wiper blades CHRYSLER CARAVAN 2002 Service Manual

WIPERS/WASHERS
TABLE OF CONTENTS
page page
WIPERS/WASHERS
DESCRIPTION..........................1
OPERATION............................2
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - FRONT WIPER
SYSTEM.............................2
DIAGNOSIS AND TESTING - FRONT
WIPER/WASHER SWITCH................2
DIAGNOSIS AND TESTING - FAILED PARK
SWITCH.............................3
DIAGNOSIS AND TESTING - REAR WIPER
SYSTEM.............................5
DIAGNOSIS AND TESTING - WASHER
SYSTEM.............................5
FRONT WASHER PUMP MOTOR
REMOVAL.............................9
INSTALLATION..........................9
FRONT WIPER ARMS
STANDARD PROCEDURE - FRONT WIPER
ARM ALIGNMENT......................9
REMOVAL.............................10
INSTALLATION.........................10
FRONT WIPER MOTOR
REMOVAL.............................10
INSTALLATION.........................10
HEADLAMP WASHERS - EXPORT
DESCRIPTION.........................11
OPERATION...........................11
DIAGNOSIS AND TESTING - HEADLAMP
WASHERS - EXPORT..................11
REMOVAL.............................13
INSTALLATION.........................13
HEADLAMP WASHER HOSE - EXPORT
REMOVAL.............................13
INSTALLATION.........................13HEADLAMP WASHER PUMP MOTOR - EXPORT
REMOVAL.............................13
INSTALLATION.........................14
REAR WASHER PUMP MOTOR
REMOVAL.............................14
INSTALLATION.........................15
REAR WIPER ARM
REMOVAL.............................15
INSTALLATION.........................15
REAR WIPER MOTOR
REMOVAL.............................16
INSTALLATION.........................16
REAR WIPER/WASHER SWITCH
DESCRIPTION.........................16
OPERATION...........................16
WASHER FLUID LEVEL SWITCH
REMOVAL.............................16
INSTALLATION.........................17
WASHER HOSES
REMOVAL.............................17
INSTALLATION.........................17
WASHER RESERVOIR
REMOVAL.............................18
INSTALLATION.........................18
WIPER BLADES
REMOVAL.............................18
CLEANING............................19
INSTALLATION.........................19
WIPER LINKAGE
REMOVAL.............................19
INSTALLATION.........................19
WIPER MODULE
REMOVAL.............................19
INSTALLATION.........................20
WIPERS/WASHERS
DESCRIPTION
FRONT WIPER/WASHER SYSTEM
The windshield wipers can be operated with the
windshield wiper switch when the ignition switch is
in the RUN or ACCESSORY positions. The wind-
shield wiper system is protected by a 30 amp fuse (9)
located in the Power Distribution Center (PDC) partof the Integrated Power Module (IPM) in the engine
compartment. The wiper/washer switch is integral to
the multi-function switch. It is a resistive MUX
switch that sends inputs to the BCM to operate the
wiper/washer system.REAR WIPER/WASHER SYSTEM
The rear windshield wiper and washers can be
operated when the ignition switch is in the RUN or
ACCESSORY positions.
RSWIPERS/WASHERS8R-1
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DIAGNOSIS AND TESTING - FAILED PARK
SWITCH
If the wiper park switch has failed, the windshield
wipers will operate as follows:
²SWITCH OFF- Wipers stop in current location
regardless of the park signal.
²INTERMITTENT MODE- Wipers operate con-
tinuously or at low speed for one or more extra
wipes.
²LOW SPEED- Wipers operate at low speed.²HIGH SPEED- Wipers operate at high speed.
²WIPE AFTER WASH- Wipers operate at low
speed in any mode setting. Wipers operate only while
the wash button is depressed with switch in the OFF
mode and wipers stop in mid-cycle when button is
released.
The windshield wiper park switch and circuit is
monitored by the BCM. The park switch and circuit
can be tested using the WIPER SYSTEM DIAGNO-
SIS table.
WIPER SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
WIPER BLADES DO NOT
PARK PROPERLY1. WIPER ARMS IMPROPERLY
PARKED.1. REMOVE WIPER ARMS AND REPARK.
