2002 CHRYSLER CARAVAN radiator

RADIATOR FAN NO. 1 (DIESEL) - GRAY 2 WAY
CAV CIRCUIT FUNCTION
1 N202 12DB/OR RADIATOR FAN NO. 1 CONTROL
2 N201 12DB/LG RADIATOR FAN RELAY NO. 1 OUTPUT
RADIATOR FAN NO. 1 (GAS) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 N23 12DB/DG RADIATOR FAN RELAY OUTPUT
2 Z223 12BK/DG GROUND
RADIATOR FAN NO. 2 (DIESEL) - GRAY 2 WAY
CAV CIRCUIT FUNCTION
1 Z823 12BK GROUND
2 N112 12DB/OR RADIATOR FAN RELAY NO. 2 AND NO. 3 COMMON
OUTPUT
RADIATOR FAN NO. 2 (GAS) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 N23 12DB/DG RADIATOR FAN RELAY OUTPUT
2 Z223 12BK/DG GROUND
RADIATOR FAN RELAY (GAS) - BLACK 4 WAY
CAV CIRCUIT FUNCTION
1 A112 12OR/RD FUSED B(+)
2 N23 12DB/DG RADIATOR FAN RELAY OUTPUT
3 Z723 18BK/DG GROUND
4 N173 16DB/VT RADIATOR FAN RELAY CONTROL
8W - 80 - 96 8W-80 CONNECTOR PIN-OUTSRS
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RADIATOR FAN RELAY NO. 1 (DIESEL) - BLUE 9 WAY
CAV CIRCUIT FUNCTION
1- -
2 N201 12DB/LG RADIATOR FAN RELAY NO. 1 OUTPUT
3- -
4 K342 16BR/WT ECM/PCM RELAY OUTPUT
5- -
6 N210 18DB/DG LOW SPEED RADIATOR FAN RELAY CONTROL
7- -
8 A201 12RD/LG FUSED B(+)
9- -
RADIATOR FAN RELAY NO. 2 (DIESEL) - BLUE 9 WAY
CAV CIRCUIT FUNCTION
1- -
2 N112 12DB/OR RADIATOR FAN RELAY NO. 2 AND NO. 3 COMMON
OUTPUT
3- -
4 K342 16BR/WT ECM/PCM RELAY OUTPUT
5- -
6 N122 18DB/YL HIGH SPEED RADIATOR FAN DUAL RELAY CONTROL
7- -
8 A112 12OR/RD FUSED B(+)
9- -
RADIATOR FAN RELAY NO. 3 (DIESEL) - BLUE 9 WAY
CAV CIRCUIT FUNCTION
1- -
2 Z823 12BK GROUND
3- -
4 K342 16BR/WT ECM/PCM RELAY OUTPUT
5 N112 12DB/OR RADIATOR FAN RELAY NO. 2 AND NO. 3 COMMON
OUTPUT
6 N122 18DB/YL HIGH SPEED RADIATOR FAN DUAL RELAY CONTROL
7- -
8 N202 12DB/OR RADIATOR FAN NO. 1 CONTROL
9- -
RS8W-80 CONNECTOR PIN-OUTS8W-80-97
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8W-91 CONNECTOR/GROUND/SPLICE LOCATION
TABLE OF CONTENTS
page
CONNECTOR/GROUND/SPLICE LOCATION
DESCRIPTION..........................1
CONNECTOR/GROUND/SPLICE
LOCATION
DESCRIPTION
This section provides illustrations identifying con-
nector, ground, and splice locations in the vehicle.Connector, ground, and splice indexes are provided.
Use the wiring diagrams in each section for connec-
tor, ground, and splice identification. Refer to the
appropriate index for the proper figure number. For
items that are not shown in this section N/S is placed
in the Fig. column.
