Chrysler Town, Dodge Caravan. Manual — part 1104
HEAT SHIELDS
REMOVAL
(1) Remove front wiper unit (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER
MODULE
-
REMOVAL).
(2) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(3) Partially drain cooling system (Refer to 7 -
COOLING/ENGINE/COOLANT - STANDARD PRO-
CEDURE).
(4) Remove thermostat housing to upper radiator
hose tube (Fig. 9).
Fig. 6 Inspect Compressor Housing for Impeller
Rubbing Condition - Typical
Fig. 7 Measure Turbocharger Axial End Play -
Typical
Fig. 8 Measure Turbocharger Bearing Radial
Clearance - Typical
1 - FEELER GAUGE
Fig. 9 TURBOCHARGER AND COOLANT PIPES
1 - TURBOCHARGER OUTLET PIPE RETAINING BOLT
2 - TURBOCHARGER OUTLET PIPE
3 - ADAPTER HOSE
4 - HEAT SHIELD
5 - HOSE CLAMPS
6 - TURBOCHARGER INLET PIPE RETAINING BOLT
7 - TURBOCHARGER INLET PIPE
8 - ADAPTER HOSE
9 - HOSE CLAMPS
10 - EGR VALVE TO INTAKE AIR INLET PIPE
11 - CLAMP
12 - THERMOSTAT HOUSING TO UPPER RADIATOR HOSE PIPE
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EXHAUST SYSTEM AND TURBOCHARGER
11 - 5
TURBOCHARGER (Continued)
(5) Remove exhaust manifold heat shield retaining
bolts and remove shield (Fig. 10).
INSTALLATION
(1) Reposition exhaust heat shield (Fig. 10).
(2) Install exhaust heat shield retaining bolts (Fig.
10). Torque bolts to 27.5N·m.
(3) Install thermostat housing to upper radiator
hose tube (Fig. 9).
(4) Refill cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(5) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
(6) Install front wiper unit (Refer to 8 - ELECTRI-
CAL/WIPERS/WASHERS/WIPER
MODULE
-
INSTALLATION).
Fig. 10 EXHAUST MANIFOLD AND
TURBOCHARGER
1 - TURBOCHARGER OIL SUPPLY BANJO BOLT
2 - COPPER WASHER
3 - EXHAUST MANIFOLD GASKET
4 - COPPER WASHER
5 - EXHAUST MANIFOLD HEAT SHIELD RETAINING BOLT
6 - TURBOCHARGER
7 - ENGINE LIFT HOOK
8 - ENGINE LIFT HOOK RETAINING BOLT
9 - SPACER
10 - EXHAUST MANIFOLD RETAINING NUT
11 - TURBOCHARGER OIL RETURN HOSE
12 - HOSE CLAMPS
13 - EXHAUST MANIFOLD STUDS
11 - 6
EXHAUST SYSTEM AND TURBOCHARGER
RG
HEAT SHIELDS (Continued)
FUEL SYSTEM
TABLE OF CONTENTS
page
page
FUEL SYSTEM 2.5L TURBO DIESEL
DESCRIPTION - DIESEL FUEL DELIVERY
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
WARNING - HIGH FUEL SYSTEM PRESSURE
DIAGNOSIS AND TESTING - AIR IN FUEL
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DIAGNOSIS AND TESTING - FUEL SUPPLY
RESTRICTIONS . . . . . . . . . . . . . . . . . . . . . . . . 3
DELIVERY SYSTEM . . . . . . . . . . . . . . . . . . . . 3
TRANSFER PUMP PRESSURE TEST . . . . . . . 4
STANDARD PROCEDURES - DRAINING
WATER FROM FUEL FILTER . . . . . . . . . . . . . . 4
STANDARD PROCEDURE - FUEL SYSTEM
AIR PURGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
STANDARD PROCEDURES - CLEANING
FUEL SYSTEM COMPONENTS . . . . . . . . . . . . 5
. . . . . . . . . . . . . . . 5
. . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . . . . . . . . . . . . . . . . . . . . . . 17
FUEL SYSTEM 2.5L TURBO
DIESEL
DESCRIPTION - DIESEL FUEL DELIVERY
SYSTEM
WARNING:
HIGH
—
PRESSURE
FUEL
LINES
DELIVER DIESEL FUEL UNDER EXTREME PRES-
SURE FROM THE INJECTION PUMP TO THE FUEL
INJECTORS. THIS MAY BE AS HIGH AS 1600 BAR
(23,200
PSI).
