2001 DODGE TOWN AND COUNTRY wiring

GROUP TAB LOCATOR
INIntroduction
INaIntroduction
0Lubrication & Maintenance
0aLubrication & Maintenance
2Suspension
2aSuspension
3Differential & Driveline
5Brakes
5aBrakes
6aClutch
7Cooling
7aCooling
8AAudio
8AaAudio
8BChime/Buzzer
8BaChime/Buzzer
8EElectronic Control Modules
8FEngine Systems
8FaEngine Systems
8GHeated Systems
8HHorn
8IIgnition Control
8JInstrument Cluster
8JaInstrument Cluster
8LLamps
8LaLamps
8MMessage Systems
8NPower Systems
8NaPower Systems
8ORestraints
8PSpeed Control
8QVehicle Theft Security
8RWipers/Washers
8WaWiring
9Engine
9aEngine
11Exhaust System
11aExhaust System
13Frame & Bumpers
14Fuel System
14aFuel System
19Steering
19aSteering
21Transmission/Transaxle
21aTransmission/Transaxle
22Tires/Wheels
23Body
24Heating & Air Conditioning
24aHeating & Air Conditioning
25Emissions Control
25aEmissions Control
Service Manual Comment Forms
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RED BRAKE WARNING INDICATOR LAMP
CONDITION POSSIBLE CAUSES CORRECTION
RED BRAKE WARNING
LAMP ON1. Parking brake lever not fully
released.1. Release parking brake lever.
2. Parking brake warning lamp
switch on parking brake lever.2. Inspect and replace switch as necessary.
3. Brake fluid level low in reservoir. 3. Fill reservoir. Check entire system for
leaks. Repair or replace as required.
4. Brake fluid level switch. 4. Disconnect switch wiring connector. If
lamp goes out, replace switch.
5. Mechanical instrument cluster
(MIC) problem.5. Refer to appropriate Diagnostic
information.
6. Amber ABS Warning Indicator
Lamp also illuminated.6. Refer to appropriate Diagnostic
information.
BRAKE NOISE
CONDITION POSSIBLE CAUSES CORRECTION
CLICK OR SQUAWK ON
PEDAL APPLICATION1. Brake lamp switch. 1. Replace switch.
2. Brake Transmission Shift Interlock
Linkage.2. Lubricate BTSI linkage.
3. Pedal pivot bushings 3. Lubricate pivot bushings. Replace if
necessary.
DISC BRAKE CHIRP 1. Excessive brake rotor runout. 1. Follow brake rotor diagnosis and testing.
Correct as necessary.
2. Lack of lubricant on brake caliper
slides.2. Lubricate brake caliper slides.
3. Caliper/shoes not fully seated. 3. Reseat caliper/shoes.
DISC BRAKE RATTLE OR
CLUNK1. Broken or missing anti-rattle
spring clips on shoes.1. Replace brake shoes.
2. Caliper guide pins/bolts loose. 2. Tighten guide pins/bolts.
DISC BRAKE SQUEAK AT
LOW SPEED (WHILE
APPLYING LIGHT BRAKE
PEDAL EFFORT)1. Brake shoe linings. 1. Replace brake shoes.
DRUM BRAKE CHIRP 1. Lack of lubricant on brake shoe
support plate where shoes ride.1. Lubricate shoe contact areas on brake
shoe support plates.
DRUM BRAKE CLUNK 1. Drum(s) have threaded machined
braking surface.1. Reface or replace drake drums as
necessary.
DRUM BRAKE HOWL OR
MOAN1. Lack of lubricant on brake shoe
support plate where shoes ride and
at the anchor.1. Lubricate shoe contact areas on brake
shoe support plates and at the anchor.
2. Rear brake shoes. 2. Replace rear brake shoes.
DRUM BRAKE SCRAPING
OR WHIRRING1. ABS wheel speed sensor or tone
wheel.1. Inspect, correct or replace faulty
component(s).
