2002 CHRYSLER CARAVAN air condition

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Page 509 of 2399

CHRYSLER CARAVAN 2002 Service Manual CONDITION POSSIBLE CAUSES CORRECTION
FOG LAMPS ARE DIM
WITH ENGINE
RUNNING ABOVE IDLE1. Charging system output too low. 1. Test and repair charging system. Refer to
Electrical, Charging.
2. Poor light

Page 513 of 2399

CHRYSLER CARAVAN 2002 Service Manual (4) Install the headlamp unit.
(5) Connect the battery negative cable.
HEADLAMP
DIAGNOSIS AND TESTING - HEADLAMP
When a vehicle experiences problems with the
headlamp system, verify the condition of t

(4) Install the headlamp unit.
(5) Connect the battery negative cable.
HEADLAMP
DIAGNOSIS AND TESTING - HEADLAMP
When a vehicle experiences problems with the
headlamp system, verify the condition of the battery
connections, fuses, charging system, headlamp bulbs,
wire connectors, relay, high beam switch, dimmer
switch, and headlamp switch. Refer to the appropri-
ate wiring information.
Each vehicle is equipped with various lamp assem-
blies. A good ground is necessary for proper lighting
operation. Grounding is provided by the lamp socket
when it comes in contact with the metal body, or
through a separate ground wire.
When changing lamp bulbs check the socket for
corrosion. If corrosion is present, clean it with a wire
brush.
When it is necessary to remove components to ser-
vice another, it should not be necessary to apply
excessive force or bend a component to remove it.
Before damaging a trim component, verify hidden
fasteners or captured edges are not holding the com-
ponent in place.
HEADLAMP DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
HEADLAMPS ARE DIM
WITH ENGINE IDLING
OR IGNITION TURNED
OFF.1. Loose or corroded battery
cables.1. Clean and secure battery cable clamps and
posts.
2. Loose or worn generator drive
belt.2. Adjust or replace generator drive belt.
3. Charging system output too low. 3. Test and repair charging system, refer to
Electrical, Charging
4. Battery has insufficient charge. 4. Test battery state-of-charge, refer to
Electrical, Battery System.
5. Battery is sulfated or shorted. 5. Load test battery, refer to Electrical, Battery
System.
6. Poor lighting circuit Z343/Z344-
ground.6. Test for voltage drop across Z343/Z344-
ground locations, refer to Electrical, Wiring
Diagram Information.
HEADLAMP BULBS
BURN OUT
FREQUENTLY.1. Integrated Power Module (IPM)
not controlling voltage.1. Test and repair Integrated Power Module.
2. Loose or corroded terminals or
splices in circuit.2. Inspect and repair all connectors and splices.
Refer to Electrical, Wiring Information.
Fig. 11 FRONT POSITION LAMP
1 - TURN SIGNAL LAMP
2 - HIGH BEAM LAMP
3 - FRONT POSITION LAMP
4 - LOW BEAM LAMP
8L - 12 LAMPS/LIGHTING - EXTERIORRS
FRONT POSITION LAMP - EXPORT (Continued)
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Page 514 of 2399

CHRYSLER CARAVAN 2002 Service Manual CONDITION POSSIBLE CAUSES CORRECTION
HEADLAMPS ARE DIM
WITH ENGINE
RUNNING ABOVE IDLE.1. Charging system output too low. 1. Test and repair charging system, refer to
Electrical, Wiring Information.
2.

Page 516 of 2399

CHRYSLER CARAVAN 2002 Service Manual HEADLAMP LEVELING MOTOR
- EXPORT
DIAGNOSIS AND TESTING - HEADLAMP LEVELING MOTOR - EXPORT
HEADLAMP LEVELING MOTOR DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
ONE MOTOR DOES NOT
OPERATE.1. Poor elec

