warning light CHRYSLER CARAVAN 2003 Owner's Manual

(22) Remove three right side instrument panel
A-pillar retaining bolts and loosen the instrument
panel roll down bolt.
(23) Using a trim stick or equivalent, gently pry
off right side upper A-pillar trim.
(24) Open glove box, pinch in sides and roll down
towards floor. With a firm pull, snap glove box door
off hinges and remove.
(25) Using a trim stick or equivalent, gently pry
up on rear of instrument panel top cover and then
pull rearward and out.
(26) Using a trim stick or equivalent, gently pry
off the filler bezel just above the cup holder to expose
the lower screws to center bezel.
(27) Remove two screws and then using a trim
stick or equivalent, gently pry off instrument panel
center bezel.
(28) Remove center bezel wiring connectors to
HVAC control and switch assembly (hazard, rear
wiper/washer, heated seats) and remove bezel.
(29) Slide cup holder assembly from instrument
panel.
(30) Remove nineteen screws to right lower instru-
ment panel trim (glove box surround), unplug glove
box lamp wire connector, and remove panel.
(31) Remove four screws and wiring connectors to
radio and remove radio.
(32) Remove one far left instrument panel speaker
retaining screw.
(33) Remove four screws along top front edge of
instrument panel cover/pad.
(34) Remove seven lower instrument panel cover/
pad retaining screws starting from right of vehicle
and only removing these seven, not all of them.
(35) Remove six upper fence line instrument panel
retaining bolts.
(36) Roll back instrument panel just enough to
increase access to the passenger airbag retaining
bolts at the reinforcement. Lift the instrument panel
up slightly so as not to damage the air distribution to
HVAC unit seal.
(37) Disconnect the passenger airbag electrical
connector. Using a trim stick or equivalent, gently
pry electrical connector off of instrument panel rein-
forcement.
(38) Remove the two passenger airbag to instru-
ment panel cover/pad retaining screws.
(39) Remove the three passenger airbag to instru-
ment panel reinforcement retaining bolts.
(40) Pull rearward slightly on the instrument
panel cover/pad to maneuver passenger airbag out
from reinforcement and instrument panel.INSTALLATION
DEPLOYED AIRBAG
Transfer all reusable components to the new
instrument panel.
(1) Install new Passenger Airbag into instrument
panel.
(2) Install airbag attaching bolts to the instrument
panel.
(a) Torque the two bolts at instrument panel
retainer bosses to 2.7   .5 N´m (24   5 in. lbs.).
(b) Torque the three bolts that attach the pas-
senger airbag to cross-car beam to 10   2 N´m (90
  15 in. lbs.).
(3) Connect yellow wire connector to passenger air-
bag and affix connector to instrument panel rein-
forcement with push pins.
(4) Install Instrument panel (Refer to 23 - BODY/
INSTRUMENT PANEL/INSTRUMENT PANEL
ASSEMBLY - INSTALLATION).
WARNING: DO NOT CONNECT THE BATTERY NEG-
ATIVE CABLE. REFER TO ELECTRICAL,
RESTRAINTS, DIAGNOSIS AND TESTING - AIRBAG
SYSTEM FIRST.
UNDEPLOYED AIRBAG
(1) Pull rearward slightly on the instrument panel
cover/pad to maneuver passenger airbag up onto
reinforcement and instrument panel.
(2) Install the three passenger airbag to instru-
ment panel reinforcement retaining bolts but leave
loose. This will help align the passenger airbag for
the cover/pad fit.
(3) Install the two passenger airbag to instrument
panel cover/pad retaining screws. Torque screws to
2.7  .5 N´m (24   5 in. lbs.).
NOTE: Insure that the instrument panel cover/pad
locator pins are indexed properly at center stack
area prior to reassembly.
(4) Tighten the three passenger airbag to instru-
ment panel reinforcement retaining bolts. Torque
bolts to 10   2 N´m (90   15 in. lbs.).
(5) Connect the passenger airbag electrical connec-
tor. Install the connector onto the instrument panel
reinforcement with the push-pin fasteners.
(6) Roll the instrument panel forward lifting
slightly so as to seat the instrument panel air distri-
bution duct on top of the HVAC unit properly to
avoid any leaks or damage to the seal.
(7) Install six upper fence line instrument panel
retaining bolts.