USE
EXTREME
CAUTION
WHEN
INSPECTING FOR HIGH - PRESSURE FUEL LEAKS.
FUEL UNDER THIS AMOUNT OF PRESSURE CAN
PENETRATE SKIN CAUSING PERSONAL INJURY
OR DEATH. INSPECT FOR HIGH - PRESSURE FUEL
LEAKS WITH A SHEET OF CARDBOARD. WEAR
SAFETY GOGGLES AND ADEQUATE PROTECTIVE
CLOTHING WHEN SERVICING FUEL SYSTEM.
The fuel system on the 2.5L Common Rail Diesel
(CRD) Engine uses a high pressure pump and an
Electronic Control Module (ECM). (Fig. 1)
The fuel delivery system consists of the:
• Accelerator pedal
• Air cleaner housing/element
• Fuel filter/water separator
• Fuel heater
• Fuel heater relay
• Fuel/Lift pump
• High Pressure Fuel injection pump
• Fuel injectors
• Fuel tank
• Fuel tank filler/vent tube assembly
• Fuel tank filler tube cap
• Fuel tank module containing fuel tank vent
valves and a fuel gauge sending unit (fuel level sen-
sor).
• Fuel tubes/lines/hoses
• High-pressure fuel injector lines
• Low-pressure fuel supply lines
• Low-pressure fuel return line
• Overflow valve
• Quick-connect fittings
• Water draining
WARNING - HIGH FUEL SYSTEM PRESSURE
WARNING: HIGH-PRESSURE FUEL LINES DELIVER
FUEL UNDER EXTREME PRESSURE FROM THE
INJECTION
PUMP
TO
THE
INJECTORS.
THIS
MAYBE AS HIGH AS 1600BAR (23,200PSI). USE
EXTREME CAUTION WHEN INSPECTING FOR HIGH-
PRESSURE
FUEL
LEAKS.
FUEL
UNDER
THIS
AMOUNT OF PRESSURE CAN PENETRATE SKIN
CAUSING PERSONAL INJURY OR DEATH. INSPECT
HIGH-PRESSURE FUEL LEAKS WITH A SHEET OF
CARDBOARD. WEAR SAFETY GOGGLES AND ADE-
QUATE PROTECTIVE CLOTHING WHEN SERVICING
FUEL SYSTEM.
RG
FUEL SYSTEM
14 - 1
Fig. 1 CRD Fuel System
1 - FUEL INJECTOR
8 - HIGH PRESSURE INJECTION PUMP
2 - FUEL INJECTOR ANTI-SEIZE LUBRICATION POINT
9 - INJECTION PUMP FUEL RETURN FITTING
3 - HIGH PRESSURE FUEL LINE
10 - FUEL INJECTOR FUEL RETURN HOSE
4 - FUEL RAIL
11 - FUEL FLOW BACK VALVE
5 - FUEL RAIL PRESSURE SENSOR
12 - FUEL INJECTOR O-RING
6 - HIGH PRESSURE FUEL LINE
13 - FUEL INJECTOR HOLD DOWN WASHER
7 - INJECTION PUMP HIGH PRESSURE OUTLET
14 - FUEL INJECTOR HOLD DOWN
14 - 2
FUEL SYSTEM
RG
FUEL SYSTEM 2.5L TURBO DIESEL (Continued)
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