Page 531 of 2399

CHRYSLER CARAVAN 2002 Service Manual from Fahrenheit to Celsius by selecting the desired
U.S./Metric option from the customer programmable
features. The displayed temperature is not an instant
reading of conditions, but an average temper

from Fahrenheit to Celsius by selecting the desired
U.S./Metric option from the customer programmable
features. The displayed temperature is not an instant
reading of conditions, but an average temperature. It
may take the temperature display several minutes to
respond to a major temperature change, such as driv-
ing out of a heated garage into winter temperatures.
When the ignition switch is turned to the Off posi-
tion, the last displayed temperature reading stays in
the electronic control modules (CT, CMTC, EVIC)
memory. When the ignition switch is turned to the
On position again, the electronic module will display
the memory temperature for one minute; then update
the display to the current average temperature read-
ing within five minutes.
The temperature function is supported by an ambi-
ent temperature sensor. The sensor is mounted out-
side the passenger compartment near the front and
center of the vehicle, and is hard wired to the Front
Control Module (FCM). The FCM sends temperature
status messages to the module over the J1850 PCI
data bus circuit.
Following are general descriptions of the major
components used in the overhead console. Refer to
Wiring Diagrams for complete circuit schematics.
OPERATION
Refer to the vehicle Owner's Manual for specific
operation of each overhead console and its systems.
DIAGNOSIS AND TESTING - OVERHEAD
CONSOLE
If the problem with the overhead console is an
inaccurate or scrambled display, refer toSelf-Diag-
nostic Testbelow. If the problem with the overhead
console is incorrect Vacuum Fluorescent Display
(VFD) dimming levels, use a DRB IIItscan tool and
the proper Diagnostic Procedures manual to test for
the correct dimming message inputs being received
from the Body Control Module (BCM) or Front Con-
trol Module (FCM) over the J1850 Programmable
Communications Interface (PCI) data bus circuit. If
the problem is a no-display condition, use the follow-
ing procedures. For complete circuit diagrams, refer
toOverhead Consolein the Wiring Diagrams sec-
tion of the service manual.
(1) Check the fused B(+) fuse in the integrated
power module. If OK, go to Step 2. If not OK, repair
the shorted circuit or component as required and
replace the faulty fuse.
(2) Check for battery voltage at the fused B(+) fuse
in the integrated power module. If OK, go to Step 3.
If not OK, repair the open fused B(+) circuit to the
fused B(+) fuse in the integrated power module as
required.(3) Check the fused ignition switch output (run/
start) fuse in the integrated power module. If OK, go
to Step 4. If not OK, repair the shorted circuit or
component as required and replace the faulty fuse.
(4) Turn the ignition switch to the On position.
Check for battery voltage at the fused ignition switch
output (run/start) fuse in the integrated power mod-
ule. If OK, go to Step 5. If not OK, repair the open
fused ignition switch output (run/start) circuit to the
ignition switch as required.
(5) Turn the ignition switch to the Off position.
Disconnect and isolate the battery negative cable.
Remove the overhead console. Check for continuity
between the ground circuit cavity of the roof wire
harness connector for the electronics module and a
good ground. There should be continuity. If OK, go to
Step 6. If not OK, repair the open ground circuit to
ground as required.
(6) Connect the battery negative cable. Check for
battery voltage at the fused B(+) circuit cavity of the
roof wire harness connector for the electronics mod-
ule. If OK, go to Step 7. If not OK, repair the open
fused B(+) circuit to the fused B(+) fuse in the inte-
grated power module as required.
(7) Turn the ignition switch to the On position.
Check for battery voltage at the fused ignition switch
output (run/start) circuit cavity of the roof wire har-
ness connector for the electronics module. If OK,
refer toSelf-Diagnostic Testlater this group for
further diagnosis of the electronics module and the
J1850 PCI data bus circuit. If not OK, repair the
open fused ignition switch output (run/start) circuit
to the fuse in the integrated power module as
required.
SELF-DIAGNOSTIC TEST
A self-diagnostic test is used to determine that the
electronics module is operating properly, and that all
the J1850 PCI data bus messages are being received
for initial operation. Initiate the self-diagnostic test
as follows:
(1) With the ignition switch in the Off position, on
Electronic Vehicle Information Center (EVIC) and
Compass Mini-Trip Computer (CMTC) equipped vehi-
cles simultaneously depress and hold theSTEP and
the RESET buttons. On Compass Temperature
Module (CT) equipped vehicles depress theC/T and
the US/M push buttons.
(2) Turn the ignition switch to the On position.
(3) Following completion of these tests, the elec-
tronics module will display one of the following mes-
sages:
a.Pass Self Test (EVIC only), PASS (CT,
CMTC)- The electronics module is working properly.
b.Failed Self Test (EVIC only), FAIL (CT,
CMTC)- The electronics module has an internal fail-
8M - 2 MESSAGE SYSTEMSRS
OVERHEAD CONSOLE (Continued)
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Page 551 of 2399