(8) Install three right side instrument panel A-pil-
lar retaining bolts and tighten the right instrument
RSRESTRAINTS8O-9
PASSENGER AIRBAG (Continued)
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HEADLAMP WASHERS -
EXPORT
DESCRIPTION
The headlamp washers on this vehicle (Fig. 3)
work in conjunction with the windshield washers.
The headlamp washers are enabled with the head-
lamps ªONº and the windshield washers activated.
With the windshield washers activated the headlamp
washers will spray twice for a predetermined amount
of time.
OPERATION
The headlamp washer system utilizes a separate
high pressure pump that is attached to the wind-
shield washer reservoir. The headlamp washer pump
feeds nozzles that are mounted in the front fascia of
the vehicle. The nozzle bodies have a telescopic
action that will extend the nozzles in front of the
headlamp assembly. These nozzles spray the head-
lamps when the system is activated.
To activate the headlamp washers, turn ON the
headlamps and them press the windshield washer
control knob. This will operate the windshield wash-
ers and direct two timed high pressure sprays onto
the headlamp lens.
DIAGNOSIS AND TESTING - HEADLAMP
WASHERS - EXPORT
The headlamp washer pump pick-up is located
above the low washer fluid level sensor. First of all
check the fluid level in the reservoir.
(1) Check fuse #30 for continuity. If no continuity,
go to Step 3.
(2) If the headlamp washers do not pop up when a
headlamp wash is requested, disconnect the head-
lamp washer hose. To disconnect the headlamp
washer hose, push down on the latch at any connec-
tor with slight force and pull apart. When reattach-
ing, push till you hear a snap. With a regulated 20
psi of air pressure, apply it to the washer hose. The
headlamp washers should pop up out of the front fas-
cia. If not, check for leaks/connections in the hose.
WARNING: IF MORE THAN 20 PSI IS APPLIED TO
THE WASHER HOSE, WASHER FLUID MAY SPRAY
OUT OF THE HEADLAMP WASHER. WEAR SAFETY
GLASSES AND DO NOT HAVE AIMING DIRECTLY
TOWARD FACE.
(3) If the hose and washer spray assembly are OK,
check the washer pump for ground and 12v power
during a washer request. If defective, repair circuit
as necessary.
Fig. 3 HEADLAMP WASHER LOCATION
8R - 10 WIPERS/WASHERSRS
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REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Hoist vehicle or support on jack stands.
(3) Disconnect the hose from the nozzle inlet. To
disconnect the headlamp washer hose, push down on
the latch with slight force and pull apart.
(4) Apply a regulated 20 psi of compressed air to
the inlet, so as to fully extend the telescopic unit.
WARNING: IF MORE THAN 20 PSI IS APPLIED TO
THE WASHER INLET, WASHER FLUID MAY SPRAY
OUT OF THE HEADLAMP WASHER. WEAR SAFETY
GLASSES AND DO NOT HAVE AIMING DIRECTLY
TOWARD FACE.
(5) Unsnap cover from telescopic assembly.
(6) Disconnect air supply from washer inlet to fully
retract the telescopic unit.
(7) Remove two screws holding the nozzle assem-
bly to the front fascia.
(8) Remove the nozzle assembly from behind fas-
cia.
INSTALLATION
(1) Place the nozzle assembly in behind the fascia.
(2) Install the two screws holding the nozzle
assembly to the front fascia.
(3) Snap cover onto telescopic assembly.
WARNING: IF MORE THAN 20 PSI IS APPLIED TO
THE WASHER INLET, WASHER FLUID MAY SPRAY
OUT OF THE HEADLAMP WASHER. WEAR SAFETY
GLASSES AND DO NOT HAVE AIMING DIRECTLY
TOWARD FACE.
On the new washer unit, there is a white tab with
pull ring holding the telescopic unit up approxi-
mately an inch. This is to ease the installation pro-
cess. Once cover is snapped on, you may either pull
up on the unit to remove the tab, or apply regulated
compressed air.
(4) Apply a regulated 20 psi of compressed air the
inlet, so as to fully extend the telescopic unit.
(5) With unit extended, pull white tab out from the
bottom of the telescopic unit and discard.
(6) Remove the air supply from the washer unit.
(7) Connect the washer hose to the telescopic unit.