CONNECTORS
CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
A/C Compressor Clutch LTGY Top of A/C Compressor 9, 10, 11, 13, 14
A/C-Heater Control C1 (MTC) BK/RD Rear of Control 15, 18, 20
A/C-Heater Control C2 (MTC) BK/BL Rear of Control 15, 18, 20
A/C Pressure Transducer GY At Throttle Body 9, 11, 12, 13
Accelerator Pedal Position Sensor
(Diesel)BK At Accelerator Pedal 36
Airbag Control Module YL/RD Right Side of Instrument Panel 15, 19, 20
Ambient Temperature Sensor BK On Radiator Closure Panel 1
ATC Remote Sensor Above ATC Control N/S
Automatic Day/Night Mirror BK At Mirror N/S
Autostick Switch BK Rear of Switch 16, 17, 18
Auto Temperature Control C1
(ATC)WT Rear of Control N/S
Auto Temperature Control C2
(ATC)BK Rear of Control N/S
Auto Temperature Control C3
(ATC)Rear of Control N/S
Back-Up Lamp Switch BK On Transmission 12
Battery Temperature Sensor
(Diesel)BK At Battery N/S
Blower Motor Resistor C1 (MTC) BK Right Side of HVAC N/S
Blower Motor Resistor C2 (MTC) Right Side of HVAC N/S
Body Control Module C1 BK Under Left Instrument Panel 35, 36
Body Control Module C2 BK/GN Under Left Instrument Panel 35, 36
Body Control Module C3 BK/WT Under Left Instrument Panel 35, 36
Body Control Module C4 BK/GY Under Left Instrument Panel 15, 16, 25
Body Control Module C5 BK Under Left Instrument Panel 15, 16, 25
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-1
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CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Passenger Heated Seat Module C2 GY At Heated Seat Back N/S
Passenger Heated Seat Module C3 GN At Heated Seat N/S
Passenger Power Seat Front Riser
MotorRD Under Seat N/S
Passenger Power Seat Horizontal
MotorBK Under Seat N/S
Passenger Power Seat Rear Riser
MotorRD Under Seat N/S
Passenger Power Seat Recliner
MotorGN Under Seat N/S
Passenger Power Seat Switch GN At Switch N/S
Passenger Power Window Motor RD At Motor 37
Passenger Power Window Switch BK At Switch 37
Passenger Seatbelt Switch On Seat Harness N/S
Passenger Seatbelt Tensioner On Seat Harness N/S
Pedal Adjust Module At Module N/S
Pedal Adjust Switch At Switch N/S
Power Folding Mirror Switch BK Near Steering Column 26
Power Liftgate Module C1 BK Left Quarter 39, 40
Power Liftgate Module C2 BK/RD Left Quarter 39, 40
Power Liftgate Motor BK Left Quarter 40
Power Mirror Switch BK Rear of Switch 25
Power Outlet NAT Instrument Panel 15, 18, 20
Power Seat Circuit Breaker GY Under Seat N/S
Powertrain Control Module C1 GY/BK LT Fender Side Shield N/S
Powertrain Control Module C2 GY LT Fender Side Shield N/S
Power Window Circuit Breaker GY Left Side Kick Panel 35 36
Radiator Fan No.1 BK Left Side At Motor 1
Radiator Fan No.1 (Diesel) GY Left Side At Motor 2
Radiator Fan No.2 BK Right Side At Motor 1
Radiator Fan No.2 (Diesel) GY Right Side At Motor N/S
Radiator Fan Relay BK Top of Left Front Frame Rail 1
Radiator Fan Relay No. 1 (Diesel) BL Left Front Engine Compartment 2
Radiator Fan Relay No. 2 (Diesel) BL Left Front Engine Compartment 2
Radiator Fan Relay No. 3 (Diesel) BL Left Front Engine Compartment 2
Radio C1 GY Rear of Radio 15
Radio C2 BK Rear of Radio 15
Rear A/C-Heater Unit LT/GN Right Quarter Panel N/S
Rear Automatic Temperature
Control Switch (ATC)BK Rear of Switch 34
Rear Blower Front Control Switch BK Rear of Switch N/S
Rear Blower Motor Power Module
C1Right Quarter N/S
8W - 91 - 8 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
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SPLICE NUMBER LOCATION FIG.
