5).
(3) Remove the cylinder block drain plug(s).
STANDARD PROCEDURE - COOLING SYSTEM
FILLING
Remove radiator pressure cap (Fig. 5) and fill sys-
tem, using a 50/50 mix of MopartAntifreeze/Coolant,
5 Year/100,000 Mile Formula and distilled water.
Continue filling system until full.Be careful not
to spill coolant on drive belts or the generator.
For cooling system capacity, (Refer to LUBRICATION
& MAINTENANCE/FLUID CAPACITIES - SPECIFI-
CATIONS).
Fill coolant recovery/reserve container (Fig. 5) to at
least the MAX mark with 50/50 solution. It may be
necessary to add coolant to the recovery/reserve con-
tainer after three or four warm up/cool down cycles
to maintain coolant level between the MAX and MIN
mark. This will allow trapped air to be removed from
the system.
STANDARD PROCEDURE - ADDING
ADDITIONAL COOLANT
The radiator cap should not be removed.
When additional coolant is needed to maintain this
level, it should be added to the coolant recovery/re-
serve container (Fig. 5). Use only 50/50 mix of ethyl-
ene glycol type antifreeze and distilled water. For the
recommeded antifreeze/coolant type (Refer to LUBRI-
CATION & MAINTENANCE/FLUID TYPES -
DESCRIPTION).
CAUTION: Do not use well water, or suspect water
supply in cooling system. A 50/50 ethylene glycol
and distilled water mix is recommended. For the
recommeded antifreeze/coolant type (Refer to
LUBRICATION & MAINTENANCE/FLUID TYPES -
DESCRIPTION).
STANDARD PROCEDURE - COOLANT LEVEL
CHECK
NOTE: Do not remove radiator cap for routine cool-
ant level inspections.
The coolant reserve system provides a quick visual
method for determining the coolant level without
removing the radiator cap.With the engine cold
and not running,simply observe the level of the
coolant in the recovery/reserve container (Fig. 5). The
coolant level should be between the MIN and MAX
marks.
7 - 4 COOLINGRS
COOLING (Continued)

INSPECTION
Hold the cap in your hand,top side up(Fig. 19).
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. 20). The radiator fan consist
of the fan blade, electric motor and a support shroud
which are all serviced as an assembly.
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%
Fig. 19 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
RSENGINE7-29
RADIATOR PRESSURE CAP (Continued)