Press firmly until snap is heard.
(8) Remove vehicle from hoist or jack stands.
(9) Connect the battery negative cable.
(10) Verify vehicle and system operation.
HEADLAMP WASHER HOSE -
EXPORT
REMOVAL
The headlamp washer hose is a special high pres-
sure hose with specific fittings, and must be replaced
as a unit.
(1) Disconnect and isolate the battery negative
cable.
(2) Hoist vehicle or support on jack stands.
(3) Remove parts as necessary to replace high
pressure headlamp washer hose. When disconnecting
hose, press down firmly on latch at headlamp washer
pump motor and telescopic washer assembly and pull
apart.
INSTALLATION
The headlamp washer hose is a special high pres-
sure hose with specific fittings, and must be replaced
as a unit.
(1) Install the new high pressure headlamp
washer hose assembly. Push fitting on until a snap is
heard.
(2) Install the parts that were removed to replace
high pressure headlamp washer hose.
(3) Remove vehicle from hoist or jack stands.
(4) Connect the battery negative cable.
(5) Verify vehicle and system operation.
HEADLAMP WASHER PUMP
MOTOR - EXPORT
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).
8R - 12 WIPERS/WASHERSRS
HEADLAMP WASHERS - EXPORT (Continued)
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DIAGNOSIS AND TESTING
DIAGNOSIS & TESTING - POWER OUTLET
For complete circuit diagrams, refer toCigar
Lighter/Power Outletin Wiring Diagrams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO RESTRAINTS BEFORE ATTEMPT-
ING ANY STEERING WHEEL, STEERING COLUMN,
SEAT OR INSTRUMENT PANEL COMPONENT DIAG-
NOSIS OR SERVICE. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
(1) Check the fused B(+) fuse in the Integrated
Power Module (IPM). If OK, go to Step 2. If not OK,
repair the shorted circuit or component as required
and replace the faulty fuse.
(2) Check for battery voltage at the fused B(+) fuse
in the IPM. If OK, go to Step 3. If not OK, repair the
open fused B(+) circuit to the IPM fuse as required.
(3)
Open the power outlet door. Check for continuity
between the inside circumference of the power outlet
receptacle and a good ground. There should be continu-
ity. If OK, go to Step 4. If not OK, go to Step 5.
(4) Check for battery voltage at the insulated con-
tact located at the back of the power outlet recepta-
cle. If not OK, go to Step 5.
(5) Disconnect and isolate the battery negative
cable. Remove the appropriate bezel. Check for conti-
nuity between the ground circuit cavity of the power
outlet wire harness connector and a good ground.
There should be continuity. If OK, go to Step 6. If not
OK, repair the open ground circuit to ground as
required.
(6) Connect the battery negative cable. Check for
battery voltage at the fused B(+) circuit cavity of the
power outlet wire harness connector. If OK, replace
the faulty power outlet receptacle. If not OK, repair
the open fused B(+) circuit to the IPM fuse as
required.
REMOVAL
(1)Disconnect and isolate the battery negative cable.
(2) Look inside and note position of the retaining
bosses (Fig. 5).
(3) Using external snap ring pliers with 90 degree
tips. Insert pliers with tips against bosses and
squeeze forcing bosses out of base.
(4) Pull out the base through mounting ring by
gently rocking pliers. A tool can be made to do the
same. Refer to (Fig. 6).
(5) Disconnect the base wires.
(6) Set base aside. Remove light ring and discon-
nect wire.
INSTALLATION
(1) Position the mounting ring on the instrument
panel and feed the wires through the ring. Index the
cap and the mounting ring with the index tab at the
9 o'clock position to the key in the instrument panel.
Install the ring.
(2) Connect the wires to the base. Orientate the
base alignment rib at the 11 o'clock position to mate
the groove in the mounting ring to the base.
(3)
Push the base into the bezel until it locks in place.
(4) Check operation of outlet or element and
install the 12 volt outlet cap.
Fig. 5 Outlet Base Removal
1 - RETAINING BOSSES-ENGAGE PLIERS HERE
2 - PARTIALLY REMOVED
3 - EXTERNAL SNAP-RING PLIERS
4 - PULL BASE OUT-THROUGH MOUNTING RING
Fig. 6 Tool For Outlet Removal
1 - 2.5MM (3/32 INS.)