5 - 4 BRAKES - BASERS
BRAKES - BASE (Continued)
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BRAKE FLUID LEVEL SWITCH
DESCRIPTION
The brake fluid level switch is located in the brake
fluid reservoir of the master cylinder (Fig. 4).
OPERATION
The purpose of the brake fluid level switch is to
provide the driver with an early warning that the
brake fluid level in the master cylinder fluid reser-
voir has dropped below a normal level. This may
indicate:
²Abnormal loss of brake fluid in the master cyl-
inder fluid reservoir resulting from a leak in the
hydraulic system.
²Brake shoe linings which have worn to a point
requiring replacement.
As the brake fluid drops below the minimum level,
the brake fluid level switch closes to complete the red
BRAKE warning indicator (lamp) circuit. This will
turn on the red BRAKE warning indicator. The mas-
ter cylinder fluid reservoir should be checked and
refilled to the Full mark with DOT 3 brake fluid.If
the brake fluid level has dropped below the add
line in the master cylinder fluid reservoir, the
entire brake hydraulic system should be
checked for evidence of a leak.
REMOVAL
(1) Remove wiring harness connector from brake
fluid reservoir level switch (Fig. 4).
(2) Using fingers, compress the retaining tabs on
the opposite end of brake fluid level switch.
(3) With retaining tabs compressed, grasp the con-
nector end of brake fluid level switch and pull it out
of master cylinder brake fluid reservoir.
INSTALLATION
(1) Insert brake fluid level switch into left side of
brake fluid reservoir. Be sure switch is pushed in
until retaining tabs lock it to brake fluid reservoir.
(2) Connect vehicle wiring harness connector to
brake fluid level switch (Fig. 4).
Tubes, Master Cylinder Bleed 8358
Adapter, Master Cylinder Pressure Bleed Cap 6921
Dial Indicator, C-3339
Gauge, Brake Safe-Set
Handle, Universal C±4171
Installer, Dust Boot C-4689 or C-4842
RSBRAKES - BASE5-9
BRAKES - BASE (Continued)
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(4) Remove the four chassis brake tubes from the
top of the junction block (Fig. 46).
(5) Remove the primary and secondary brake
tubes from the top of the junction block.
(6) Remove the bolts attaching the junction block
mounting bracket to the front suspension crossmem-
ber (Fig. 46), then remove the junction block.
INSTALLATION - NON-ABS JUNCTION BLOCK
(1) Install the junction block and mounting bracket
on the front suspension crossmember (Fig. 46).
Install the mounting bolts and tighten to a torque of
28 N´m (250 in. lbs.).
(2) Install the primary and secondary brake tubes
from the master cylinder in their ports. Tighten tube
nuts to a torque of 17 N´m (145 in. lbs.).Take care
not to twist tubes when tightening tube nuts.
They must be properly positioned to allow free
movement with rubber isolated suspension
crossmember.
(3) Install the four chassis brake tubes into the
outlet ports of the junction block. Tighten all 6 tube
nuts to a torque of 17 N´m (145 in. lbs.).
(4) If the vehicle is equipped with speed control,
perform the following:
(a) Install the speed control servo with its
mounting nuts.
(b) Connect the wiring harness to the speed con-
trol servo.
(c) Install the battery tray (Refer to 8 - ELEC-
TRICAL/BATTERY SYSTEM/TRAY - INSTALLA-
TION).(d) Install the screw securing the coolant filler
neck to the battery tray.
(e) Reconnect the vacuum hose connector at the
tank built into the battery tray.
(f) Install the battery (Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/BATTERY - INSTALLA-
TION).
(g) Install the battery shield.
(5) Remove the brake pedal holder.
(6) Connect negative cable back on negative post of
the battery.
(7) Bleed the brake system thoroughly to ensure
that all air has been expelled from the hydraulic sys-
tem. (Refer to 5 - BRAKES - STANDARD PROCE-
DURE).