CHRYSLER CARAVAN 2002 Service Manual WARNING: USE EXTREME CAUTION WHEN TEST-
ING PINCH SENSOR OPERATION.
FULL OPEN SWITCH
DESCRIPTION
Vehicles equipped with a power liftgate utilize a
full open switch. This switch is located on the gear

WARNING: USE EXTREME CAUTION WHEN TEST-
ING PINCH SENSOR OPERATION.
FULL OPEN SWITCH
DESCRIPTION
Vehicles equipped with a power liftgate utilize a
full open switch. This switch is located on the gear
motor housing (Fig. 5) and is used to signal the
power liftgate module when the liftgate is in the full
open position. Two wires are used from the full open
switch contacts to the gear motor assemblies main
electrical connector.
The full open switch is a serviceable component.
Consult your Mopar parts catalog for a specific part
number.
OPERATION
When the power liftgate reaches the full open posi-
tion, the gear motor housing mounted full open
switch electrical contacts come in contact with each
other. This sends a ground signal to the power lift-
gate control module, telling the module that the lift-
gate has reached the full open position.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.(2) Remove the lift gear and link rod assembly
from the vehicle(Refer to 8 - ELECTRICAL/POWER
DOORS/CONTROL ROD - REMOVAL).
(3) Cut the two wires leading to the full open
switch or back the wires out of the electrical connec-
tor (Fig. 5). Refer to the Wiring section of the service
manual for detailed instructions.
(4) Remove the full open switch retaining screw
and remove the full open switch from the gear motor
housing assembly.
INSTALLATION
(1) Perform a wiring repair on the full open switch
wires following the approved procedure in the Wiring
section of the service manual. Or install new termi-
nals on the wire ends and reinstall in the main lift-
gate motor electrical connector.
(2) Position and install the full open switch retain-
ing screw.
(3) Install the power liftgate lift gear and link rod
assembly. (Refer to 8 - ELECTRICAL/POWER
DOORS/CONTROL ROD - INSTALLATION)
(4) Connect the negative battery cable.
(5) Using an appropriate scan tool, check any
erase any power liftgate control module diagnostic
trouble codes.
(6) Verify power liftgate system and full open
switch operation. Cycle the power liftgate through
one complete open and close cycle, this will allow the
power liftgate control module to relearn its cycle with
the new components.
LIFTGATE MOTOR
DESCRIPTION
Vehicles equipped with a power liftgate, utilize a
liftgate gear motor assembly (Fig. 6). The gear motor
assembly consists of a DC motor, hall effect sensor,
engage actuator, full open switch, lift gear, aluminum
housing, drive gears and wire harness. The gears and
motor portion of the assembly provides the power
and torque required to open or close the liftgate
under the worst case conditions. The hall effect sen-
sor is used to provide the liftgate control module with
a speed reading, which is used to monitor the resis-
tance of liftgate travel. This speed reading also
allows the power liftgate control module to detect
obstructions and move the liftgate accordingly. The
engage actuator is used to toggle between power
open/close mode and full manual mode when desired.
The full open switch is used to let the power liftgate
control module know when the liftgate is approach-
ing the full open position.
Fig. 5 FULL OPEN SWITCH LOCATION
1 - FULL OPEN SWITCH
2 - GEAR MOTOR ASSEMBLY RETAINING BOLT (1 OF 3)
8N - 10 POWER LIFTGATE SYSTEMRS
PINCH SENSOR (Continued)
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Page 583 of 2399