2 - WELD
3 - 100MM (4 INS.)
4 - 22.25 TO 22.45MM (7/8 TO 57/64 INS.)
8W - 97 - 6 8W-97 POWER DISTRIBUTION SYSTEMRS
POWER OUTLET (Continued)
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(3) Remove torque converter or clutch housing
cover and inspect rear of block for evidence of oil.
Use a black light to check for the oil leak. If a leak is
present in this area, remove transmission for further
inspection.
(a) Circular spray pattern generally indicates
seal leakage or crankshaft damage.
(b) Where leakage tends to run straight down,
possible causes are a porous block, oil gallery cup
plug, bedplate to cylinder block mating surfaces
and seal bore. See proper repair procedures for
these items.
(4) If no leaks are detected, pressurize the crank-
case as previously described.
CAUTION: Do not exceed 20.6 kPa (3 psi).
(5) If the leak is not detected, very slowly turn the
crankshaft and watch for leakage. If a leak is
detected between the crankshaft and seal while
slowly turning the crankshaft, it is possible the
crankshaft seal surface is damaged. The seal area on
the crankshaft could have minor nicks or scratches
that can be polished out with emery cloth.
CAUTION: Use extreme caution when crankshaft
polishing is necessary to remove minor nicks and
scratches. The crankshaft seal flange is especially
machined to complement the function of the rear oil
seal.
(6) For bubbles that remain steady with shaft
rotation, no further inspection can be done until dis-
assembled.
(7) After the oil leak root cause and appropriate
corrective action have been identified, replace compo-
nent(s) as necessary.
DIAGNOSIS AND TESTING - CYLINDER
COMPRESSION PRESSURE TEST
The results of a cylinder compression pressure test
can be utilized to diagnose several engine malfunc-
tions.
Ensure the battery is completely charged and the
engine starter motor is in good operating condition.
Otherwise the indicated compression pressures may
not be valid for diagnosis purposes.
(1) Check engine oil level and add oil if necessary.
(2) Drive the vehicle until engine reaches normal
operating temperature. Select a route free from traf-
fic and other forms of congestion, observe all traffic
laws, and accelerate through the gears several times
briskly.
(3) Remove all spark plugs from engine. As spark
plugs are being removed, check electrodes for abnor-
mal firing indicators fouled, hot, oily, etc. Record cyl-
inder number of spark plug for future reference.(4) Remove the Auto Shutdown (ASD) relay from
the PDC.
(5) Be sure throttle blade is fully open during the
compression check.
(6) Insert compression gauge adaptor Special Tool
8116 or the equivalent, into the #1 spark plug hole in
cylinder head. Connect the 0±500 psi (Blue) pressure
transducer (Special Tool CH7059) with cable adap-
tors to the DRBIIIt. For Special Tool identification,
(Refer to 9 - ENGINE - SPECIAL TOOLS).
(7) Crank engine until maximum pressure is
reached on gauge. Record this pressure as #1 cylin-
der pressure.
(8) Repeat the previous step for all remaining cyl-
inders.
(9) Compression should not be less than 689 kPa
(100 psi) and not vary more than 25 percent from cyl-
inder to cylinder.
(10) If one or more cylinders have abnormally low
compression pressures, repeat the compression test.
(11) If the same cylinder or cylinders repeat an
abnormally low reading on the second compression
test, it could indicate the existence of a problem in
the cylinder in question.The recommended com-
pression pressures are to be used only as a
guide to diagnosing engine problems. An engine
should not be disassembled to determine the
cause of low compression unless some malfunc-
tion is present.
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE TEST
The combustion pressure leakage test provides an
accurate means for determining engine condition.
Combustion pressure leakage testing will detect:
²Exhaust and intake valve leaks (improper seat-
ing).
²Leaks between adjacent cylinders or into water
jacket.
²Any causes for combustion/compression pressure
loss.
WARNING: DO NOT REMOVE THE PRESSURE CAP
WITH THE SYSTEM HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM COOLANT CAN
OCCUR.
Check the coolant level and fill as required. DO
NOT install the pressure cap.
Start and operate the engine until it attains nor-
mal operating temperature, then turn the engine
OFF.
Clean spark plug recesses with compressed air.
Remove the spark plugs.