(8) Road test the vehicle to verify proper operation
of the brake system.
MASTER CYLINDER
DESCRIPTION
The master cylinder is located on the power brake
booster in the engine compartment on the driver's
side (Fig. 47). This vehicle uses 3 different master
cylinders. Master cylinder usage depends on what
type of brake system the vehicle is equipped with.
CAUTION: Master cylinders are not interchangeable
between systems. Performance and stopping dis-
tance issues will result if the incorrect master cyl-
inder is installed on the vehicle.
Fig. 46 NON-ABS JUNCTION BLOCK
1 - MASTER CYLINDER
2 - JUNCTION BLOCK
3 - SUSPENSION CROSSMEMBER
4 - MOUNTING BOLTS
Fig. 47 MASTER CYLINDER AND BOOSTER
LOCATION
1 - MASTER CYLINDER
2 - POWER BRAKE BOOSTER
RSBRAKES - BASE5-33
JUNCTION BLOCK (Continued)
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(6) Thoroughly clean all surfaces of the brake fluid
reservoir and master cylinder. Use only solvent such
as MopartBrake Parts Cleaner or equivalent.
(7) Remove wiring harness connector from brake
fluid level switch in master cylinder brake fluid res-
ervoir (Fig. 48).
(8) Disconnect primary and secondary brake tubes
from master cylinder housing (Fig. 48). Install seal-
ing plugs in the now open brake tube outlet ports.
CAUTION: Before removing the master cylinder
from the power brake vacuum booster, the master
cylinder and vacuum booster must be thoroughly
cleaned. This must be done to prevent dirt particles
from falling into the power brake vacuum booster.
(9) Clean area where master cylinder assembly
attaches to power brake booster. Use only a solvent
such as MopartBrake Parts Cleaner or equivalent.
(10) Remove two nuts attaching master cylinder to
power brake booster (Fig. 49).
(11) Slide master cylinder straight out of power
brake booster.
CAUTION: A seal on the rear of the master cylinder
is used to create the seal for holding vacuum in the
power brake vacuum booster. The vacuum seal on
the master cylinder MUST be replaced whenever the
master cylinder is removed from the power brake
vacuum booster.
(12) Remove vacuum seal located on the mounting
flange of the master cylinder. The vacuum seal isremoved from master cylinder bycarefullypulling it
off the rear of master cylinder.Do not attempt to
pry the seal off the master cylinder by inserting
a sharp tool between seal and master cylinder
casting.
DISASSEMBLY - MASTER CYLINDER (FLUID
RESERVOIR)
(1) Clean master cylinder housing and brake fluid
reservoir. Use only a solvent such as Mopar Brake
Parts Cleaner or an equivalent.
(2) Remove brake fluid reservoir cap. Using a
syringe or equivalent type tool empty as much brake
fluid as possible from the reservoir.
CAUTION: When removing fluid reservoir from the
master cylinder, do not pry off using any type of
tool. This can damage the fluid reservoir or master
cylinder housing.
(3) Remove the master cylinder assembly from the
power brake vacuum booster. (Refer to 5 - BRAKES -
BASE/HYDRAULIC/MECHANICAL/MASTER CYL-
INDER - REMOVAL).
(4) Mount the master cylinder in a vise using the
master cylinder mounting flange.
(5) Using correct size pin punch, remove the two
retaining pins between the fluid reservoir and master
cylinder housing (Fig. 50).
(6) Rock the brake fluid reservoir from side to side
while pulling up to remove it from the seal grommets
in master cylinder housing.
(7) Remove the two master cylinder housing to
brake fluid reservoir seal grommets (Fig. 51).
