coolant capacity CHRYSLER CARAVAN 2005 Service Manual

DIAGNOSIS AND TESTING - COOLING SYSTEM
AERATION
Low coolant level in a cross flow radiator will
equalize in both tanks with engine off. With engine
at running and at operating temperature, the high
pressure inlet tank runs full and the low pressure
outlet tank drops, resulting in cooling system aera-
tion. Aeration will draw air into the water pump
resulting in the following:
²High reading shown on the temperature gauge.
²Loss of coolant flow through the heater core.
²Corrosion in the cooling system.
²Water pump seal may run dry, increasing the
risk of premature seal failure.
²Combustion gas leaks into the coolant can also
cause the above problems.
DIAGNOSIS AND TESTING - COOLING SYSTEM
DEAERATION
Air can only be removed from the system by gath-
ering under the pressure cap. On the next heat up it
will be pushed past the pressure cap into the coolant
recovery bottle by thermal expansion of the coolant.
It then escapes to the atmosphere in the coolant
recovery bottle and is replaced with coolant on cool
down.
To effectively deaerate the system, multiple ther-
mal cycles of the system may be required.
NOTE: Deaeration does not occur at engine idleÐ
higher engine speeds are required. Normal driving
will deaerate cooling system.
STANDARD PROCEDURE
STANDARD PROCEDURE - COOLING SYSTEM
DRAINING
WARNING: DO NOT REMOVE OR LOOSEN THE
COOLANT PRESSURE CAP, CYLINDER BLOCK
DRAIN PLUGS, OR THE DRAINCOCK WHEN THE
SYSTEM IS HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM THE COOLANT
CAN OCCUR.
(1)Without removing radiator pressure cap
and with system not under pressure, using a
screwdriver, open the draincock. The draincock is
located on the lower left side of radiator.
(2) After the coolant recovery/reserve container is
empty, then remove coolant pressure cap (Fig. 5).
(3) Remove the cylinder block drain plug(s).
STANDARD PROCEDURE - COOLING SYSTEM
FILLING
Remove radiator pressure cap (Fig. 5) and fill sys-
tem, using a 50/50 mix of MopartAntifreeze/Coolant,
5 Year/100,000 Mile Formula and distilled water.
Continue filling system until full.Be careful not
to spill coolant on drive belts or the generator.
For cooling system capacity, (Refer to LUBRICATION
& MAINTENANCE/FLUID CAPACITIES - SPECIFI-
CATIONS).
Fill coolant recovery/reserve container (Fig. 5) to at
least the MAX mark with 50/50 solution. It may be
necessary to add coolant to the recovery/reserve con-
tainer after three or four warm up/cool down cycles
to maintain coolant level between the MAX and MIN
mark. This will allow trapped air to be removed from
the system.
STANDARD PROCEDURE - ADDING
ADDITIONAL COOLANT
The radiator cap should not be removed.
When additional coolant is needed to maintain this
level, it should be added to the coolant recovery/re-
serve container (Fig. 5). Use only 50/50 mix of ethyl-
ene glycol type antifreeze and distilled water. For the
recommeded antifreeze/coolant type (Refer to LUBRI-
CATION & MAINTENANCE/FLUID TYPES -
DESCRIPTION).
CAUTION: Do not use well water, or suspect water
supply in cooling system. A 50/50 ethylene glycol
and distilled water mix is recommended. For the
recommeded antifreeze/coolant type (Refer to
LUBRICATION & MAINTENANCE/FLUID TYPES -
DESCRIPTION).
STANDARD PROCEDURE - COOLANT LEVEL
CHECK
NOTE: Do not remove radiator cap for routine cool-
ant level inspections.
The coolant reserve system provides a quick visual
method for determining the coolant level without
removing the radiator cap.With the engine cold
and not running,simply observe the level of the
coolant in the recovery/reserve container (Fig. 5). The
coolant level should be between the MIN and MAX
marks.