REFER TO WIPER ARM REMOVAL AND
INSTALLATION.
2. WIPER ARMS ARE LOOSE ON
PIVOT SHAFT.2. REMOVE WIPER ARM AND REPARK.
REFER TO WIPER ARM REMOVAL AND
INSTALLATION.
3. MOTOR CRANK LOOSE AT
OUTPUT SHAFT.3. REMOVE WIPER ARM, RUN WIPER
MOTOR TO PARK POSITION AND
REMOVE THE MODULE. WITHOUT
ROTATING THE MOTOR OUTPUT SHAFT,
REMOVE THE CRANK AND CLEAN ANY
FOREIGN MATTER FROM THE MOTOR
SHAFT. INSTALL THE MOTOR CRANK IN
ITS ORIGINAL POSITION.
4. STRIPPED WIPER ARM HEAD. 4. REPLACE WIPER ARM.
MOTOR STOPS IN ANY
POSITION WHEN THE
SWITCH IS TURNED OFFOPEN PARK CIRCUIT. CHECK PARK SWITCH BY
DISCONNECTING THE WIRE
CONNECTOR AND APPLY BATTERY
VOLTAGE TO PIN 4. PLACE A JUMPER
WIRE FROM PIN 2 TO PIN 3 AND THEN
TO AN EXTERNAL GROUND. REPLACE
MOTOR IF MOTOR DOES NOT PARK.
MOTOR WILL NOT STOP
WHEN THE SWITCH IS
TURNED OFF1. FAULTY SWITCH. 1. CHECK SWITCH IN LOW, HIGH AND
INTERMITTENT POSITION.
2. LACK OF DYNAMIC BRAKE ON
WET GLASS.2. ENSURE PARK SWITCH HAS CLEAN
GROUND.
WIPER BLADES SLAP
AGAINST COWL SCREEN
OR WINDOW MOLDINGS.WIPER ARMS ARE PARKED
INCORRECTLY.PARK WIPER ARMS. REFER TO WIPER
ARM ADJUSTMENT.
BLADES CHATTER 1. FOREIGN SUBSTANCE SUCH
AS POLISH ON GLASS OR
BLADES.1. CLEAN GLASS AND BLADE ELEMENT
WITH NON-ABRASIVE CLEANER.
2. ARMS TWISTED, BLADE AT
WRONG ANGLE ON GLASS.2. REPLACE ARM.
RSWIPERS/WASHERS8R-3
WIPERS/WASHERS (Continued)
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(4) Repeat Step 1, and align as necessary until
wiper stops chattering and wipes the windshield
clear.
REMOVAL
CAUTION: The driver side wiper arm must be
parked above the passenger side. Failure to do so
will result in damage to the arms, blades or system.
(1) Lift the arm cap upward.
(2) Remove the nut holding wiper arm to the wiper
pivot.
(3) Using a suitable two jaw puller, separate the
wiper arm from the wiper pivot (Fig. 1).
INSTALLATION
(1) Verify that the wiper motor and linkage are in
the park position.
(2) Place the wiper arm in position over the wiper
pivot (Fig. 2).
(3) Install the nut to hold the wiper arm to the
wiper pivot. Torque nut to 35 N´m (26 ft. lbs.).
CAUTION: It is important to torque the wiper arm
nut properly to insure that the wiper arm head does
not strip and damage the arm, blade, and pivot of
both wiper arms.
(4) Push the arm cap cover down.
FRONT WIPER MOTOR
REMOVAL
(1) Remove the front wiper motor from vehicle
(Refer to 8 - ELECTRICAL/WIPERS/WASHERS/
WIPER MODULE - REMOVAL).
(2) Remove four backwall bolts and four brace
nuts.
(3) Remove wiper linkage from wiper module.
(4) Disconnect wire connectors from back of wiper
motor.
(5) Remove wiper linkage from motor crank. DO
NOT remove crank from motor.
(6) Remove bolts holding wiper motor and remove
motor.
INSTALLATION
(1) Place wiper module on a suitable work surface.
(2) Install wiper linkage into wiper unit.
(3) Connect wire connectors to wiper motor.
(4) Place the wiper module into engine compart-
ment and connect wiper module wire connector to
engine wire harness (Fig. 10).