Fig. 48 MASTER CYLINDER AND BOOSTER
1 - POWER BRAKE BOOSTER
2 - BOOSTER IDENTIFICATION LABEL
3 - FLUID LEVEL SWITCH CONNECTOR
4 - PRIMARY BRAKE TUBE NUT
5 - SECONDARY BRAKE TUBE NUT
6 - MASTER CYLINDER
Fig. 49 MASTER CYLINDER MOUNTING
1 - MASTER CYLINDER MOUNTING NUTS
2 - MASTER CYLINDER
3 - SECONDARY TUBE NUT AT ICU
4 - PRIMARY TUBE NUT AT ICU
RSBRAKES - BASE5-35
MASTER CYLINDER (Continued)
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ASSEMBLY - MASTER CYLINDER (FLUID
RESERVOIR)
(1) Install new master cylinder housing to brake
fluid reservoir sealing grommets in master cylinder
housing (Fig. 51).
(2) Lubricate reservoir mounting area with fresh
clean brake fluid. Place reservoir in position over
sealing grommets. Seat reservoir into sealing grom-
mets using a rocking motion while firmly pressing
down on fluid reservoir.
(3) Be sure fluid reservoir is positioned properly on
master cylinder.Bottom of fluid reservoir is to be
touching the top of both sealing grommets
when properly installed on master cylinder
housing.(4) Install the two fluid reservoir to master cylin-
der retaining pins (Fig. 50).
(5) Install the master cylinder assembly on the
power brake booster. (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/MASTER CYLINDER -
INSTALLATION)
(6) Fill fluid reservoir to its proper level as indi-
cated on the side of the fluid reservoir.
INSTALLATION - MASTER CYLINDER
CAUTION: Different types of master cylinders are
used on this vehicle depending on brake options. If
a new master cylinder is being installed, be sure it
is the correct master cylinder for the type of brake
system the vehicle is equipped with.
CAUTION: When replacing the master cylinder on a
vehicle, a NEW vacuum seal MUST be installed on
the master cylinder.
(1) Install a NEW vacuum seal on master cylinder
making sure seal fits squarely in groove of master
cylinder casting.
(2) Position master cylinder on studs of power
brake booster, aligning booster push rod with master
cylinder piston.
(3) Install the two master cylinder mounting nuts
(Fig. 49). Tighten both mounting nuts to a torque of
25 N´m (225 in. lbs.).
CAUTION: When tightening the primary and sec-
ondary brake tube nuts at master cylinder, be sure
brake tubes do not contact any other components
within the vehicle and that there is slack in the flex-
ible sections of the tubes. This is required due to
the movement between the ABS ICU and the master
cylinder while the vehicle is in motion.
(4) Connect primary and secondary brake tubes to
master cylinder primary and secondary ports (Fig.
48). Brake tubes must be held securely when tight-
ened to control orientation of flex section. Tighten
tube nuts to a torque of 17 N´m (145 in. lbs.).
(5) Install wiring harness connector to brake fluid
level switch mounted in brake fluid reservoir (Fig.
48).
(6) Install battery, clamp and nut.
(7) Install battery shield.
(8) Connect positive battery terminal.
(9) Connect negative battery terminal.
(10) Fill master cylinder with clean, fresh Mopart
Brake Fluid or equivalent.
(11) Road test vehicle to ensure proper operation of
brakes.
Fig. 50 Fluid Reservoir Retaining Pins (Typical)
1 - FLUID RESERVOIR
2 - RETAINING PINS
3 - MASTER CYLINDER
Fig. 51 Master Cylinder To Fluid Reservoir Seal
Grommets
1 - SEAL GROMMETS
2 - MASTER CYLINDER
5 - 36 BRAKES - BASERS
MASTER CYLINDER (Continued)
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DIAGNOSIS AND TESTING - POWER BRAKE
BOOSTER
BASIC TEST
(1) With engine off, depress and release the brake
pedal several times to purge all vacuum from the
power brake booster.
(2) Depress and hold the pedal with light effort (15
to 25 lbs. pressure), then start the engine.
