drain bolt CHRYSLER CARAVAN 2003 Workshop Manual

SIDE VIEW MIRROR GLASS
REMOVAL
WARNING: ALWAYS WEAR EYE AND HAND PRO-
TECTION WHEN SERVICING THE MIRROR ASSEM-
BLY. FAILURE TO OBSERVE THESE WARNINGS
MAY RESULT IN PERSONAL INJURY FROM BRO-
KEN GLASS.
(1) Carefully pull/pry the broken glass holder from
the mirror assembly.
(2) Disconnect the heated mirror electrical connec-
tors from the terminals on the mirror glass holder, if
equipped.
INSTALLATION
CAUTION: It is important to make sure the motor is
square to the glass holder (attaching fingers) prior
to glass holder attachment, otherwise the glass
holder could be installed incorrectly causing poor
retention and possible repeat failure.
(1) Position the new mirror glass holder to the
mirror assembly.
NOTE: Position the mirror glass holder so that the
moisture drain hole on the mirror glass holder
assembly is facing downward.
(2) Align the mirror glass holder's attaching fin-
gers to the mirror motor housing.
NOTE: Ensure that the protective rubber cover of
the mirror motor housing is positioned correctly
around the bottom of the fingers area.
(3) Using one hand, firmly press the mirror glass
holder assembly into place while at the same time
supporting the housing assembly from the backside
with the other hand.
NOTE: Pressure must be applied equally over the
center portion of the mirror to engage the mirror
glass holder's attaching fingers to the correspond-
ing fingers on the housing assembly. One or more
clicks may be heard when finger engagement takes
place.
(4) Verify retention of the mirror glass holder
assembly by gently pulling outward on the mirror
glass holder.
Fig. 21 SIDE VIEW MIRROR
1 - MIRROR
2 - MIRROR TRIM COVER
3 - A-PILLAR
4 - BOLTS
23 - 58 EXTERIORRS
SIDE VIEW MIRROR (Continued)
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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. 9).
(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. 10).
(6) Remove (1) bolt securing A/C lines to block
located at A/C housing, behind rear wheel, and sepa-
rate block (Fig. 13).
(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.
Fig. 10 Front Lines Connected to Rear Lines
Fig. 11 Rear Heater Hose Connection
1 - REAR HEATER HOSE
Fig. 12 Rear heater hose quick connects
1 - INSERT
2 - QUICK CONNECT
3 - COMPRESS INSERT FOR REMOVAL
Fig. 13 Rear A/C Block Connection
1 - CLEAN AREA AROUND BLOCK BEFORE REMOVAL
24 - 104 PLUMBING - REARRS
UNDERBODY LINES (Continued)
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NOTE: Do not activate the Dosing Pump Prime
more than one time. This will put excess fuel in the
DCHA Heater Module an cause smoke to emit from
the DCHA exhaust pipe when heater activation
occurs.
NOTE: A clicking noise heard coming from the Dos-
ing Pump indicates that the pump is operational.
(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 thefuel 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 and that there are (2)
spacer washers installed between the rubber grom-
mets.
(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) Position the two spacer washers between the
body and the rubber grommets for the two M8
mounting points on the rail.
(5) 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.
(6) Install the seat hex nut at the heater mounting
flange to the cross members. Tighten to 60 Nm (44 ft.
lbs.)
(7) 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.
RSDIESEL SUPPLEMENTAL HEATER - DCHA - EXPORT24 - 111
FUEL LINE (Continued)
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