CHRYSLER CARAVAN 2002 Service Manual CAUTION: Do not disconnect the switch from the
rear of the door key cylinder. This switch is a one
time use switch. Once it is removed from the rear of
the switch, it is not reusable and must be repla

CAUTION: Do not disconnect the switch from the
rear of the door key cylinder. This switch is a one
time use switch. Once it is removed from the rear of
the switch, it is not reusable and must be replaced.
Test the switch at the harness connector.
DOOR CYLINDER LOCK SWITCH RESISTANCE
SWITCH POSITION RESISTANCE VALUE
COUNTERCLOCKWISE 5.4K OHMS
NEUTRAL 18.4K OHMS
CLOCKWISE 2K OHMS
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the door trim panel of the effected door
cylinder lock switch (Refer to 23 - BODY/DOOR -
FRONT/TRIM PANEL - REMOVAL).
(3) Close the door window.
(4) Disconnect the door cylinder lock switch wire
connector from the door harness, and wiring clip
from the impact beam.
(5) Remove the outer door handle from the door.
(6) Remove the switch from the key cylinder in the
door handle and remove from vehicle.
INSTALLATION
(1) Install the switch on the key cylinder in the
door handle.
(2) Install the door handle.
(3) Connect the door cylinder lock switch wire con-
nector to the door harness, and the wiring clip to the
impact beam.
(4) Install the door trim panel of the affected door
cylinder lock switch (Refer to 23 - BODY/DOOR -
FRONT/TRIM PANEL - INSTALLATION).
(5) Connect the battery negative cable.
(6) Verify system operation.
DOOR LOCK MOTOR
DIAGNOSIS AND TESTING - DOOR LOCK
MOTOR
Verify battery condition before testing door lock
motor(s) (Refer to 8 - ELECTRICAL/BATTERY SYS-
TEM/BATTERY - DIAGNOSIS AND TESTING).
To determine which motor is faulty, check each
individual door for electrical lock and unlock or dis-
connect the motor connectors one at a time, while
operating the door lock switch. In the event that
none of the motors work, the problem may be caused
by a shorted motor or a bad switch. Disconnecting
the defective motor will allow the others to work.To test an individual door lock motor, disconnect
the electrical connector from the motor. To lock the
door, connect a 12 volt power source to the positive
pin of the lock motor and a ground wire to the other
pin. Refer to the appropriate wiring information. The
wiring information includes wiring diagrams, proper
wire and connector repair procedures, further details
on wire harness routing and retention, as well as
pin-out and location views for the various wire har-
ness connectors, splices and grounds. To unlock the
door reverse the wire connections at the motor pin
terminals. If these results are NOT obtained, replace
the motor.
DOOR LOCK SWITCH
DIAGNOSIS AND TESTING - DOOR LOCK
SWITCH
(1) Remove door trim panel. Refer to Body, Door -
Front, Trim Panel, Removal and Installation.
(2) Disconnect wire connector from back of door
lock switch.
(3) Depress switch to LOCK position.
(4) Using an ohmmeter, test switch resistance
between Pins 2 and 3. Refer to the DOOR LOCK
SWITCH CONTINUITY test and (Fig. 2).
(5) Depress switch to UNLOCK position.
(6) Test resistance between Pins 2 and 3.
(7) Test resistance between pins 2 and 3 while
switch is in its normal unactuated mode.
(8) If resistance values are not within the param-
eters shown replace the door lock switch.
DOOR LOCK SWITCH CONTINUITY
SWITCH
POSITIONCONTINUITY
BETWEENRESISTANCE
VALUE
LOCK 2 and 3 5.3K Ohm 5%
UNLOCK 2 and 3 2.0K Ohm 5%
UNACTUATED 2 and 3 18.3K Ohms
5%
Fig. 2 DOOR LOCK SWITCH
8N - 42 POWER LOCKSRS
DOOR CYLINDER LOCK SWITCH (Continued)
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Page 600 of 2399

CHRYSLER CARAVAN 2002 Service Manual (7) Remove the power seat switch from the out-
board seat cushion side shield.
INSTALLATION
(1) Position the power seat switch onto the out-
board seat cushion side shield.
(2) Install and tighten the

