service CHRYSLER CARAVAN 2002 Service Manual

FUEL DOSING PUMP
DESCRIPTION
The dosing pump is a combined delivery, dosing
and shut-off system for the fuel supply to the heater
from the vehicles fuel tank.
OPERATION
The dosing pump is an electrically operated pump
that receives its operation instructions from the sup-
plemental heater electronic control module. The
pump supplies diesel fuel from the fuel tank to the
heater unit.
REMOVAL
The dosing pump is serviceable without removing
the component from the vehicle.
(1) Disconnect the rubber hose at the fuel line to
heater fuel pump. Leave the rubber hose on the fuel
line.(Refer to 24 - HEATING & AIR CONDITION-
ING/CABIN HEATER/FUEL LINE - REMOVAL)
(Fig. 2).
(2) Disconnect the fuel line between the dosing
pump and the heater unit.NOTE: Position and retain heater fuel line to pre-
vent fuel leakage while servicing dosing pump.
NOTE: Utilize an approved fuel storage container to
catch any residual fuel.
(3) Disconnect the electrical connector to the fuel
pump by depressing the integral spring and pulling
the connector away from the pump.
(4) Remove the dosing pump from the rubber iso-
lation.
INSTALLATION
(1) Mount the rubber isolation back onto the
splash shield mounting flanges at two locations.
(2) Connect fuel lines to the dosing pump and the
heater unit. The connectors should point towards the
heater fuel line.
(3) Use aviation style clamps to attach the hose to
the fuel pump nipples(Refer to 24 - HEATING & AIR
CONDITIONING/CABIN HEATER/FUEL LINE -
INSTALLATION).
Fig. 1 Diesel Cabin Heater Exhaust System
1 - Mounting screws (3)
2 - Steel heater exhaust pipe
3 - Exhaust clamp (2)
4 - Flexible heater exhaust pipe5 - Heater and heater shield
6 - Exhaust pipe mounting clips (3)
RSDIESEL SUPPLEMENTAL HEATER - DCHA - BUX24 - 111
EXHAUST TUBE (Continued)
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(7) With the DRBIIItin Cabin Heater, select Sys-
tem Tests and Dosing Pump Prime. Allow the Dosing
Pump to run for the full 45 second cycle time. When
the 45 second cycle is complete, press Page Back on
the DRBIIItkey pad to exit the Dosing Pump Prime.
The Dosing Pump priming procedure is now com-
plete.
HEATER UNIT
REMOVAL
WARNING: ALLOW THE DCHA TO COOL BEFORE
PERFORMING A COMPONENT INSPECTION/REPAIR
OR REPLACEMENT. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL
INJURY.
WARNING: ALLOW THE EXHAUST SYSTEM TO
COOL BEFORE PERFORMING A COMPONENT
INSPECTION/REPAIR OR REPLACEMENT. FAILURE
TO FOLLOW THESE INSTRUCTION MAY RESULT IN
PERSONAL INJURY.
(1) Elevate the vehicle on a hoist/lift taking note of
heater exhaust tube flexible section.
(2) Drain cooling system(Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Carefully open one hose to the underbody tube
assembly and drain the remaining coolant. A salvage
hose is a good idea to control the residual coolant, as
flow will occur from both the heater and the hose and
tube assemblies.
(4) Remove the second hose from the underbody
hose and tube assembly.
(5) Loosen the hose and tube assembly from the
toe-board cross member at two locations.
(6) Disconnect the electrical connector from the
body harness near the toe board cross member and
rail.
(7) Remove the wiring harness from the toe board
cross member(Refer to 24 - HEATING & AIR CON-
DITIONING/CABIN HEATER/HEATER UNIT -
REMOVAL).
(8) Open the fuel fill cap. Disconnect the rubber
fuel hose between the body tube assembly and the
fuel pump nipple at the body tube joint. A minimal
amount of fuel may flow from the open port.
NOTE: Utilize an approved fuel storage container to
catch any residual fuel.
(9) Loosen the two M8 fasteners at the rail. Take
care to notice that the exhaust tube bracket tab is on
top of the heater bracket.(10) Remove the heater exhaust tube flex section
from the exhaust tube by loosening the M6 bolt of
the clamp assembly. Remove the hose from the
exhaust tube. Removal of the rail tube assembly may
aid in this service operation.(Refer to 24 - HEATING
& AIR CONDITIONING/CABIN HEATER/EXHAUST
TUBE - REMOVAL).
(11) Remove seat hex nut at the heater mounting
flange to cross member.
(12) Loosen the remaining M6 and M8 fasteners
which mount the exhaust tube assembly to the vehi-
cle.