The pedal should fall slightly, then hold. Less effort
should be needed to apply the pedal at this time. If
the pedal fell as indicated, perform the VACUUM
LEAK TEST listed after the BASIC TEST. If the
pedal did not fall, continue on with this BASIC TEST.
(3) Disconnect the vacuum hose on the vacuum
check valve, then place a vacuum gauge in line
between the vacuum hose and the valve.
(4) Start the engine.
(5) When the engine is at warm operating temper-
ature, allow it to idle and check the vacuum at the
gauge.
If the vacuum supply is 12 inches Hg (40.5 kPa) or
more, the power brake booster is defective and must
be replaced. If the vacuum supply is below 12 inches
Hg, continue on with this BASIC TEST.
(6) Shut off the engine.
(7) Connect the vacuum gauge to the vacuum ref-
erence port on the engine intake manifold.
(8) Start the engine and observe the vacuum
gauge.
If the vacuum is still low, check the engine tune
and repair as necessary. If the vacuum is above 12
inches Hg, the hose or check valve to the booster has
a restriction or leak.
Once an adequate vacuum supply is obtained,
repeat the BASIC TEST.
VACUUM LEAK TEST
(1) Disconnect the vacuum hose on the vacuum
check valve, then place a vacuum gauge in line
between the vacuum hose and the valve.
(2) Start the engine.
(3) Allow the engine to warm up to normal operat-
ing temperature and engine idle.
(4) Using vacuum line pliers, close off the vacuum
supply hose near the booster, but before the vacuum
gauge, then observe the vacuum gauge.
If the vacuum drop exceeds 1.0 inch Hg (3.3 kPa)
in one minute, repeat the above steps to confirm the
reading. The vacuum loss should be less than 1.0
inch Hg in one minute time span. If the loss is more
than 1.0 inch Hg, replace the power brake booster. If
it is not, continue on with this test.
(5) Remove the pliers from the hose temporarily.
(6) Apply light effort (approximately 15 lbs. of
force) to the brake pedal and hold the pedal steady.Do not move the pedal once the pressure is applied
or the test results may vary.
(7) Have an assistant reattach the vacuum line
pliers to the vacuum supply hose.
(8) Allow 5 seconds for stabilization, then observe
the vacuum gauge.
If the vacuum drop exceeds 3.0 inches Hg (10 kPa)
in 15 seconds, repeat the above steps to confirm the
reading. The vacuum loss should be less than 3.0
inches Hg in 15 seconds time span. If the loss is
more than 3.0 inches Hg, replace the power brake
booster. If it is not, the booster is not defective.
(9) Remove the pliers and vacuum gauge.
REMOVAL - POWER BRAKE BOOSTER
CAUTION: Reserve vacuum in power brake booster
must be pumped down (removed) before removing
master cylinder from booster. This is necessary to
prevent booster from sucking in any contamination
as master cylinder is removed. This can be done
simply by pumping the brake pedal, with the vehi-
cle's engine not running, until a firm feeling brake
pedal is achieved.
(1) With engine not running, pump the brake
pedal until a firm pedal is achieved (4-5 strokes).
(2) Remove negative battery cable terminal from
battery.
(3) Remove positive battery cable terminal from
battery.
(4) Remove battery thermal guard shield.
(5) Remove battery clamp, nut and battery from
the battery tray.
(6) Remove screw securing engine coolant filler
tube to battery tray.
(7) If the vehicle is equipped with speed control,
disconnect the vacuum hose at the vacuum tank built
into the battery tray.
(8) Remove the two nuts and one bolt securing bat-
tery tray in place. Remove battery tray.
(9) If vehicle is equipped with speed control:
(a) Disconnect wiring harness connector from
the speed control servo.
(b) Remove the two servo mounting nuts.
(c) Lay speed control servo off to the side, out of
the way.
(10) Remove the wiper module (unit). (Refer to 8 -
ELECTRICAL/WIPERS/WASHERS/WIPER MOD-
ULE - REMOVAL)
(11) Disconnect wiring harness connector from
brake fluid level switch in master cylinder fluid res-
ervoir (Fig. 54).