(7) Remove the power seat switch from the out-
board seat cushion side shield.
INSTALLATION
(1) Position the power seat switch onto the out-
board seat cushion side shield.
(2) Install and tighten the screws that secure the
power seat switch to the inside of the outboard seat
cushion side shield. Tighten the screws to 1.5 N´m
(14 in. lbs.).
(3) Reconnect the power seat wire harness connec-
tor to the power seat switch connector receptacle.
(4) Position the outboard seat cushion side shield
onto the seat cushion frame
(5) Install and tighten the screws that secure the
outboard seat cushion side shield to the seat cushion
frame. Tighten the screws to 1.5 N´m (14 in. lbs.).
(6) Install the switch knobs on the switch control
levers, if equipped.
(7) Reconnect the battery negative cable.
MEMORY MIRROR/SEAT
MODULE
DESCRIPTION
Vehicles equipped with the memory mirror/seat
option, utilize a memory module located under the
drivers front seat. This module is basically wired in-
line between the power seat switch and the power
seat track/adjuster motors, or in-line between the
power mirror switch and the power side view mirror.
The MSMM contains a central processing unit that
communicates with other modules on the Program-
mable Communications Interface (PCI) data bus net-
work.
The Memory Seat/Mirror Module (MSMM) receives
hard wired inputs from the driver power seat switch
and the potentiometers on each of the driver side
power seat track motors, or from the power mirror
switch and the potentiometers on the side view mir-
ror. The MSMM receives messages over the PCI data
bus from the Body Control Module (BCM) (memory
switch status), the Powertrain Control Module (PCM)
(vehicle speed status). The MSMM will prevent the
seat memory recall function from being initiated if
the driver side seat belt is buckled, if the transmis-
sion gear selector lever is not in the Park or Neutral
positions, or if the vehicle is moving.
For diagnosis of the MSMM or the PCI data bus, a
DRBIIItscan tool and the proper Diagnostic Proce-
dures manual are recommended. The MSMM cannot
be repaired and, if faulty or damaged, it must be
replaced. Refer toMemory Systemin the Power
Seat or Power Mirror section of this manual for more
information on the memory system option.
OPERATION
When memory system operation is requested
(depressing of the memory switch), a resistor multi-
plexed signal is sent from the memory switch to the
body control module (BCM). The body control module
will then send the appropriate signals out to the
memory/mirror seat module, the memory/mirror seat
module then applies the voltage supply to the power
seat track or side-view mirror if the proper require-
ments are met. The vehicle speed must equal zero
and the transmission must be in park or neutral in
order for the memory system to function.
DIAGNOSIS AND TESTING - MEMORY
MIRROR/SEAT MODULE
Visually inspect the related wiring harness connec-
tors. Look for broken, bent, pushed out, or corroded
terminals. If any of the above conditions are present,
repair as necessary. If not, use a DRB IIItscan tool
and the proper Diagnostic Procedures Manual to test
the memory/mirror seat module. For complete circuit
diagrams, refer toWiring Diagrams.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the driver side front bucket seat
retaining nuts from under the vehicle (Refer to 23 -
BODY/SEATS/SEAT - REMOVAL).
(3) Lift the drivers seat up and out of the mount-
ing holes in the floor pan and lay the seat rearward
to access the module located under the seat. It is not
necessary to disconnect the seat electrical, just use
care not to damage the wiring by over-extending.
(4) Disconnect the memory/mirror seat module
electrical connectors. Depress the retaining tab and
pull straight apart.
(5) Remove the module retaining bolts and remove
the module from the bracket.
INSTALLATION
(1) Position and install the module retaining bolts.
(2) Connect the memory/mirror seat module elec-
trical connectors.
(3) Position the drivers seat in the mounting holes
in the floor pan.
(4) Install the driver side front bucket seat retain-
ing nuts from under the vehicle (Refer to 23 - BODY/
SEATS/SEAT - INSTALLATION).
(5) Connect the battery negative cable.
RSPOWER SEAT SYSTEM8N-59
PASSENGER SEAT SWITCH (Continued)
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