(a) Install a suitable cabin heater support device
under the cabin heater and secure the cabin heater
to the device.
(13) Loosen the remaining three M6 fasteners to
the cross members.
(14) Remove the loosened fasteners that support
the heater while supporting the weight of the heater.
(15) Swing the unit mounting bracket from
between the exhaust bracket and rail mounting loca-
tion. Drain any residual coolant from the heater unit.
(16) Lower the cabin heater and remove from the
supporting device and place on a suitable work area.
INSTALLATION
(1) Install the unit mounting bracket between the
exhaust bracket and the rail mounting location.
(2) Install the fasteners that support the heater
while supporting the weight of the heater.
(3) Install the three M6 fasteners to the cross
members. Tighten the M6 fasteners to 7 Nm (5 ft.
lbs.).
(4) Tighten the remaining M6 fasteners to 7 Nm (5
ft. lbs.) and the M8 fasteners to 23 Nm (17 ft. lbs.)
which mount the exhaust tube assembly to the vehi-
cle.
(5) Install the seat hex nut at the heater mounting
flange to the cross members. Tighten to 60 Nm (44 ft.
lbs.)
(6) Install the heater exhaust tube flex section to
the exhaust tube by tightening the M6 bolt of the
clamp assembly. Install the hose to the exhaust tube.
(7) Tighten the two M8 fasteners at the rail to 23
Nm (17 ft. lbs.). Taking care so that the exhaust tube
bracket tab is on the top of the heater bracket.
(8) Install the wiring harness(Refer to 24 - HEAT-
ING & AIR CONDITIONING/CABIN HEATER/
HEATER UNIT - INSTALLATION).
(9) Tighten the hose and tube assembly to the toe-
board cross member at two locations.
(10) Install the second hose to the underbody hose
and tube assembly.
(11) Connect the rubber fuel hose between the
body tube assembly and the fuel pump nipple at the
body tube joint. Close the fuel fill cap.
24 - 114 DIESEL SUPPLEMENTAL HEATER - DCHA - BUXRS
FUEL LINE (Continued)
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REMOVAL
REMOVAL - 2.4L
The EGR valve and Electrical EGR Transducer are
serviced as an assembly (Fig. 1).
(1) Disconnect vacuum tube from electric EGR
transducer. Inspect vacuum tube for damage.
(2) Remove electrical connector from solenoid.
(3) Remove EGR tube bolts from EGR valve.
(4) Remove EGR valve from cylinder head adaptor.
(5) Clean gasket surface and discard old gasket.
Check for any signs of leakage or cracked surfaces.
Repair or replace as necessary.
REMOVAL - 3.5L
(1) Disconnect the negative battery cable.
(2) Disconnect the fresh air makeup hose on rear
valve cover.
(3) Remove the air box bolt.
(4) Remove the hose clamp at throttle body.
(5) Unlatch 2 clamps for air box cover.
(6) Remove air box cover.
(7) Unlock the electrical connector.
(8) Disconnect the electrical connector from the
EGR valve.
(9) Remove the 2 bolts for the front EGR tube
(10) Remove the 2 bolts for the rear EGR tube
(11) Remove the 2 EGR valve mounting bolts.
(12) Remove the EGR valve.
INSTALLATION
INSTALLATION - 2.4L
The EGR valve and Electrical EGR Transducer are
serviced as an assembly (Fig. 1).
(1) Assemble EGR valve with new gasket onto the
cylinder head adaptor.
(2) Loose assemble the bolts from EGR valve to
EGR tube.
(3) Loose assemble the bolts from EGR valve to
cylinder head.
(4) Tighten bolts from EGR valve to cylinder head
to 22.8 N´m (200  25 in. lbs.) torque.
(5) Tighten bolts from EGR valve to EGR tube to
11.9 N´m (105  20 in. lbs.) torque.
(6) Reconnect vacuum hose and electrical connec-
tor to electrical EGR transducer.
INSTALLATION - 3.5L
(1) Install the EGR valve.
(2) Install the 2 bolts for the rear EGR tube
(3) Install the 2 bolts for the front EGR tube
(4) Tighten the EGR tube bolts.
(5) Tighten the EGR valve mounting bolts.
(6) Connect the electrical connector to the EGR
valve.
(7) Lock the electrical connector.
(8) Install air box cover.
(9) Latch 2 clamps for air box cover.
(10) Install the hose clamp at throttle body.
(11) Connect the fresh air makeup hose on rear
valve cover.
(12) Connect the negative battery cable.
RSEXHAUST GAS RECIRCULATION25-23
VALVE (Continued)
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