Remove the oil filler cap.
Remove the air cleaner.
RSENGINE 2.4L9-9
ENGINE 2.4L (Continued)
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(3) Remove torque converter or clutch housing
cover and inspect rear of block for evidence of oil.
Use a black light to check for the oil leak. If a leak is
present in this area, remove transmission for further
inspection.
(a) Circular spray pattern generally indicates
seal leakage or crankshaft damage.
(b) Where leakage tends to run straight down,
possible causes are a porous block, oil gallery cup
plug, bedplate to cylinder block mating surfaces
and seal bore. See proper repair procedures for
these items.
(4) If no leaks are detected, pressurize the crank-
case as previously described.
CAUTION: Do not exceed 20.6 kPa (3 psi).
(5) If the leak is not detected, very slowly turn the
crankshaft and watch for leakage. If a leak is
detected between the crankshaft and seal while
slowly turning the crankshaft, it is possible the
crankshaft seal surface is damaged. The seal area on
the crankshaft could have minor nicks or scratches
that can be polished out with emery cloth.
CAUTION: Use extreme caution when crankshaft
polishing is necessary to remove minor nicks and
scratches. The crankshaft seal flange is especially
machined to complement the function of the rear oil
seal.
(6) For bubbles that remain steady with shaft
rotation, no further inspection can be done until dis-
assembled.
(7) After the oil leak root cause and appropriate
corrective action have been identified, replace compo-
nent(s) as necessary.
DIAGNOSIS AND TESTING - CYLINDER
COMPRESSION PRESSURE TEST
The results of a cylinder compression pressure test
can be utilized to diagnose several engine malfunc-
tions.
Ensure the battery is completely charged and the
engine starter motor is in good operating condition.
Otherwise the indicated compression pressures may
not be valid for diagnosis purposes.
(1) Check engine oil level and add oil if necessary.
(2) Drive the vehicle until engine reaches normal
operating temperature. Select a route free from traf-
fic and other forms of congestion, observe all traffic
laws, and accelerate through the gears several times
briskly.
(3) Remove all spark plugs from engine. As spark
plugs are being removed, check electrodes for abnor-
mal firing indicators fouled, hot, oily, etc. Record cyl-
inder number of spark plug for future reference.(4) Remove the Auto Shutdown (ASD) relay from
the PDC.
(5) Be sure throttle blade is fully open during the
compression check.
(6) Insert compression gauge adaptor Special Tool
8116 or the equivalent, into the #1 spark plug hole in
cylinder head. Connect the 0±500 psi (Blue) pressure
transducer (Special Tool CH7059) with cable adap-
tors to the DRBIIIt. For Special Tool identification,
(Refer to 9 - ENGINE - SPECIAL TOOLS).
(7) Crank engine until maximum pressure is
reached on gauge. Record this pressure as #1 cylin-
der pressure.
(8) Repeat the previous step for all remaining cyl-
inders.
(9) Compression should not be less than 689 kPa
(100 psi) and not vary more than 25 percent from cyl-
inder to cylinder.
(10) If one or more cylinders have abnormally low
compression pressures, repeat the compression test.
(11) If the same cylinder or cylinders repeat an
abnormally low reading on the second compression
test, it could indicate the existence of a problem in
the cylinder in question.The recommended com-
pression pressures are to be used only as a
guide to diagnosing engine problems. An engine
should not be disassembled to determine the
cause of low compression unless some malfunc-
tion is present.
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE TEST
The combustion pressure leakage test provides an
accurate means for determining engine condition.
Combustion pressure leakage testing will detect:
²Exhaust and intake valve leaks (improper seat-
ing).
²Leaks between adjacent cylinders or into water
jacket.
²Any causes for combustion/compression pressure
loss.
WARNING: DO NOT REMOVE THE PRESSURE CAP
WITH THE SYSTEM HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM COOLANT CAN
OCCUR.
Check the coolant level and fill as required. DO
NOT install the pressure cap.
Start and operate the engine until it attains nor-
mal operating temperature, then turn the engine
OFF.
Clean spark plug recesses with compressed air.
Remove the spark plugs.
Remove the oil filler cap.
Remove the air cleaner.
RSENGINE 3.3/3.8L9-83
ENGINE 3.3/3.8L (Continued)
ProCarManuals.com

nect rubber fuel fill or vent hoses from tank at this
time.
