Caravan L4-2.4L VIN B (2003)
Headlamp Washer Pump: Service and Repair
REMOVAL
1. Disconnect and isolate the battery negative cable.
2. Remove the engine fresh air housing inside the engine compartment (Refer to ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING -
REMOVAL).
3. Disconnect the washer hose at the in-line connector forward of the cowl grille so that the in-line connector remains with the washer hose from the
fresh air plenum.
4. Disconnect the washer hose from the hose clip located on the front fender side shield.
5. Remove the filler tube screw.
6. Hoist and support vehicle on hoist or jack stands.
7. Remove the right front wheel and tire assembly (Refer to TIRES/WHEELS - REMOVAL).
8. Disconnect the left right front wheelhouse splash shield and move aside (Refer to BODY/ EXTERIOR/WHEELHOUSE SPLASH SHIELD -
REMOVAL).
9. Drain washer fluid from the reservoir and into a suitable clean container. This can be done by disconnecting the windshield washer hose from the
front (outboard) washer pump and allowing the washer fluid to drain into a container through a temporary jumper hose connected to the front
washer pump.
10. Disconnect the rear washer pump hose from washer pump.
11. Disconnect the high pressure headlamp washer pump hose by pressing down firmly on latch and pulling hose off.
12. Disconnect the electrical body harness connectors to the washer pump motors and the fluid level sensor. Slide the red lock on the connector to the
release position, then, depress the black tab and pull the connector off the pump or sensor.
13. Remove the two reservoir mounting screws.
14. Disconnect the reservoir from the body mount by raising the reservoir upward slightly and then down so that the reservoir filler neck and front
washer hose pull through the opening in the front fender side shield.
15. Remove pump from reservoir by pulling pump up and away from reservoir cavity and out of mounting grommet. Do not damage reservoir/pump
sealing surface or puncture reservoir during removal.
16. Remove pump grommet and discard.
INSTALLATION
1. Use new grommet when installing a new pump assembly.
2. Assure pump upper retention tab is pressed into reservoir slot and assure the pump is aligned to and fully seated in the reservoir cavity.
3. Push filler neck and front washer hose through the opening in the front fender side shield. Connect the reservoir to the body mount by lowering the
reservoir down.
4. Install the two reservoir mounting screws. Torque screws to 8.5 - 11.3 N.m (75 - 100 in. lbs.).
5. Connect the electrical body harness connectors to the washer pump motors and the fluid level sensor. Slide the red lock on the connector to the
closed or locked position.
6. Connect front and rear washer pump hoses and assure that they are properly routed to prevent pinching and possible inoperative washers.
7. Connect the high pressure headlamp washer hose by firmly pushing hose onto inlet until a snap is heard.
8. Connect the left right front wheelhouse splash shield and move aside (Refer to BODY/EXTERIOR/WHEELHOUSE SPLASH SHIELD -
INSTALLATION).
9. Install the right front wheel and tire assembly (Refer to TIRES/WHEELS - INSTALLATION).
10. lower vehicle from hoist or jack stands.
11. Install the filler tube screw. Torque screw to 8.5 - 11.3 N.m (75 - 100 in. lbs.).
12. Connect the washer hose to the hose clip located on the front fender side shield.
13. Connect the washer hose at the in-line connector forward of the cowl grille.
14. Install the engine fresh air housing inside the engine compartment (Refer to ENGINE/AIR INTAKE SYSTEM/AIR CLEANER HOUSING -
INSTALLATION).
15. Connect the battery negative cable.
16. Verify vehicle and system operation.