S117 (2.4L) Neat T/O for G101 and G103 10
S117 (3.3L/3.8L) Near T/O for Output Speed Sensor 14
S118 (2.4L) Near T/O for Knock Sensor 10
S119 (2.5L) Near T/O for Engine Starter Motor 11
S120 (2.4L) Near T/O for Oxygen Sensors 9
S120 (3.3L/3.8L) Near T/O for Oxygen Sensors 14
S121 (3.3L/3.8L) Near T/O for Output Speed Sensor 14
S122 (2.4L) In T/O to Engine Starter Motor 10
S122 (3.3L/3.8L) In T/O to Engine Starter Motor 14
S123 In T/O to Low Note Horn 5
S124 (2.4L) Near T/O for Fuel Injector No.2 N/S
S124 (3.3L/3.8L) Near T/O for Fuel Injector No.5 and No.6 N/S
S125 (2.4L) In T/O for Manifold Absolute Pressure Sensor N/S
S126 In Right Headlamp Leveling Assembly N/S
S127 (2.5L) Near T/O for Engine Starter Motor N/S
S128 (2.5L) Near T/O for Engine Starter Motor 11
S129 (2.5L) Near T/O for Battery (+) N/S
S130 (2.5L) Near T/O for Battery (+) N/S
S131 (3.3L/3.8L) Near T/O for Transmission Control Module N/S
S132 (2.5L) Near T/O for Battery (+) N/S
S133 (2.5L) Near T/O for Intelligent Power Module C3 N/S
S134 Near T/O for Controller Antilock Brake N/S
S135 (2.5L) Near T/O for Glow Plug No.2 11
S136 (2.5L) Between T/O for Radiator Fan No.2 and T/O for G102 N/S
S137 (2.5L) Near T/O for A/C Compressor Clutch 11
S138 (2.5L) Between T/O for Radiator Fan No.2 and T/O for G102 N/S
S139 (2.5L) Between T/O for Engine Starter Motor and T/O for
Engine Control Module C112
S141 (2.4L) Near T/O for Powertrain Control Module N/S
S141 (2.5L) Near /t/O for G100 N/S
S141 (3.3L/3.8L) Near T/O for Powertrain Control Module N/S
S142 (3.3L/3.8L) Near T/O for A/C Compressor Clutch 14
S143 (2.5L) Near T/O for Engine Control Module C1 11
S143 (3.3L/3.8L) Near T/O for Intelligent Power Module - C3 N/S
S144 (2.5L) Between T/O for Battery Temperature Sensor and T/O
for C10311
S145 (2.5L) Near T/O for Battery (+) N/S
S148 (2.5L) Near T/O for Engine Starter Motor 11
S150 (2.5L) Between T/O for Battery Temperature Sensor and T/O
for C103N/S
S151 (2.5L) Near T/O for Radiator Fan Relay No.1 2
S152 (2.5L) Near T/O for Left Fog Lamp N/S
S157 (2.5L) Near T/O for Glow Plug No.1 11
8W - 91 - 12 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
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SPLICE NUMBER LOCATION FIG.