(7) Place a transmission jack under center of fuel
tank. Apply a slight amount of pressure to fuel tank
with transmission jack.
(8) Remove fuel tank mounting strap nuts from
mounting strap studs.
(9)Lower the tank just enough so that the
filler tube fitting is the highest point of the fuel
tank.
(10) Remove filler tube from fuel tank. Tank will
be drained through this fitting.
WARNING: WRAP SHOP TOWELS AROUND HOSES
TO CATCH ANY GASOLINE SPILLAGE.(11) Drain fuel tank into holding tank or a prop-
erly labeledGasolinesafety container.
CAUTION: GASOLINE OR GASOLINE VAPORS ARE
HIGHLY FLAMMABLE. A FIRE COULD OCCUR IF AN
IGNITION SOURCE IS PRESENT. NEVER DRAIN OR
STORE GASOLINE OR DIESEL FUEL IN AN OPEN
CONTAINER, DUE TO THE POSSIBILITY OF FIRE
OR EXPLOSION.
(12) If fuel pump module removal is necessary,
refer to Fuel Pump Module Removal/Installation in
this section.
SPECIFICATIONS
FUEL SYSTEM PRESSURE
400 kpa  34 kpa (58 psi   5 psi)
TORQUE
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Fuel Filler Neck Clamp 3.3 30
Fuel Rail 2.4L 22 200
Fuel Rail 3.3/3.8L 11.8 105
Fuel Tank Strap 54 40
Fuel Tank T Strap 28.2 250
Fuel Filter Bolt 4.5 40
SPECIAL TOOLS
FUEL
Pressure Gauge Assembly C±4799±B
Fuel Pressure Test Adapter 6539
RSFUEL DELIVERY14-3
FUEL DELIVERY (Continued)
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OPERATION
The power steering pump is a constant displace-
ment vane type pump. The 2.4L pump has an inte-
gral fluid reservoir and there is a secondary remote
non-flow reservoir which acts only as a fluid fill and
check point. The 3.3L/3.8L pump houses very little
fluid and is therefore supplied by a remote flow
through reservoir.
WARNING
WARNING: POWER STEERING FLUID, ENGINE
PARTS AND EXHAUST SYSTEM MAY BE
EXTREMELY HOT IF ENGINE HAS BEEN RUNNING.DO NOT START ENGINE WITH ANY LOOSE OR DIS-
CONNECTED HOSES. DO NOT ALLOW HOSES TO
TOUCH HOT EXHAUST MANIFOLD OR CATALYST.
WARNING: FLUID LEVEL SHOULD BE CHECKED
WITH THE ENGINE OFF TO PREVENT PERSONAL
INJURY FROM MOVING PARTS.
CAUTION
CAUTION: When the system is open, cap all open
ends of the hoses, power steering pump fittings or
power steering gear ports to prevent entry of for-
eign material into the components.
STANDARD PROCEDURE - POWER STEERING
PUMP INITIAL OPERATION
WARNING: FLUID LEVEL SHOULD BE CHECKED
AND ADJUSTED WITH ENGINE OFF TO PREVENT
INJURY FROM MOVING ENGINE COMPONENTS.
CAUTION: Use only MoparTAutomatic Transmis-
sion Fluid (MS-9602) in power steering system. Use
of other MoparTpower steering fluids (MS5931 and
MS9933) should be avoided to ensure peak perfor-
mance of the power steering system under all oper-
ating conditions. Do not overfill.
Read the fluid level through the side of the power
steering fluid reservoir. The fluid level should indi-
cateªFILL RANGEºwhen the fluid is at a temper-
ature of approximately 21ÉC to 27ÉC (70ÉF to 80ÉF).
(1) Wipe the filler cap and area clean, then remove
the cap.
(2) Fill the fluid reservoir to the proper level and
let the fluid settle for at least two (2) minutes.
(3) Start the engine and let run for a few seconds,
then turn the engine off.
(4) Add fluid if necessary. Repeat the above steps
until the fluid level remains constant after running
the engine.
(5) Raise the front wheels off the ground.
(6) Start the engine.
(7) Slowly turn the steering wheel right and left,
lightly contacting the wheel stops.
(8) Add fluid if necessary.
