2002 CHRYSLER CARAVAN ignition

RED BRAKE WARNING
INDICATOR
DESCRIPTION
The red BRAKE warning indicator (lamp) is
located in the instrument panel cluster and is used to
indicate a low brake fluid condition or that the park-
ing brake is applied. In addition, the brake warning
indicator is turned on as a bulb check by the ignition
switch every time the ignition switch is placed in the
crank position.
OPERATION
The red BRAKE warning indicator (lamp) is sup-
plied a 12-volt ignition feed anytime the ignition
switch is on. The bulb is then illuminated by com-
pleting the ground circuit either through the switch
on the parking brake lever, the brake fluid level
switch in the master cylinder reservoir, or the igni-
tion switch when it is placed in the crank position.
RSINSTRUMENT CLUSTER8J-13
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OPERATION - TURN SIGNAL SYSTEM.......21
DIAGNOSIS AND TESTING - MULTI-
FUNCTION SWITCH...................22
REMOVAL.............................22
INSTALLATION.........................22
PARK/TURN SIGNAL LAMP
REMOVAL.............................22
INSTALLATION.........................22
PARK/TURN SIGNAL LAMP - EXPORT
REMOVAL.............................22
INSTALLATION.........................23
REAR FOG LAMP - EXPORT
DESCRIPTION.........................23REPEATER LAMP - EXPORT
REMOVAL.............................23
INSTALLATION.........................23
TAIL LAMP
REMOVAL.............................23
INSTALLATION.........................23
TAIL LAMP - EXPORT
REMOVAL.............................23
INSTALLATION.........................24
TAIL LAMP UNIT
REMOVAL.............................24
INSTALLATION.........................24
LAMPS/LIGHTING - EXTERIOR
DESCRIPTION
LAMP SYSTEMS
Lighting circuits are protected by fuses. Lighting
circuits require an overload protected power source,
on/off device, lamps and body ground to operate prop-
erly. Plastic lamps require a wire in the harness to
supply body ground to the lamp socket. Replace sock-
ets and bulbs that are corroded.
Some of the interior and exterior lighting functions
are governed by the Body Control Module (BCM).
The headlamp, dome, and the door ajar switches pro-
vide signals to the BCM. The BCM in turn sends a
Programmable Communication Interface (PCI) bus
message to the Front Control Module (FCM) to
enable the necessary drivers to set the required illu-
mination configuration.
Wire connectors can make intermittent contact or
become corroded. Before coupling wire connectors,
inspect the terminals inside the connector. Male ter-
minals should not be bent or disengaged from the
insulator. Female terminals should not be sprung
open or disengaged from the insulator. Bent and
sprung terminals can be repaired using needle nose
pliers and pick tool. Corroded terminals appear
chalky or green. Corroded terminals should be
replaced to avoid recurrence of the problem symp-
toms.
Begin electrical system failure diagnosis by testing
related fuses in the fuse block and intelligent power
module. Verify that bulbs are in good condition and
test continuity of the circuit ground. Refer to the
appropriate wiring information.
AUTOMATIC HEADLAMP SYSTEM
The Automatic Headlamp system turns the instru-
mentation and exterior illumination lamps ON when
the ambient light levels are Night and the engine
RPM is 450 or above, and OFF when light levels are
Day.
DAYTIME RUNNING LAMPS
Operating the high-beam headlamps at reduced
power provides daytime running lamps, which are
required on all new Canadian vehicles.
HEADLAMPS ON WITH WINDSHIELD WIPERS
For vehicles equipped with the Automatic Head-
lamp System, the instrumentation and exterior illu-
mination lamps will be turned ON when the
headlamp switch is in the AUTO position, RPM >
450 and the windshield wipers have been in the
intermittent, low or high mode of operation for more
than ten seconds. When the windshield wipers are
turned OFF the Body Control Module will determine
if the instrumentation and exterior illumination
lamps should remain ON base upon the current
ambient light level.
HEADLAMP SYSTEM
The configuration of the headlamp system of head-
lamps, park lamps and fog lamps is determined by
the BCM. The BCM determines the lighting configu-
ration as a result of the inputs from the ignition
switch, headlamp switch and multi-function switch. A
PCI bus is transmitted from the BCM to the FCM to
enable the necessary drivers to set the illumination
configuration. Four wires are connected between the
headlamp switch and the BCM. The first wire con-
tains information regarding the position of the head-
lamp switch (Off, Automatic Headlamps, Automatic
Headlamp switch fog, Park with Fog, Head, or Head
with Fog Lamps). The second wire contains informa-
tion regarding the position of the dimmer switch
(Dome Lamp, Daytime Brightness, Dimming Level or
Off). The third wire is a dedicated signal return
(ground) wire. The fourth wire provides power to the
front fog lamp indicator.
HEADLAMP TIME DELAY SYSTEM
The headlamp time delay system is controlled by
the Body Control Module (BCM) via a PCI bus mes-
8L - 2 LAMPS/LIGHTING - EXTERIORRS
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sage transmitted by the BCM to the FCM to turn off
the headlamps.