5 - 38 BRAKES - BASERS
POWER BRAKE BOOSTER (Continued)
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CAUTION: The master cylinder (and its rear seal) is
used to create the seal for holding vacuum in the
vacuum booster. The vacuum seal on the master
cylinder MUST be replaced with a NEW seal when-
ever the master cylinder is removed from the vac-
uum booster.
CAUTION: When removing the vacuum seal from
the master cylinder do not use a sharp tool.
(8) Using a soft tool such as a trim stick, remove
the vacuum seal from the master cylinder mounting
flange.
(9) Install a NEW vacuum seal on rear mounting
flange of the master cylinder (Fig. 60).
(10) Position master cylinder on studs of booster,
aligning push rod on booster with master cylinder
piston.
(11) Install the two nuts mounting the master cyl-
inder to the booster (Fig. 55). Tighten both mounting
nuts to a torque of 25 N´m (225 in. lbs.).
(12) Connect wiring harness connector to brake
fluid level switch in the master cylinder fluid reser-
voir (Fig. 54).
(13) Connect primary and secondary brake tubes
to ABS ICU or non-ABS junction block (Fig. 55).
Tighten the tube nuts to 17 N´m (145 in lbs.).
(14) Install wiper module (unit). (Refer to 8 -
ELECTRICAL/WIPERS/WASHERS/WIPER MOD-
ULE - INSTALLATION)
(15) If equipped with speed control, install speed
control servo and connect wiring connector. Tighten
the mounting nuts to a torque of 14 N´m (124 in.
lbs.).(16) Install the battery tray. Install the two nuts
and one bolt attaching the battery tray to the vehicle.
Tighten the bolt and nuts to a torque of 14 N´m (124
in. lbs.).
(17) If vehicle is equipped with speed control, con-
nect the servo vacuum hose to the vacuum tank on
the battery tray.
(18) Install the air inlet resonator and hoses as an
assembly on the throttle body and air cleaner hous-
ing. Securely tighten hose clamp at air cleaner hous-
ing and throttle body.
(19) Secure the engine coolant filler neck to the
battery tray with its mounting screw.
(20) Install the battery, clamp and mounting nut.
(21) Install the positive battery cable on the bat-
tery.
(22) Install the negative battery cable on the bat-
tery.
(23) Install the battery thermal guard shield.
(24) Bleed the base brakes as necessary. (Refer to
5 - BRAKES - STANDARD PROCEDURE)
(25) Road test vehicle to ensure operation of the
brakes.
PROPORTIONING VALVE
DESCRIPTION - PROPORTIONING VALVE
(HEIGHT SENSING)
NOTE: Only vehicles without antilock brakes (ABS)
have a proportioning valve. Vehicles with ABS uti-
lize electronic brake distribution which is controlled
through the ABS integrated control unit.
Vehicles not equipped with ABS use a height sens-
ing proportioning valve. It is mounted to the body of
the vehicle above the rear axle (Fig. 61). It has an
actuator lever that attaches to the rear axle and
moves with the axle to help the valve sense the vehi-
cle height.
CAUTION: The height sensing proportioning valve
is not adjustable. No attempt should be made to
adjust it. It is replaced as a complete assembly.
CAUTION: The use of after-market load leveling or
load capacity increasing devices on this vehicle are
prohibited. Using air shock absorbers or helper
springs on this vehicle will cause the height sens-
ing proportioning valve to inappropriately reduce
the hydraulic pressure to the rear brakes. This inap-
propriate reduction in hydraulic pressure potentially
could result in increased stopping distance of the
vehicle.
Fig. 60 Vacuum Seal (Typical)
1 - MASTER CYLINDER ASSEMBLY
2 - VACUUM SEAL
RSBRAKES - BASE5-41
POWER BRAKE BOOSTER (Continued)
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