(9) Lower the vehicle, then turn the steering wheel
slowly from lock-to-lock.
(10) Stop the engine. Check the fluid level and
refill as required.
(11) If the fluid is extremely foamy, allow the vehi-
cle to stabilize a few minutes, then repeat the above
procedure.
Fig. 1 POWER STEERING PUMP (2.4L)
1 - PULLEY
2 - BRACKET
3 - PRESSURE FITTING
4 - RETURN FITTING
5 - SUPPLY FITTING
Fig. 2 POWER STEERING PUMP (3.3L/3.8L)
1 - SUPPLY FITTING
2 - PRESSURE FITTING
3 - PULLEY
RSPUMP19-37
PUMP (Continued)
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DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - WATER LEAKS
Water leaks can be caused by poor sealing,
improper body component alignment, body seam
porosity, missing plugs, or blocked drain holes. Cen-
trifugal and gravitational force can cause water to
drip from a location away from the actual leak point,
making leak detection difficult. All body sealing
points should be water tight in normal wet-driving
conditions. Water flowing downward from the front of
the vehicle should not enter the passenger or luggage
compartment. Moving sealing surfaces will not
always seal water tight under all conditions. At
times, side glass or door seals will allow water to
enter the passenger compartment during high pres-
sure washing or hard driving rain (severe) condi-
tions. Overcompensating on door or glass
adjustments to stop a water leak that occurs under
severe conditions can cause premature seal wear and
excessive closing or latching effort. After completing
a repair, water test vehicle to verify leak has stopped
before returning vehicle to use.
VISUAL INSPECTION BEFORE WATER LEAK TESTS
Verify that floor and body plugs are in place, body
drains are clear, and body components are properly
aligned and sealed. If component alignment or seal-
ing is necessary, refer to the appropriate section of
this group for proper procedures.
WATER LEAK TESTS
WARNING: DO NOT USE ELECTRIC SHOP LIGHTS
OR TOOLS IN WATER TEST AREA. PERSONAL
INJURY CAN RESULT.
When the conditions causing a water leak have
been determined, simulate the conditions as closely
as possible.
²If a leak occurs with the vehicle parked in a
steady light rain, flood the leak area with an open-
ended garden hose.
²If a leak occurs while driving at highway speeds
in a steady rain, test the leak area with a reasonable
velocity stream or fan spray of water. Direct the
spray in a direction comparable to actual conditions.
²If a leak occurs when the vehicle is parked on an
incline, hoist the end or side of the vehicle to simu-
late this condition. This method can be used when
the leak occurs when the vehicle accelerates, stops or
turns. If the leak occurs on acceleration, hoist the
front of the vehicle. If the leak occurs when braking,
hoist the back of the vehicle. If the leak occurs on left
turns, hoist the left side of the vehicle. If the leak
occurs on right turns, hoist the right side of the vehi-cle. For hoisting recommendations (Refer to LUBRI-
CATION & MAINTENANCE/HOISTING -
STANDARD PROCEDURE).
WATER LEAK DETECTION
To detect a water leak point-of-entry, do a water
test and watch for water tracks or droplets forming
on the inside of the vehicle. If necessary, remove inte-
rior trim covers or panels to gain visual access to the
leak area. If the hose cannot be positioned without
being held, have someone help do the water test.
Some water leaks must be tested for a considerable
length of time to become apparent. When a leak
appears, find the highest point of the water track or
drop. The highest point usually will show the point of
entry. After leak point has been found, repair the
leak and water test to verify that the leak has
stopped.
Locating the entry point of water that is leaking
into a cavity between panels can be difficult. The
trapped water may splash or run from the cavity,
often at a distance from the entry point. Most water
leaks of this type become apparent after accelerating,
stopping, turning, or when on an incline.
MIRROR INSPECTION METHOD
When a leak point area is visually obstructed, use
a suitable mirror to gain visual access. A mirror can
also be used to deflect light to a limited-access area
to assist in locating a leak point.
BRIGHT LIGHT LEAK TEST METHOD
Some water leaks in the luggage compartment can
be detected without water testing. Position the vehicle
in a brightly lit area. From inside the darkened lug-
gage compartment inspect around seals and body
seams. If necessary, have a helper direct a drop light
over the suspected leak areas around the luggage com-
partment. If light is visible through a normally sealed
location, water could enter through the opening.