OPERATION
AUTOMATIC HEADLAMP SYSTEM
Automatic headlamps are controlled by the Body Con-
trol Module (BCM). With the headlamp switch in the
AUTO position, the BCM will control the headlamp, park-
ing, side marker, tail and instrumentation lamps based on
ambient light levels. Ambient light levels are monitored
by the BCM using the Day/Night signal and Electrochro-
matic Mirror (ECM) present from the Compass Mini Trip
(CMTC) located on the front windshield in front of the
rear view mirror ECM. Ambient light readings are aver-
aged to limit cycling the lamps ON and OFF when pass-
ing through areas with varying light levels. The
automatic headlamps will only function when the engine
is running with RPM > 450. When the headlamp switch is
in the AUTO position (Automatic mode), the Headlamp
Time Delay system will function when the ignition switch
is placed in any position other than run/start.
DAYTIME RUNNING LAMPS
Power is reduced using pulse-width modulation to
the high beams, where by the power is switched on
and off rapidly instead of remaining on continuously.
The duration and interval of the power pulses is pro-
grammed into the FCM.
HEADLAMP SYSTEM
The headlamp system will default to headlamps
ON position when ignition switch is ON and when an
open or short circuit failure occurs on the headlamp
switch input. The system will return to normal oper-
ation when the open or short is repaired. A fault will
be reported by the BCM when a failure occurs on the
dimmer or headlamp switch input.
If the exterior lamps are ON and the headlamp
switch is in any position other than OFF or AUTO
and with the ignition switch OFF (LOCK) after 3
minutes the BCM sends a message via PCI bus to
the FCM informing the FCM to turn off the head-
lamps, park lamps and fog lamps. This feature pre-
vents the vehicle battery from being discharged when
the vehicle lights have been left ON.
HEADLAMP TIME DELAY SYSTEM
The headlamp time delay system is activated by
turning the headlamps ON (high or low beam) while
the engine is running, turning the ignition switch
OFF, and then turning the headlamp switch OFF
within 45 seconds. The system will not activate if
more than 45 seconds elapse between ignition switch
OFF and headlamp switch OFF. The BCM will allow
the headlamps to remain ON for 90 seconds (config-urable) before they automatically turn off (If the key
is in the ignition during the headlamp time delay
mode, then both the headlamps and park lamps
(including panel dimming) will be ON). Refer to the
Owner's Manual for more information.
If the headlamp switch is in the Auto Headlamp
Position, the headlamps are ON due to the night sig-
nal from the CMTC and the ignition switch is in any
position other than run/start, the BCM shall enter a
90 second (configurable) Auto Headlamps time delay
mode. If the key is in the ignition during the head-
lamp time delay mode, then both the headlamps and
park lamps (including panel dimming) will be ON. If
the key is not in the ignition, then only the head-
lamps will be ON. The BCM will allow the head-
lamps to remain ON for 90 seconds before they
automatically turn OFF. Refer to the Owner's Man-
ual for more information.
OPTICAL HORN/HIGH BEAMS
When the multi-function switch is pulled to the
first detent (optical horn) signal, the headlamps are
ON, key-in the ignition the BCM shall send a mes-
sage via PCI bus to the FCM to turn on the head-
lamps drivers to illuminate all four filaments (Low
and High beams). When the multi-function switch is
pulled to the second detent (high beam) signal and
the headlamps are ON, the BCM shall send a mes-
sage via PCI bus to the FCM to turn on the head-
lamps drivers. The High Beams are illuminated and
the Low Beams and Fog Lamps (if ON) are extin-
guished. If the headlamps were in the high beam
configuration when power was removed from the
headlamps, the headlamps will be configured as low
beam the next time they are activated.
WARNING
WARNING: EYE PROTECTION SHOULD BE USED
WHEN SERVICING GLASS COMPONENTS. PER-
SONAL INJURY CAN RESULT.
CAUTION: Do not touch the glass of halogen bulbs
with fingers or other possibly oily surface, reduced
bulb life will result. Do not use bulbs other than
those indicated in the Bulb Application table. Dam-
age to lamp and/or Daytime Running Lamp Module
can result. Do not use fuses, circuit breakers or
relays having greater amperage value than indi-
cated on the fuse panel or in the Owners Manual.
CAUTION: Do not use bulbs other than those listed
in the Bulb Application Table. Damage to lamp can
result. Do not touch halogen bulbs with fingers or
other oily surfaces. Bulb life will be reduced.
RSLAMPS/LIGHTING - EXTERIOR8L-3
LAMPS/LIGHTING - EXTERIOR (Continued)
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(3) Install the retaining screws.
(4) Reconnect the battery negative cable.
FOG LAMP
DIAGNOSIS AND TESTING - FOG LAMP
When a vehicle experiences problems with the fog
lamp system, verify the condition of the battery con-
nections, fuses, charging system, fog lamp bulbs, wire
connectors, relay, high beam switch, and headlamp
switch. Refer to the appropriate 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.