7 - 4 COOLINGRS
COOLING (Continued)

INSTALLATION
(1)Be sure the air seal is in position before
radiator is installed.Slide radiator down into posi-
tion. Seat the radiator with the rubber isolators into
the mounting holes provided, with a 10 lbs. force.
(2) Position air conditioning condenser onto the
radiator lower mounts and ingage upper mounting
tabs. (Fig. 15).
(3) Install the radiator upper and lower hoses (Fig.
13) or (Fig. 14).
(4) Connect the coolant reserve/recovery hose.
(5) Connect the vapor purge solenoid to the mount-
ing bracket.
(6) Install the radiator fans. (Refer to 7 - COOL-
ING/ENGINE/RADIATOR FAN - INSTALLATION)
(7) Install the radiator upper crossmember sup-
port. (Refer to 23 - BODY/EXTERIOR/GRILLE
OPENING REINFORCEMENT - INSTALLATION)
(8) Fill the cooling system. (Refer to 7 - COOLING
- STANDARD PROCEDURE)
(9) Connect negative cable to battery.
RADIATOR DRAINCOCK
REMOVAL
NOTE: It is not necessary to remove draincock dur-
ing a routine coolant drain.
(1) Drain the cooling system. (Refer to 7 - COOL-
ING - STANDARD PROCEDURE)
(2) Using a screwdriver, open the draincock by
turning it counterclockwise until it stops.
(3) Pull the draincock from the radiator tank.
INSTALLATION
(1) Align draincock stem to radiator tank opening.
(2) Push draincock into the radiator tank opening.
CAUTION: Do not overtighten. The head of the
draincock may break off.
(3) Using a screwdriver, tighten the draincock by
turning clockwise until it stops.
(4) Fill the cooling system. (Refer to 7 - COOLING
- STANDARD PROCEDURE)
RADIATOR PRESSURE CAP
DESCRIPTION
The cooling system pressure cap is located on the
radiator. The cap construction includes; stainless
steel swivel top, rubber seals, and retainer, main
spring, and a spring loaded valve (Fig. 16).
OPERATION
The cooling system is equipped with a pressure cap
that releases excessive pressure; maintaining a range
of 97-124 kPa (14-18 psi).
The cooling system will operate at higher than
atmospheric pressure. The higher pressure raises the
coolant boiling point thus, allowing increased radia-
tor cooling capacity.
There is also a vent valve in the center of the cap.
This valve also opens when coolant is cooling and
contracting, allowing the coolant to return to cooling
system from coolant reserve system tank by vacuum
through a connecting hose.If valve is stuck shut,
or the coolant recovery hose is pinched, the
radiator hoses will be collapsed on cool down.
Clean the vent valve (Fig. 16) and inspect cool-
ant recovery hose routing, to ensure proper
sealing when boiling point is reached.
The gasket in the cap seals the filler neck, so that
vacuum can be maintained, allowing coolant to be
drawn back into the radiator from the reserve tank.
If the gasket is dirty or damaged, a vacuum
may not be achieved, resulting is loss of coolant
and eventual overheating due to low coolant
level in radiator and engine.
Fig. 16 Cooling System Pressure Cap Filler Neck
1 - OVERFLOW NIPPLE
2 - MAIN SPRING
3 - GASKET RETAINER
4 - STAINLESS-STEEL SWIVEL TOP
5 - RUBBER SEALS
6 - VENT VALVE
7 - RADIATOR
8 - FILLER NECK
RSENGINE7-27
RADIATOR (Continued)

²a rotary adjustment knob for temperature.
²a rotary adjustment for fan speed control.
AUTOMATIC TEMPERATURE CONTROL
Two different automatic temperature control (ATC)
heating-A/C systems are available for this model
depending on the market.
The Dual-Zone ATC system allows the driver and
front occupants to each select individual comfort tem-
peratures.
The Three-Zone ATC system allows both the driver
and front occupants and the rear intermediate occu-
pants to select individual comfort temperatures.
NOTE: Individual comfort temperatures are the per-
ceived temperature level at the individual seating
areas, NOT the actual passenger compartment air
temperature.
The ATC system includes a particulate air filter.