PRESSURIZED LEAK TEST METHOD
When a water leak into the passenger compart-
ment cannot be detected by water testing, pressurize
the passenger compartment and soap test exterior of
the vehicle. To pressurize the passenger compart-
ment, close all doors and windows, start engine, and
set heater control to high blower in HEAT position. If
engine can not be started, connect a charger to the
battery to ensure adequate voltage to the blower.
With interior pressurized, apply dish detergent solu-
tion to suspected leak area on the exterior of the
vehicle. Apply detergent solution with spray device or
soft bristle brush. If soap bubbles occur at a body
seam, joint, seal or gasket, the leak entry point could
be at that location.
23 - 2 BODYRS
BODY (Continued)
ProCarManuals.com

BASE COAT/CLEARCOAT
FINISH
DESCRIPTION
On most vehicles a two-part paint application
(basecoat/clearcoat) is used. Color paint that is
applied to primer is called basecoat. The clearcoat
protects the basecoat from ultraviolet light and pro-
vides a durable high-gloss finish.
CAUTION: Do not use abrasive chemicals or com-
pounds on painted surfaces. Damage to finish can
result.
Do not use harsh alkaline based cleaning solvents
on painted surfaces. Damage to finish or color can
result.
PAINT CODE
DESCRIPTION
Exterior vehicle body colors are identified on the
Body Code plate. (Refer to VEHICLE DATA/VEHI-
CLE INFORMATION/BODY CODE PLATE -
DESCRIPTION). The paint code is also identified on
the Vehicle Safety Certification Label which is
located on the drivers door shut face. The first digit
of the paint code listed on the vehicle indicates the
sequence of application, i.e.: P = primary coat, Q =
secondary coat. The codes listed in the Color Code
Chart are used for manufacturing purposes.
PAINTED TOUCH-UP
DESCRIPTION
When a painted metal surface has been scratched
or chipped, it should be touched up as soon as possi-
ble to avoid corrosion. For best results, use Mopart
Scratch Filler/Primer, Touch Up Paints and Clear Top
Coat. (Refer to VEHICLE DATA/VEHICLE INFOR-
MATION/BODY CODE PLATE - DESCRIPTION).
WARNING: USE AN OSHA APPROVED RESPIRATOR
AND SAFETY GLASSES WHEN SPRAYING PAINT
OR SOLVENTS IN A CONFINED AREA. PERSONAL
INJURY CAN RESULT.
TOUCH UP PROCEDURE
(1) Scrape loose paint and corrosion from inside
scratch or chip.
(2) Clean affected area with MopartTar/Road Oil
Remover, and allow to dry.
(3) Fill the inside of the scratch or chip with a coat
of filler/primer. Do not overlap primer onto good sur-
face finish. The applicator brush should be wet
enough to puddle-fill the scratch or chip without run-
ning. Do not stroke brush applicator on body surface.
Allow the filler/primer to dry hard.
(4) Cover the filler/primer with color touch up
paint. Do not overlap touch up color onto the original
color coat around the scratch or chip. Butt the new
color to the original color, if possible. Do not stroke
applicator brush on body surface. Allow touch up
paint to dry hard.
(5) On vehicles without clearcoat, the touch up
color can be lightly finesse sanded (1500 grit) and
polished with rubbing compound.
(6) On vehicles with clearcoat, apply clear top coat
to touch up paint with the same technique as
described in Step 4. Allow clear top coat to dry hard.
If desired, Step 5 can be performed on clear top coat.
WARNING: AVOID PROLONGED SKIN CONTACT
WITH PETROLEUM OR ALCOHOL ± BASED CLEAN-
ING SOLVENTS. PERSONAL INJURY CAN RESULT.
FINESSE SANDING/BUFFING &
POLISHING
DESCRIPTION
Minor acid etching, orange peel, or smudging in
clearcoat or single-stage finishes can be reduced with
light finesse sanding, hand buffing, and polishing.If
the finish has been finesse sanded in the past,
it cannot be repeated. Finesse sanding opera-
tion should be performed by a trained automo-
tive paint technician.
CAUTION: Do not remove clearcoat finish, if
equipped. Basecoat paint must retain clearcoat for
durability.
23 - 84 PAINTRS
ProCarManuals.com