drain bolt CHRYSLER CARAVAN 2002 Manual PDF

REMOVAL
REMOVAL - REAR HEATER LINES
(1) Raise and support vehicle.
(2) Pinch off rubber heater line hose.
(3) Disconnect quick connect fitting at C-pillar.
(4) Loosen one screw and remove the other screw
at each of the three brackets holding the front of the
line to the underbody.
(5) Lower rear of line and drain coolant into a
suitable container.
(6) Loosen hose clamps at front of line and remove
line from vehicle.
REMOVAL - REAR AIR CONDITIONING LINES
(1) Recover A/C system.
(2) Hoist and support vehicle.
(3) Loosen one screw and remove the other screw
at each of the three brackets holding the A/C lines to
the underbody (Fig. 8).
(4) Remove both A/C lines from the two rear
retaining clamps, behind rear wheel.
(5) Remove both compression fittings at front of
A/C lines (Fig. 9).
(6) Remove (1) bolt securing A/C lines to block
located at A/C housing, behind rear wheel, and sepa-
rate block (Fig. 12).
(7) Remove rear wheel.
(8) Separate ABS harness from flex hose clamps.
(9) Remove heater lines from underbody brackets.
(10) Pinch off rubber heater line hoses at front of
vehicle.
(11) Loosen hose clamps at front of heater lines
and allow them to hang from vehicle.
(12) Remove rear A/C lines from vehicle.
(13) Remove nylon wedge holding lines into rear
block (Fig. 13).
Fig. 10 Rear Heater Hose Connection
1 - REAR HEATER HOSE
Fig. 11 Rear heater hose quick connects
1 - INSERT
2 - QUICK CONNECT
3 - COMPRESS INSERT FOR REMOVAL
Fig. 12 Rear A/C Block Connection
1 - CLEAN AREA AROUND BLOCK BEFORE REMOVAL
RSPLUMBING - REAR24 - 107
UNDERBODY LINES (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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VALVE COOLER
DESCRIPTION
The EGR valve on this engine uses a cooler to cool
the exhaust gases before the returned to the intake
manifold (Fig. 2). The EGR cooler attaches to the
EGR valve and is cooled with engine coolant.
REMOVAL
(1) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(2) Partially drain cooling system (Refer to 7 -
COOLING/ENGINE/COOLANT - STANDARD PRO-
CEDURE).
(3) Remove front wiper unit (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
REMOVAL).
(4) Disconnect coolant supply and return lines at
EGR cooler (Fig. 2).
(5) Remove EGR cooler to exhaust manifold retain-
ing bolt (Fig. 2).
(6) Remove EGR cooler to EGR valve retaining
bolts (Fig. 2) and remove cooler.
INSTALLATION
(1) Clean gasket sealing surfaces.
(2) Connect EGR valve cooler and new gasket to
EGR valve (Fig. 2). Torque bolts to 32.4N´m.
(3) Install EGR valve cooler to exhaust manifold
attaching bolt (Fig. 2). Torque bolt to 32.4N´m.
(4) Connect EGR cooler coolant supply and return
hoses to cooler (Fig. 2).
(5) Install front wiper unit (Refer to 8 - ELECTRI-
CAL/WIPERS/WASHERS/WIPER MODULE -
INSTALLATION).
(6) Refill cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(7) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
Fig. 2 EGR COMPONENTS
1 - HOSE CLAMP
2 - COOLANT HOSE
3 - HOSE CLAMP
4 - EGR VALVE RETAINING NUT
5 - E G R VA LV E
6 - COOLANT HOSE
7 - EGR VALVE GASKET
8 - EGR VALVE RETAINING STUDS
9 - EGR COOLER RETAINING BOLT
10 - HOSE CLAMP
11 - HOSE CLAMP
12 - EGR COOLER
13 - EGR COOLER TO EGR VALVE RETAINING BOLT
14 - TURBOCHARGER BRACKET
15 - TURBOCHARGER BRACKET RETAINING BOLT
16 - TURBOCHARGER DOWNPIPE
17 - TURBOCHARGER DOWNPIPE RETAINING NUT
18 - DOWNPIPE GASKET
19 - DOWNPIPE STUD
RGEXHAUST GAS RECIRCULATION25a-5
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