S177 In Right Headlamp Wiring Assembly N/S
S179 In Left Headlamp Wiring Assembly N/S
S187 (2.5L) Near T/O for Engine Control Module C1 11
S188 (2.5L) Near T/O for Radiator Fan Relay No.1 2
S201 In T/O to Instrument Panel Speaker 15, 21
S202 Near T/O for Instrument Panel Switch Bank 15, 21
S203 Near T/O for Instrument Panel Switch Bank 15, 21
S204 Near T/O to Instrument Panel Speaker 15, 21
S205 Near T/O for C201 15
S206 Near T/O for Instrument Cluster 15
S207 In A/C Unit Assembly N/S
S208 (RHD) Between T/O for Antenna Connector and T/O for Front
Cigar Lighter21
S209 (RHD) Between T/O for Front Cigar Lighter and T/O for Brake
Transmission Shift Interlock Solenoid21
S210 (RHD) Near T/O for C203 21
S211 In Steering Column Wiring Assembly N/S
S212 In Steering Column Wiring Assembly N/S
S302 In Floor Pan Track Wiring 31
S303 In T/O to Data Link Connector 31
S304 Near T/O for C307 32
S305 Near T/O for Memory Seat/Mirror Module - C2 N/S
S306 In Floor Pan Track Wiring 32
S307 Near T/O for Memory Power Seat Switch N/S
S308 In Floor Pan Track Wiring 31
S309 In Floor Pan Track Wiring 31
S310 Near T/O for C301 30
S311 In Floor Pan Track Wiring 29
S312 Near T/O for C320 N/S
S313 Near T/O for Power Liftgate Module 40
S314 In Floor Pan Track Wiring 29
S315 In Floor Pan Track Wiring 29
S316 In Floor Pan Track Wiring 29
S317 Near T/O for C101 30
S318 Near T/O for Power Seat Circuit Breaker N/S
S319 In Floor Pan Track Wiring 32
S320 Near T/O for C200 31
S321 In T/O to Data Link Connector 31
S322 Near T/O for C301 30
S323 In Floor Pan Track Wiring 31
S324 In Floor Pan Track Wiring 29
S325 In Floor Pan Track Wiring 29
S326 Near T/O for C101 30
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-13
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
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NOTE: Multi-Layer Steel (MLS) head gaskets require
a scratch free sealing surface.
Only use the following for cleaning gasket surfaces:
²Solvent or a commercially available gasket
remover
²Plastic or wood scraper (Fig. 3)
²Drill motor with 3M RolocŸ Bristle Disc (white
or yellow) (Fig. 3)
CAUTION: Excessive pressure or high RPM (beyond
the recommended speed), can damage the sealing
surfaces. The mild (white, 120 grit) bristle disc is
recommended. If necessary, the medium (yellow, 80
grit) bristle disc may be used on cast iron surfaces
with care.
STANDARD PROCEDURE - MEASURING
BEARING CLEARANCE USING PLASTIGAGE
Engine crankshaft bearing clearances can be deter-
mined by use of Plastigage or equivalent. The follow-
ing is the recommended procedure for the use of
Plastigage:
(1) Remove oil film from surface to be checked.
Plastigage is soluble in oil.
(2) Place a piece of Plastigage across the entire
width of the bearing shell in the cap approximately
6.35 mm (1/4 in.) off center and away from the oil
holes (Fig. 4). (In addition, suspected areas can be
checked by placing the Plastigage in the suspected
area). Torque the bearing cap bolts of the bearing
being checked to the proper specifications.(3) Remove the bearing cap and compare the
width of the flattened Plastigage with the metric
scale provided on the package. Locate the band clos-
est to the same width. This band shows the amount
of clearance in thousandths of a millimeter. Differ-
ences in readings between the ends indicate the
amount of taper present. Record all readings taken.
Compare clearance measurements to specs found in
engine specifications (Refer to 9 - ENGINE - SPECI-
FICATIONS).Plastigage generally is accompa-
nied by two scales. One scale is in inches, the
other is a metric scale.
NOTE: Plastigage is available in a variety of clear-
ance ranges. Use the most appropriate range for
the specifications you are checking.
(4) Install the proper crankshaft bearings to
achieve the specified bearing clearances.
REMOVAL - ENGINE ASSEMBLY
(1) Perform fuel pressure release procedure (Refer
to 14 - FUEL SYSTEM/FUEL DELIVERY - STAN-
DARD PROCEDURE)
(2) Disconnect battery negative cable.
(3) Remove air cleaner housing and inlet tube.