The filter element is the same size as the A/C evap-
orator to ensure ample capacity. A door at the base of
the HVAC housing below the glove box provides easy
access to the filter element.
The ATC computer utilizes integrated circuitry and
information carried on the programmable communi-
cations interface (PCI) data bus network to monitor
many sensors and switch inputs throughout the vehi-
cle. In response to those inputs, the internal circuitry
and programming of the ATC computer allow it to
control electronic functions and features of the ATC
system. The inputs to the ATC computer are:
²Vehicle Speed/Engine RPM± The ATC com-
puter monitors engine rpm, vehicle speed and mani-
fold absolute pressure information from the
powertrain control module (PCM).
²Coolant Temperature± ATC computer moni-
tors coolant temperature received from the PCM and
converts it to degrees Fahrenheit.
²Ambient Temperature± ATC computer moni-
tors ambient temperature from the compass mini trip
computer (CMTC) and converts it to degrees Fahren-
heit.
²Engine Miscellaneous Sensor Status±ATC
computer monitors A/C disable information from the
PCM.
²Refrigerant Pressure± ATC computer moni-
tors barometric pressure, intake air temperature,
high side pressure and methanol content as broad-
cast by the PCM.
²Door Ajar Status± The ATC computer moni-
tors driver front door, passenger front door, left rear
door, right rear door and liftgate ajar information, as
identified by the body control module (BCM), to
determine if all in-car temperatures should be main-
tained.²Dimming± The ATC computer monitors dim-
ming status from the BCM to determine the required
level of brightness and will dim accordingly.
²Vehicle Odometer± The ATC computer moni-
tors the vehicle odometer information from the BCM
to prevent flashing the vacuum-flourescent (VF) dig-
ital display icons if the manual motor calibration or
manual cool down tests have failed. Flashing of the
display icons will cease when the vehicle odometer is
greater than 3 miles.
²English/Metric± The ATC computer monitors
the English/Metric information broadcast by the
CMTC. The set temp displays for both the front and
rear control heads will be set accordingly.
²Vehicle Identification Number± The ATC
computer monitors the last eight characters of the
VIN broadcast by the PCM and compares it to the
information stored in EEPROM. If it is different, the
new number will be stored over the old one and a
motor calibration shall be initiated.
²A/C System Information± The ATC computer
will send a message for evaporator temperature too
low, fan blower relay status, evaporator sensor fail-
ure, rear window defogger relay and A/C select.
FRONT CONTROL PANEL
The front A/C-heater control and integral computer
is mounted in the instrument panel and contains:
²a power button which allows the system to be
completely turned off. The display is blank when the
system is off.
²a rocker switch that selects a cool-down rate.
LO-AUTO or HI-AUTO are displayed when the sys-
tem is in automatic operation.
²three rocker switches that select comfort temper-
atures from 15É to 30É C (59É to 85É F), which are
shown in the VF digital display. If the set temp is 15É
C (59É F) and the down button is pressed, the set
temp value will become 13É C (55É F) but the display
will show LO. If the set temp is 29É C (85É F) and the
up button is pressed, the set temp value will become
32É C (90É F) but the display will show HIGH. Tem-
peratures can be displayed in either metric or Fahr-
enheit, which is controlled from the overhead console.
²an air conditioning button that allows the com-
pressor to be turned off. A Snowflake symbol is illu-
minated when air conditioning is on, whether under
manual or automatic control.
²an air recirculation button. A Recirculation sym-
bol appears in the display when the button is
pressed, or when the system exceeds 80 percent recir-
culated air under automatic control due to high air
conditioning demand.
²a rear window defogger on/off switch. A graphic
symbol shows when the defroster is on.
RSHEATING & AIR CONDITIONING24-3
HEATING & AIR CONDITIONING (Continued)

TEMPERATURE CONTROL
If the heater outlet air temperature cannot be
adjusted with the temperature control knob on the
A/C-heater control panel, the following could require
service:
²Blend door binding.
²Faulty blend door actuator.
²Faulty A/C-heater control.
²Faulty related wiring harness or connectors.²Improper engine coolant temperature.