FOG LAMP DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
FOG LAMPS 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 Z349/Z248
ground.6. Test for voltage drop across Z349/248
ground locations. Refer to Electrical, Wiring
Information.
FOG LAMP BULBS
BURN OUT
FREQUENTLY1. Charging system output too
high.1. Test and repair charging system. Refer to
Electrical, Charging.
2. Loose or corroded terminals or
splices in circuit.2. Inspect and repair all connectors and splices.
Refer to Electrical, Wiring Information.
Fig. 6 CHMSL BULB
1 - CHMSL UNIT
2 - CHMSL BULB
RSLAMPS/LIGHTING - EXTERIOR8L-7
CENTER HIGH MOUNTED STOP LAMP UNIT (Continued)
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(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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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. Poor lighting circuit Z343/Z344-
ground.2. Test for voltage drop across Z343/Z344-
ground locations, refer to Electrical, Wiring
Information.
3. High resistance in headlamp
circuit.3. Test amperage draw of headlamp circuit.
HEADLAMPS FLASH
RANDOMLY1. Poor lighting circuit Z343/Z344-
ground.1. Test for voltage drop across Z343/Z344-
ground locations, refer to Electrical, Wiring
Information.
2. Variable resistance in headlamp
circuit.2. Test amperage draw of headlamp circuit.
3. Loose or corroded terminals or
splices in circuit.3. Inspect and repair all connectors and splices,
refer to Electrical, Wiring Information.
4. Faulty headlamp switch. 4. Replace headlamp switch.
HEADLAMPS DO NOT
ILLUMINATE.1. No voltage to headlamps. 1. Repair open headlamp circuit, refer to
Electrical, Wiring Information.
2. No Z343/Z344-ground at
headlamps.2. Repair circuit ground, refer to Electrical,
Wiring Information.
3. Broken connector terminal or
wire splice in headlamp circuit.3. Repair connector terminal or wire splice.
4. Faulty or burned out bulb. 4. Replace headlamp bulb(s).
5. Body Control Module
malfunction.5. Refer to appropriate Body Control Module
diagnostics.
6. PCI Bus Communication 6. Verify messages being transmitted by BCM
and received by FCM.
7. IPM/FCM Malfunction. 7. Refer to appropriate IPM/FCM diagnostics.
HEADLAMPS ON WITH
IGNITION IN RUN, WITH
HEADLAMP SWITCH
OFF.1. Faulty headlamp switch. 1. Replace headlamp switch (review BCM
logged faults).
2. Diagnostic tool indicates (4.7 -
5.0V) on headlamp switch input to
BCM.2. Inspect and repair terminals, connectors and
open circuits.
3. PCI Bus Communication. 3. Verify messages being transmitted by BCM
and received by FCM.
RSLAMPS/LIGHTING - EXTERIOR8L-13
HEADLAMP (Continued)
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(4) Reconnect the battery negative cable.
LICENSE LAMP
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove two screws (Fig. 24).
(3) Twist bulb socket and remove (Fig. 25).
(4) Pull bulb from socket.
INSTALLATION
(1) Push bulb into socket.
(2) Install socket into lamp.
(3) Install two screws.
(4) Reconnect the battery negative cable.
MULTI-FUNCTION SWITCH
DESCRIPTION - TURN SIGNAL SYSTEM
The turn signals are actuated with a lever on
Multi-Function Switch, located on the left side of the
steering wheel. The signals are automatically turned
off by a canceling cam (two lobes molded to the clock
spring mechanism). The cam comes in contact with
the cancel actuator on the turn signal (multi-func-
tion) switch assembly. Either cam lobe, pushing on
the cancel actuator, returns the switch to the OFF
position. The multi-function switch is a resistive
MUX switch that feeds inputs to the BCM.
OPERATION - TURN SIGNAL SYSTEM
Lane change signaling is actuated by applying par-
tial turn signal stalk movement toward the direction
desired until the indicator lamps flashes in the
instrument cluster. When the switch stalk is released
the stalk will spring back into the neutral position
turning OFF the turn signal.
With the ignition switch ON and the turn signal
switch stalk actuated left or right, current flows
through the:
²Multi-function switch
²Body Control Module
²Integrated Power Module (IPM)
²Turn indicator lamp
²Front and rear turn signal bulbs.
A chime will sound after the vehicle has traveled a
distance of approximately 1.0 mile and a speed of 15
mph, with the turn signal ON.
Fig. 23 HEADLAMP UNIT
1 - HEADLAMP UNIT
2 - HEADLAMP
3 - PARK/TURN SIGNAL LAMP
4 - WIRE HARNESS RETAINER
Fig. 24 LICENSE PLATE LAMP UNITS
1 - SCREW
2 - LICENSE PLATE LAMP
Fig. 25 LICENSE PLATE LAMP - REMOVE/INSTALL
1 - LICENSE PLATE LAMP UNIT
2 - BULB
RSLAMPS/LIGHTING - EXTERIOR8L-21
HEADLAMP UNIT (Continued)
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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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