(4) Disconnect the fuel line from fuel rail. (Refer to
14 - FUEL SYSTEM/FUEL DELIVERY/FUEL LINES
- STANDARD PROCEDURE)
(5) Disconnect all vacuum hoses.
(6) Drain cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(7) Remove radiator fans. (Refer to 7 - COOLING/
ENGINE/RADIATOR FAN - REMOVAL)
(8) Remove radiator upper and lower hoses.
Fig. 3 Proper Tool Usage For Surface Preparation
1 - ABRASIVE PAD
2 - 3M ROLOCŸ BRISTLE DISC
3 - PLASTIC/WOOD SCRAPER
Fig. 4 Plastigage Placed in Lower ShellÐTypical
1 - PLASTIGAGE
9 - 12 ENGINE 2.4LRS
ENGINE 2.4L (Continued)
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INSTALLATION - ENGINE ASSEMBLY
(1) Position engine and transmission assembly
under vehicle and slowly lower the vehicle over the
engine and transmission.
(2) Align engine and transmission mounts to
attaching points. Install mounting bolts at the right
(Fig. 9) and left mounts (Fig. 10).
(3) Remove safety straps.
(4) Slowly raise vehicle enough to remove the
engine dolly and cradle Special Tools 6135 and 6710.
(5) Install rear mount bracket and rear mount
through bolt. (Refer to 9 - ENGINE/ENGINE
MOUNTING/REAR MOUNT - INSTALLATION)
(6) Install the flex plate to torque converter bolts.
(7) Install structural collar. (Refer to 9 - ENGINE/
ENGINE BLOCK/STRUCTURAL COVER - INSTAL-
LATION)
(8) Install front mount bracket and front mount
through bolt. (Refer to 9 - ENGINE/ENGINE
MOUNTING/FRONT MOUNT - INSTALLATION)
(9) Connect exhaust system to manifold (Fig. 7).
(10) Install crossmember cradle plate (Fig. 6).
(11) Install new oil filter.
(12) Install power steering pump and bracket.(13) Connect power steering supply line to pump
and remove pinch-off pliers.
(14) Connect A/C compressor hoses to compressor.
(15) Install accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION)
(16) Install axle shafts. (Refer to 3 - DIFFEREN-
TIAL & DRIVELINE/HALF SHAFT - INSTALLA-
TION)
(17) Install accessory drive belt splash shield.
(18) Install front wheels and tires.
(19) Remove plugs from transmission cooler hoses
and install transaxle oil cooler line service splice kit.
Refer to instructions included with kit.
(20) Connect the transaxle shift linkage and elec-
trical connectors.
(21) Connect heater hoses (Fig. 5).
(22) Install ground straps.
(23) Connect all engine and throttle body electrical
connections.
(24) Connect all vacuum lines.
(25) Connect the throttle cables.
(26) Connect the fuel line. (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY/QUICK CONNECT FIT-
TING - STANDARD PROCEDURE)
(27) Connect radiator lower and upper hoses.
(28) Install radiator fans. (Refer to 7 - COOLING/
ENGINE/RADIATOR FAN - INSTALLATION)
(29) Fill cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(30) Connect battery cables.
(31) Install air cleaner and inlet hose.
Fig. 9 RIGHT MOUNT TO RAIL AND ENGINE
1 - BOLT - MOUNT TO RAIL 68 N´m (50 ft. lbs.)
2 - BOLT - MOUNT TO ENGINE 54 N´m (40 ft. lbs.)
3 - BOLT - MOUNT TO RAIL (HORIZONTAL) 68 N´m (50 ft. lbs.)
4 - RIGHT ENGINE MOUNT
5 - RIGHT FRAME RAIL
Fig. 10 LEFT MOUNT TO FRAME BRACKET
1 - FRAME BRACKET
2 - FRAME RAIL - LEFT
3 - BOLT
4 - TRANSAXLE MOUNT
9 - 16 ENGINE 2.4LRS
ENGINE 2.4L (Continued)
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