SPECIFICATIONS
A/C SYSTEM
The R-134a refrigerant system charge capacity for
this vehicle can be found on the underhood Specifica-
tion Label.
SYSTEM SPECIFICATIONS
Item Description Notes
A/C Compressor Denso 10S17 ± 2.4L/2.5L/2.8L/3.3L
without rear A/C
Denso 10S20 ± 3.3L/3.8L with rear
A/CND-8 PAG Oil
Freeze±up Control Evaporator temperature sensor HVAC housing mounted (RS models),
Evaporator mounted (RG models) - input to
A/C-heater control module
Low PSI Control A/C pressure transducer Liquid line mounted - input to Powertrain Control
Module (PCM) - PCM opens compressor clutch
relay above 200 kPa (29 psi)
High PSI Control A/C pressure transducer Liquid line mounted - input to PCM - PCM
opens compressor clutch relay below 3100 kPa
(450 psi)
High Pressure relief valve Compressor mounted - opens above 3445-4135
kPa (500-600 psi), closes below 2756 kPa (400
psi)
Compressor Clutch Coil
DrawDenso 10S17 ± 3.3 amps @ 12V  
0.5V @ 21É C (70É F)
Denso 10S20 ± 2.2 amps @ 12V  
0.5V @ 21É C (70É F)
Compressor Clutch Air
Gap0.35 - 0.60 mm (0.014 - 0.024 in.)
TORQUE SPECIFICATIONS
Description N´m Ft. Lbs. In. Lbs.
A/C Compressor Shaft Bolt 17.5 ± 155
A/C Compressor Mounting Bolts (2.4L/2.5L/2.8L) 28 21 ±
A/C Compressor Mounting Bolts (3.3L/3.8L) 54 40 ±
A/C Compressor Mounting Bracket Bolts (2.4L) 54 40 ±
A/C Condenser Mounting Bracket Screws 5 ± 45
A/C Expansion Valve Screws 11 ± 97
A/C-Heater Control Screws 2 ± 17
Blend Door Actuator Screws 2 ± 17
Blower Motor Screws 2 ± 17
Blower Motor Power Module Screws (ATC) 2 ± 17
Blower Motor Resistor Block Screws (MTC) 2 ± 17
Center Bezel Outlet Screws 2 ± 17
RSHEATING & AIR CONDITIONING24-11
HEATING & AIR CONDITIONING (Continued)

PLUMBING - FRONT
DESCRIPTION
CAUTION: The system must be completely empty
before opening any fitting or connection in the
refrigeration system. Open fittings with caution
even after the system has been emptied. If any
pressure is noticed as a fitting is loosened,
retighten fitting and evacuate the system again.
The use of correct wrenches when making connec-
tions is very important. Improper wrenches or
improper use of wrenches can damage the fittings.
The internal parts of the A/C system will remain sta-
ble as long as moisture-free refrigerant and refrig-
erant oil is used. Abnormal amounts of dirt,
moisture or air can upset the chemical stability.
This may cause operational troubles or even seri-
ous damage if present in more than very small
quantities. Before disconnecting a refrigerant line
or hose, clean the outside of the fittings thoroughly
to prevent contamination from entering the refriger-
ant system.
When opening a refrigeration system, have every-
thing you will need to repair the system ready to
minimize the amount of time the system is opened.
Cap or plug all refrigerant line fittings as soon as
they are opened. This will help prevent the entrance
of dirt and moisture. All new lines and components
should be capped or sealed until they are ready to
be used. Before connecting a refrigerant line or
hose, clean the outside of the fittings thoroughly to
prevent contamination from entering the refrigerant
system.
All tools, including the refrigerant dispensing mani-
fold, manifold gauge set and test hoses should be
kept clean and dry.
