Chrysler Town, Dodge Caravan. Manual — part 65
INSTALLATION
LHD
(1) Install interlock switch into pedal bracket hole,
and secure harness with retainer as shown in (Fig.
28). Make sure switch wing tabs are fully expanded.
(2) Connect interlock switch connector.
(3) Install knee bolster (Fig. 24).
(4) Install instrument panel lower silencer (Fig.
23).
(5) Connect battery negative cable.
(6) Verify function of starter interlock switch.
Switch must actuate when pedal is depressed.
RHD
(1) Install interlock switch to pedal bracket assem-
bly as shown in (Fig. 28). Secure connector with
retainer to hole in bracket.
(2) Install clutch pedal bracket assembly into posi-
tion. Install pedal bracket mounting nuts and torque
to 28 N·m (250 in. lbs.).
(3) Connect interlock and upstop switch connec-
tors.
(4) Install clutch master cylinder into position and
rotate 45° counter-clockwise to secure to pedal
bracket (Fig. 26). Secure dash panel grommet and
secure hydraulic pluming into dash panel retainers.
(5) Connect master cylinder pushrod to clutch
pedal pin and secure with retainer clip (Fig. 26).
(6) Install knee bolster (Fig. 24).
Fig. 26 Clutch Master Cylinder at Pedal Bracket
1 - CLUTCH MASTER CYLINDER
2 - RETAINER CLIP
3 - CLUTCH PEDAL PIN
4 - PUSH ROD
Fig. 27 Clutch Pedal/Bracket Assembly
1 - CLUTCH PEDAL/BRACKET ASSY.
2 - NUT (4)
Fig. 28 Clutch Pedal Interlock Switch
1 - CLUTCH INTERLOCK SWITCH
2 - CLUTCH PEDAL/BRACKET ASSY.
6 - 14
CLUTCH
RS
CLUTCH PEDAL INTERLOCK SWITCH (Continued)
(7) Install instrument panel lower silencer (Fig.
23).
(8) Connect battery negative cable.
(9) Verify function of starter interlock switch.
Switch must actuate when pedal is depressed.
CLUTCH PEDAL UPSTOP
SWITCH
REMOVAL
LHD
(1) Disconnect battery negative cable.
(2) Remove instrument panel lower silencer (Fig.
29).
(3) Remove knee bolster (Fig. 30).
(4) Remove upstop switch by depressing four (4)
plastic wing tabs, and sliding switch through mount-
ing bracket. If necessary, remove mounting bracket
and remove switch (Fig. 31).
Fig. 29 Instrument Panel Lower Silencer—LHD
Shown
1 - INSTRUMENT PANEL LOWER SILENCER
Fig. 30 Knee Bolster—LHD Shown
1 - KNEE BOLSTER
Fig. 31 Interlock/Upstop Switch Location
1 - INTERLOCK SWITCH
2 - UPSTOP SWITCH
3 - RETAINER - UPSTOP BRACKET
4 - CONNECTORS
RS
CLUTCH
6 - 15
CLUTCH PEDAL INTERLOCK SWITCH (Continued)
RHD
(1) Disconnect battery negative cable.
(2) Remove instrument panel lower silencer (Fig.
29).
(3) Remove knee bolster (Fig. 30).
(4) Disconnect upstop switch connector (Fig. 32).
(5) Remove upstop switch/bracket-to-clutch pedal
bracket nut. Remove switch (Fig. 32).
INSTALLATION
LHD
(1) Install upstop switch into bracket (Fig. 31).
Ensure switch wing tabs are fully expanded. If
removed, re-install bracket and torque to 13 N·m
(115 in. lbs.).
(2) Connect upstop switch connector.
(3) Install knee bolster (Fig. 30).
(4) Install instrument panel lower silencer (Fig.
29).
(5) Connect battery negative cable.
RHD
(1) Install switch and bracket assembly. Torque
nut to 12 N·m (110 in. lbs.) (Fig. 32).
(2) Connect upstop switch assembly (Fig. 32).
(3) Install knee bolster (Fig. 30).
(4) Install instrument panel lower silencer (Fig.
29).
(5) Connect battery negative cable.
Fig. 32 Clutch Pedal Upstop Switch—RHD
1 - CONNECTOR
2 - NUT
3 - UPSTOP SWITCH/BRACKET
6 - 16
CLUTCH
RS
CLUTCH PEDAL UPSTOP SWITCH (Continued)
COOLING
TABLE OF CONTENTS
page
page
COOLING
DIAGNOSIS AND TESTING - COOLING
SYSTEM LEAK TEST . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING - COOLING
SYSTEM FLOW CHECK . . . . . . . . . . . . . . . . . 3
DIAGNOSIS AND TESTING - COOLING
SYSTEM AERATION . . . . . . . . . . . . . . . . . . . . 3
DIAGNOSIS AND TESTING - COOLING
SYSTEM DEAERATION . . . . . . . . . . . . . . . . . . 4
SYSTEM DRAINING . . . . . . . . . . . . . . . . . . . . 4
SYSTEM FILLING . . . . . . . . . . . . . . . . . . . . . . 5
ADDITIONAL COOLANT . . . . . . . . . . . . . . . . . 5
LEVEL CHECK . . . . . . . . . . . . . . . . . . . . . . . . 5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
. . . . . . . . . . . . . . . . . . . . . 6
. . . . . . . . . . . . . . . . . . . . . . . 7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
. . . . . . . . . . . . . . . . . . . . . . . . . 37
COOLING
DESCRIPTION
DESCRIPTION - COOLING SYSTEM
The cooling system components consist of a radia-
tor, electric fan motors, shroud, pressure cap, thermo-
stat, transmission oil cooler, water pump, hoses,
clamps, coolant, and a coolant reserve system to com-
plete the circuit.
DESCRIPTION - HOSE CLAMPS
The cooling system uses spring type hose clamps.
If a spring type clamp replacement is necessary,
replace with the original Mopar
t equipment spring
type clamp.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps. If replacement
is necessary, use only a original equipment clamp
with matching number or letter (Fig. 1).
Fig. 1 Spring Clamp Size Location
1 - SPRING CLAMP SIZE LOCATION
RS
COOLING
7 - 1
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