(5) Install the four backwall bolts and four brace
nuts to wiper module.
(6) Operate wiper motor and verify that the wiper
motor parks when wiper switch is turned OFF.
Fig. 1 WIPER ARM REMOVAL
1 - WASHER NOZZLE
2 - HOOD
3 - COWL COVER
4 - WINDSHIELD
5 - TWO JAW PULLER
6 - ARM CAP
7 - WINDSHIELD WIPER ARM
Fig. 2 WIPER ARM ADJUSTMENT
1 - WIPER BLADES
2 - WINDSHIELD
3 - WASHER NOZZLES
4 - WIPER ARMS
8R - 10 WIPERS/WASHERSRS
FRONT WIPER ARMS (Continued)
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WASHER RESERVOIR
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the engine fresh air housing inside the
engine compartment (Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER HOUSING -
REMOVAL).
(3) Disconnect the washer hose at the in-line con-
nector forward of the cowl grille so that the in-line
connector remains with the washer hose from the
fresh air plenum.
(4) Disconnect the washer hose from the hose clip
located on the front fender side shield.
(5) Remove the filler tube screw.
(6) Hoist and support vehicle on hoist or jack
stands.
(7) Remove the right front wheel and tire assembly
(Refer to 22 - TIRES/WHEELS - REMOVAL).
(8) Disconnect the left right front wheelhouse
splash shield and move aside (Refer to 23 - BODY/
EXTERIOR/WHEELHOUSE SPLASH SHIELD -
REMOVAL).
(9) Drain washer fluid from the reservoir and into
a suitable clean container. This can be done by dis-
connecting the windshield washer hose from the
front (outboard) washer pump and allowing the
washer fluid to drain into a container through a tem-
porary jumper hose connected to the front washer
pump.
(10) Disconnect the electrical body harness connec-
tors to the washer pump motors and the fluid level
sensor. Slide the red lock on the connector to the
release position, then, depress the black tab and pull
the connector off the pump or sensor.
(11) Remove the two reservoir mounting screws.
(12) Disconnect the reservoir from the body mount
by raising the reservoir upward slightly and then
down so that the reservoir filler neck and front
washer hose pull through the opening in the front
fender side shield.
INSTALLATION
(1) Push filler neck and front washer hose through
the opening in the front fender side shield. Connect
the reservoir to the body mount by lowering the res-
ervoir down.
(2) Install the two reservoir mounting screws.
Torque screws to 8.5 - 11.3 N´m (75 - 100 in. lbs.).
(3) Connect the electrical body harness connectors
to the washer pump motors and the fluid level sen-
sor. Slide the red lock on the connector to the closed
or locked position.
(4) Assure that washer is properly routed to pre-
vent pinching and possible inoperative washers.(5)
Connect the left right front wheelhouse splash
shield and move aside (Refer to 23 - BODY/EXTERIOR/
WHEELHOUSE SPLASH SHIELD - INSTALLATION).
(6) Install the right front wheel and tire assembly
(Refer to 22 - TIRES/WHEELS - INSTALLATION).
(7) lower vehicle from hoist or jack stands.
(8) Install the filler tube screw. Torque screw to 8.5
- 11.3 N´m (75 - 100 in. lbs.).
(9) Connect the washer hose to the hose clip
located on the front fender side shield.
(10) Connect the washer hose at the in-line con-
nector forward of the cowl grille.
(11) Install the engine fresh air housing inside the
engine compartment (Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER HOUSING -
INSTALLATION).
(12) Connect the battery negative cable.
(13) Verify system operation.
WIPER BLADES
REMOVAL
(1) Lift the wiper arm away from the glass.
(2) Disengage the release tab holding the wiper
blade to the wiper arm and remove the wiper blade
from the wiper arm (Fig. 8) and (Fig. 9).
Fig. 8 WINDSHIELD WIPER BLADE
1 - RELEASE TAB
Fig. 9 REAR WIPER
1 - WIPER ARM
2 - BLADE LATCH
8R - 18 WIPERS/WASHERSRS
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CLEANING
Wiper blades exposed to the weather for a long
period of time tend to lose their wiping effectiveness.
Periodic cleaning of the wiper blade is recommended
to remove the accumulation of salt and road grime.