The A/C refrigerant lines and hoses are used to
carry the refrigerant between the various A/C system
components. The refrigerant lines and hoses for the
R-134a system on this vehicle consist of a barrier-
hose design with a nylon tube sandwiched between
rubber layers. The nylon tube helps to contain the
R-134a refrigerant, which has a smaller molecular
structure than R-12 refrigerant. The ends of the
refrigerant lines are made from lightweight alumi-
num or steel, and commonly use braze-less fittings.Any kinks or sharp bends in the refrigerant lines
and hoses will reduce the capacity of the entire A/C
system and can reduce the flow of refrigerant in the
system. The radius of all bends in the flexible hose
refrigerant lines should be at least ten times the
diameter of the hose and the refrigerant lines should
be routed so they are at least 80 millimeters (3
inches) away from the exhaust manifold(s) and
exhaust pipe(s).
OPERATION
High pressures are produced in the refrigerant sys-
tem when the A/C compressor is operating. Extreme
care must be exercised to make sure that each of the
refrigerant system connections is pressure-tight and
leak free. It is a good practice to inspect all flexible
hose refrigerant lines at least once a year to make
sure they are in good condition and properly routed.
The refrigerant lines and hoses are coupled to
other A/C system components with block-type fit-
tings. An O-ring seal, or a flat steel gasket with an
integral O-ring (dual plane seal), is used to mate the
refrigerant line fittings with A/C system components
to ensure the integrity of the refrigerant system.
The refrigerant lines and hoses cannot be repaired
and, if faulty or damaged, they must be replaced.
WARNING
ENGINE COOLING SYSTEM
WARNING: THE ENGINE COOLING SYSTEM IS
DESIGNED TO DEVELOP INTERNAL PRESSURES
OF 97 TO 123 KILOPASCALS (14 TO 18 POUNDS
PER SQUARE INCH). DO NOT REMOVE OR
LOOSEN THE COOLANT PRESSURE CAP, CYLIN-
DER BLOCK DRAIN PLUGS, RADIATOR DRAIN,
RADIATOR HOSES, HEATER HOSES, OR HOSE
CLAMPS WHILE THE ENGINE COOLING SYSTEM IS
HOT AND UNDER PRESSURE. FAILURE TO
OBSERVE THIS WARNING CAN RESULT IN SERI-
OUS BURNS FROM THE HEATED ENGINE COOL-
ANT. ALLOW THE VEHICLE TO COOL FOR A
MINIMUM OF 15 MINUTES BEFORE OPENING THE
COOLING SYSTEM FOR SERVICE.
RSPLUMBING - FRONT24-65

WARNING: HIGH PRESSURES ARE PRODUCED IN
THE REFRIGERANT SYSTEM WHEN THE A/C COM-
PRESSOR IS OPERATING. HIGH TEMPERATURE
COOLANT IS PRESENT IN THE HEATER PLUMBING
WHEN THE ENGINE IS OPERATING. EXTREME
CARE MUST BE EXERCISED WHEN SERVICING
THE REAR HEATER AND A/C LINES TO PREVENT
POSSIBLE PERSONAL INJURY.
Any kinks or sharp bends in the rear heater-A/C
plumbing will reduce the capacity of the entire heat-
ing-A/C system. Kinks and sharp bends reduce the
system flow. High pressures are produced in the
refrigerant system when the A/C compressor is oper-
ating. High temperature coolant is present in the
heater plumbing when the engine is operating.
Extreme care must be exercised to make sure that
each of the connections is pressure-tight and leak
free.
REMOVAL
UNDERBODY HEATER TUBES
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
WARNING).
(1) Drain the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM DRAIN).(2) Raise and support vehicle.
(3) Disconnect the underbody heater tubes at the
rear of the vehicle by releasing the insert in the
underbody heater tube quick connect fittings and
carefully pulling downward on the heater tube fit-
tings (Fig. 14).
(4) Lower the underbody heater tubes and drain
any residual coolant from the tubes into a suitable
container.
Fig. 12 Rear Heater and A/C Lines ± Typical
1 - REAR HEATER TUBE CONNECTIONS2 - REAR A/C LINE CONNECTIONS
Fig. 13 Front Extension Lines to Underbody Lines ±
Typical
RSPLUMBING - REAR24 - 109
UNDERBODY LINES (Continued)