Chrysler Town, Dodge Caravan. Manual — part 340
(4) Position steering so front wheels are straight
ahead.
CAUTION: Do not rotate steering wheel after disen-
gaging lower coupling from steering gear, damage
to air bag clock spring can result.
(5) Remove clinch bolt attaching steering column
coupling to steering gear shaft (Fig. 10).
(6) Remove steering column coupling from tele-
scoping steering gear shaft.
(7) Hoist vehicle and support on safety stands.
(8) Position a drain pan under power steering
pump and oil return hose coupling.
(9) Using a hose pinch-off pliers (C-4390), pinch
power steering oil return hose off between the cross-
member coupling and the pump.
(10) Loosen hose clamp at the cradle crossmember
coupling.
(11) Disconnect return hose from metal tube.
(12) While holding pressure relief valve nut on
back of power steering pump, Remove flare nut
attaching high pressure hose to back of pump.
(13) Remove high pressure hose from pump.
(14) Allow power steering fluid to drain into pan.
(15) Remove bolts attaching anti-lock brake sensor
leads to cradle crossmember.
(16) Position anti-lock brake leads out of the way.
(17) Disconnect stabilizer bar links from ends of
stabilizer bar.
(18) Disconnect lower ball joints from lower steer-
ing knuckles (Refer to 2 - SUSPENSION/FRONT/
LOWER BALL JOINT - REMOVAL).
(19) Remove the rear engine mount heat shield
(Fig. 11).
(20) Remove through bolt attaching rear engine
mount to cradle crossmember (Fig. 12).
(21) Using paint or grease pencil, mark outline of
cradle crossmember on frame rails to aid installation.
(22) Support cradle crossmember on suitable lift-
ing device (Fig. 14).
(23) Remove bolts attaching crossmember to front
frame rails (Fig. 13).
(24) Remove cradle crossmember from vehicle (Fig.
14).
Fig. 10 STEERING COUPLING
1 - STEERING SHAFT BOOT
2 - STEERING SHAFT
3 - CROSSMEMBER
4 - STEERING GEAR
5 - MOUNT
6 - TRANSAXLE
Fig. 11 REAR MOUNT HEAT SHIELD
1 - BOLT
2 - HEAT SHIELD
3 - CLIP
4 - REAR ENGINE MOUNT
13 - 10
FRAME & BUMPERS
RS
FRONT CRADLE CROSSMEMBER (Continued)
INSTALLATION
NOTE: If cradle crossmember requires replacement.
Refer to Group 2, Suspension, to transfer suspen-
sion components and Group 19, Steering, to trans-
fer steering components.
(1) Support crossmember on suitable lifting device
(Fig. 14).
(2) Position crossmember to vehicle.
(3) Loosely install bolts attaching cradle cross-
member to front frame rails.
(4) Align crossmember to previously made marks
on frame rails.
(5) Tighten bolts attaching cradle crossmember to
frame rails.
(6) Install through bolt attaching rear engine
mount to cradle crossmember (Fig. 12) and tighten to
68 N·m (50 ft. lbs.) torque.
(7) Install the rear mount heat shield (Fig. 11).
(8) Connect lower ball joints to steering knuckles
(Refer to 2 - SUSPENSION/FRONT/LOWER BALL
JOINT - INSTALLATION)
(9) Connect stabilizer bar links to ends of stabi-
lizer bar.
(10) Install bolts attaching anti-lock brake sensor
leads to cradle crossmember.
(11) Install high pressure hose to pump.
(12) Connect return hose to metal tube.
(13) Tighten hose clamp at the cradle crossmember
coupling.
(14) Remove pinch-off pliers.
(15) Position steering so front wheels are straight
ahead.
(16) Install steering column coupling to telescoping
steering gear shaft.
(17) Install clinch bolt attaching steering column
coupling to steering gear shaft.
(18) Install steering column cover backing plate
(Refer to 23 - BODY/INSTRUMENT PANEL/STEER-
ING
COLUMN
COVER
BACKING
PLATE
-
INSTALLATION)
(19) Install steering column lower cover from
instrument panel (Refer to 23 - BODY/INSTRU-
MENT
PANEL/STEERING
COLUMN
OPENING
COVER - INSTALLATION).