The wiper blades, arms and windshield should be
cleaned with a sponge or cloth and a mild detergent
or nonabrasive cleaner. If the wiper blades continue
to streak or smear, they should be replaced. The
wiper blade should run smoothly across the wind-
shield in both directions. The wiper blade should
slightly roll over center when the blade reverses
direction. A wiper blade insert that has lost flexibility
or a wiper arm that has lost spring tension, will
cause the blade to skip or chatter across the wind-
shield. If the wiper blades are new and the wiper
arm spring tension is OK and a chattering sound is
emitted from the wiper(s), the wiper blade is not roll-
ing over center. If this condition exists, (refer to 8 -
ELECTRICAL/WIPERS/WASHERS/WIPER ARMS -
ADJUSTMENTS).
INSTALLATION
(1) Position the blade onto the arm.
(2) Engage the blade to the retainer by pulling up
on the blade until the tabs snap into position (Fig. 8).
WIPER LINKAGE
REMOVAL
(1) Remove the front windshield wiper unit from
vehicle (Refer to 8 - ELECTRICAL/WIPERS/WASH-
ERS/WIPER MODULE - REMOVAL).
(2) Place the wiper unit on a suitable work sur-
face.
(3) Remove nuts holding the cowl cover brackets to
the wiper unit.
(4) Remove cowl cover brackets from the wiper
unit.
(5) Remove nuts holding linkage to the wiper unit.
(6) Remove the wiper linkage from the wiper unit.
(7) Disconnect the wire connectors from back of
the wiper motor.
INSTALLATION
(1) Connect the wire harness connector.
(2) Install the linkage on the wiper unit.
(3) Install the nut holding the linkage to the wiper
unit.
(4) Install the cowl cover brackets to the wiper
nut.
(5) Install the front wiper unit (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
INSTALLATION).(6) Install the cowl cover.
(7) Install the wiper arms and blades.
WIPER MODULE
REMOVAL
(1) Release the hood latch and open hood.
(2) Disconnect and isolate the battery negative
cable.
(3) Remove the wiper arms.
(4) Remove the cowl cover (Refer to 23 - BODY/
EXTERIOR/COWL GRILLE - REMOVAL).
(5) Disconnect the positive lock on the wiper mod-
ule wire connector (Fig. 10).
(6) Disconnect the wiper module wire connector
from the engine compartment wire harness.
(7) Disconnect the windshield washer hose from
coupling outside the module.
(8) Disconnect the drain tubes from nipples on bot-
tom of the wiper module.
(9) Remove nuts holding wiper module to lower
windshield fence.
(10) Remove bolts holding the wiper module to the
dash panel (Fig. 11).
(11) Lift wiper module from weld-studs on lower
windshield fence.
CAUTION: Do not allow wiper module to rest on
brake master cylinder reservoir, damage to brake
system can result.
(12) Remove wiper module.
Fig. 10 WIPER MODULE WIRE CONNECTOR
1 - WIPER SYSTEM WIRE CONNECTOR
2 - LOCK TAB
3 - POSITIVE LOCK
4 - WIPER MODULE
RSWIPERS/WASHERS8R-19
WIPER BLADES (Continued)
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INSTALLATION
(1) Position the wiper module into the cowl.
(2) Install the bolts that secure the wiper module
to the dash (Fig. 11).
(3) Install the nuts that retain the wiper module.
(4) Connect the drain tubes to the nipples on the
wiper module.
(5) Connect the windshield washer tube.
(6) Connect the wire harness connector to the
wiper module (Fig. 11).
(7) Connect the positive lock on the wiper module
wire connector (Fig. 10).
CAUTION: Do not allow wiper module to rest on
brake master cylinder reservoir, damage to brake
system can result.
(8) Install the cowl cover (Refer to 23 - BODY/EX-
TERIOR/COWL GRILLE - INSTALLATION).
(9) Install the wiper arms and blades.
(10) Connect the battery negative cable.
(11) Close the hood.
Fig. 11 WIPER MODULE
1 - BOLT
2 - NUTS
3 - BOLT
4 - WIPER MODULE
5 - WINDSHIELD
8R - 20 WIPERS/WASHERSRS
WIPER MODULE (Continued)
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