(20) Connect battery negative cable.
Fig. 12 REAR MOUNT
1 - BOLT
2 - REAR MOUNT BRACKET
3 - THROUGH BOLT
4 - REAR MOUNT
Fig. 13 CRADLE CROSSMEMBER MOUNT
1 - CROSSMEMBER MOUNT
2 - BRAKE HOSE MOUNT
3 - STEERING TIE ROD
4 - FRONT CROSSMEMBER
5 - FRAME RAIL
RS
FRAME & BUMPERS
13 - 11
FRONT CRADLE CROSSMEMBER (Continued)
FRONT CROSSMEMBER
MOUNT BUSHINGS
REMOVAL
(1) Using paint or grease pencil, mark outline of
cradle crossmember on frame rails.
(2) Loosen bolts attaching crossmember to frame
rails.
(3) Remove bolt on bushing that requires replace-
ment.
(4) Allow cradle crossmember to drop down enough
to gain clearance for bushing removal.
(5) Remove bushing from vehicle.
INSTALLATION
(1) Apply rubber lubrication or soap to replace-
ment bushing.
(2) Insert lower half of bushing into square hole in
cradle crossmember.
(3) Place upper half of bushing on top of cross-
member aligned to receive square tube protruding
upward from lower bushing half.
(4) Squeeze bushing halves together to ensure they
are properly mated.
(5) Lift cradle crossmember upward to close gap
between the bushing and frame.
(6) Verify that lower bushing is fully seated into
cradle crossmember and upper bushing.
(7) Install bolt attaching bushing and crossmember
to frame rail hand tight.
(8) Align cradle crossmember to reference marks
on frame rails.
(9) Tighten cradle crossmember to frame rails
attaching bolts to 163 N·m (120 ft. lbs.) torque.
Fig. 14 CRADLE CROSSMEMBER
1 - ENGINE OIL PAN
2 - TRANSAXLE
3 - LOWER CONTROL ARM
4 - FRONT CROSSMEMBER
5 - LIFT DEVICE
6 - SPINDLE
13 - 12
FRAME & BUMPERS
RS
FRONT CRADLE CROSSMEMBER (Continued)
FUEL SYSTEM
TABLE OF CONTENTS
page
page
. . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . 17
FUEL DELIVERY
TABLE OF CONTENTS
page
page
FUEL DELIVERY
. . . . . . . . . . . . . . . . . . . . . . . . 2
PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING - FUEL DELIVERY
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
STANDARD PROCEDURE - FUEL SYSTEM
PRESSURE RELEASE PROCEDURE . . . . . . . 2
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUEL FILTER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUEL LEVEL SENDING UNIT / SENSOR
. . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
. . . . . . . . . . . . . . . . . . . . . . . . . . 5
FUEL LINES
DESCRIPTION - FUEL LINES/HOSES AND
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
STANDARD PROCEDURE - HOSES AND
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FUEL PRESSURE REGULATOR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
. . . . . . . . . . . . . . . . . . . . . . . . . . 7
FUEL PUMP
. . . . . . . . . . . . . . . . . . . . . . . . . . 7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FUEL PUMP MODULE
. . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . . . . . . . . . . . . . . . . . . . . . . . . . 9
FUEL RAIL
. . . . . . . . . . . . . . . . . . . . . . . 9
. . . . . . . . . . . . . . . . . . . . 9
. . . . . . . . . . . . . . . . . . 10
. . . . . . . . . . . . . . . . 10
FUEL TANK
. . . . . . . . . . . . . . . . . . . . . . . . . 10
. . . . . . . . . . . . . . . . . . . . . . . . . . . 10
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
. . . . . . . . . . . . . . . . . . . . . . . . . 11
FUEL TANK FILLER TUBE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
. . . . . . . . . . . . . . . . . . . . . . . . . 12
INLET FILTER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
. . . . . . . . . . . . . . . . . . . . . . . . . 13
QUICK CONNECT FITTING
STANDARD PROCEDURE - QUICK-CONNECT
. . . . . . . . . . . . . . . . . . . . . . . . . . . 13
RS
FUEL SYSTEM
14 - 1
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