2002 CHRYSLER CARAVAN battery location

MASS AIR FLOW (MAF)
SENSOR
DESCRIPTION
The Mass Air Flow (MAF) Sensor is mounted
inline in the air intake between the air filter and the
turbocharger (Fig. 8).
OPERATION
The ECM uses the mass air flow (MAF) sensor to
measure air density. The MAF sensor contains a
ceramic element. A signal voltage is provided to the
element. As engine speed increases, airflow across
the ceramic element increases. Changes in air flow
and air density cause the temperature of the ceramic
element to fluxuate. The ceramic element changes
resistance respectively to changes in temperature.
The change in resistance varies the signal voltage
output to the ECM. The diesel power relay supplies
battery power the to MAF sensor. Ground is providedby the ECM. The MAF sensor signal is provided by
the ECM.
REMOVAL
(1) Disconnect negative battery cable.
(2) Disconnect MAF sensor electrical connector
(Fig. 9).
(3) Loosen MAF sensor retaining clamps (Fig. 9).
(4) Remove MAF sensor from airduct (Fig. 9).
INSTALLATION
(1) Install MAF sensor in airduct (Fig. 9).
(2) Tighten retaining clamps (Fig. 9).
(3) Connect MAF sensor electrical connector (Fig.
9).
(4) Connect negative battery cable.
Fig. 8 MASS AIR FLOW (MAF) SENSOR
Fig. 9 MASS AIR FLOW (MAF) SENSOR LOCATION
1 - MAF SENSOR ELECTRICAL CONNECTOR
2 - RETAINING CLAMPS
3 - MASS AIR FLOW (MAF) SENSOR
4 - AIR CLEANER HOUSING
14a - 16 FUEL INJECTIONRG
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IGNITION SWITCH
REMOVAL
The ignition switch attaches to the lock cylinder
housing on the end opposite the lock cylinder (Fig. 7).
For ignition switch terminal and circuit identifica-
tion, 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.
(1) Disconnect negative cable from battery.
(2) Remove steering column cover retaining screws
(Fig. 8).(3) Remove parking brake release cable from han-
dle (Fig. 9).
(4) Remove screws holding steering column
shrouds (Fig. 10)and remove lower shroud.
Fig. 7 Ignition SwitchÐViewed From Below Column
1 - IGNITION SWITCH
2 - LOCK CYLINDER HOUSING
3 - RETAINING TABS
Fig. 8 Steering Column Cover
1 - SCREWS
2 - STEERING COLUMN COVER
Fig. 9 Parking Brake Release Cable
1 - PARKING BRAKE CABLE
2 - PARKING BRAKE HANDLE
Fig. 10 Steering Column Shroud Screws
1 - STEERING WHEEL
2 - SCREWS
3 - LOWER STEERING COLUMN SHROUD
RSCOLUMN19-15
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ASSEMBLY
(1) Install low/reverse servo assembly (Fig. 208).
(2) Install low/reverse servo snap ring (Fig. 205).
SHIFT INTERLOCK SOLENOID
DESCRIPTION
The Brake/Transmission Shift Interlock system
consists of an electro-magnetic solenoid mounted to
the steering column (Fig. 209). The solenoid's plunger
consists of an integrated hook, which operates the
shift lever pawl (part of shift lever assembly), and a
plunger return spring (Fig. 210). The solenoid also
has an integrated bracket, which facilitates fastening
to the steering column.
OPERATION
The Brake/Transmission Shift Interlock (BTSI)
Solenoid prevents the transmission shift lever from
being moved out of PARK (P) unless the brake pedal
is applied. The BTSI solenoid is hardwired to and
controlled by the Intelligent Power Module (IPM).
Battery voltage is applied to one side of the solenoid
with the ignition key is in either the OFF, ON/RUN,
or START positions (Fig. 211). The ground side of the
solenoid is controlled by a driver within the IPM. It
relies on voltage supplied from the stop lamp switch
to the stop lamp sense circuit within the IPM to tell
when the brake pedal is depressed. When the brake
pedal is depressed, the ground circuit opens, de-ener-
gizing the solenoid. When the brake pedal is
released, the ground circuit is closed, energizing the
solenoid.
Fig. 208 Low/Reverse Servo Assembly
1 - SERVO PISTON
2 - SPRINGFig. 209 Brake/Transmission Shift Interlock (BTSI)
Solenoid Location
1 - BTSI SOLENOID
Fig. 210 Solenoid Plunger and Return Spring
1 - PLUNGER
2 - RETURN SPRING
3 - BTSI SOLENOID
RS31TH AUTOMATIC TRANSAXLE21 - 115
SERVO - LOW/REVERSE (Continued)
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(3) Remove coolant recovery bottle (Fig. 10).
(4) Remove fluid level indicator/tube assembly.
Plug opening to prevent debris from entering trans-
axle.
(5) Using a blade or suitable hose cutter, cut trans-
axle oil cooler lines off flush with fittings. Plug lines
and fittings to prevent debris from entering transaxle
or cooler circuit. A service splice kit will be installed
upon reassembly.
(6) Disconnect input and output shaft speed sensor
connectors (Fig. 11).
(7) Disconnect transmission range sensor (TRS)
connector (Fig. 11).
(8) Disconnect solenoid/pressure switch assembly
connector (Fig. 11).
(9) Disconnect gear shift cable from manual valve
lever and upper mount bracket (Fig. 12).
(10) Disconnect crankshaft position sensor (if
equipped). Remove sensor from bellhousing.
(11) Reposition leak detection pump harness and
hoses.
(12) Remove rear mount bracket-to-transaxle case
bolts (Fig. 13).
(13) Remove transaxle upper bellhousing-to-block
bolts.
(14) Raise vehicle on hoist.
(15) Remove transaxle oil pan and drain fluid into
suitable container.
(16) Remove front wheel/tire assemblies.
(17) Remove left and right halfshaft assemblies.
(Refer to 3 - DIFFERENTIAL & DRIVELINE/HALF
SHAFT - REMOVAL)
Fig. 10 Coolant Recovery Bottle
1 - UPPER BOLT ATTACHING TO BATTERY TRAY
2 - COOLANT RECOVERY CONTAINER
3 - UPPER BOLT
4 - HOSE
5 - LOWER BOLT (QTY. 2)
6 - LEFT SIDE FRAME RAIL
Fig. 11 Component Connector LocationÐTypical
1 - SOLENOID/PRESSURE SWITCH ASSY. CONNECTOR
2 - INPUT SPEED SENSOR CONNECTOR
3 - OUTPUT SPEED SENSOR CONNECTOR
4 - TRANSMISSION RANGE SENSOR CONNECTOR
Fig. 12 Gearshift Cable at Transaxle - Typical
1 - MANUAL VALVE LEVER
2 - GEAR SHIFT CABLE
3 - UPPER MOUNT BRACKET
21 - 170 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)
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(20) Connect solenoid/pressure switch assembly
(Fig. 167).
(21) Connect transmission range sensor connector
(Fig. 167).
(22) Connect input and output speed sensor con-
nectors (Fig. 167).(23) Remove plugs and install transaxle oil cooler
line service splice kit. Refer to instructions included
with kit.
(24) Remove plug and Install fluid level indicator/
tube assembly.
(25) Install coolant recovery bottle (Fig. 168).
(26) Install battery shield.
(27) Connect battery cables.
(28) Fill transaxle with suitable amount of ATF+4
(Automatic Transmission FluidÐType 9602). (Refer
to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC
- 41TE/FLUID - STANDARD PROCEDURE)
Fig. 167 Component Connector Location - Typical
1 - SOLENOID/PRESSURE SWITCH ASSY. CONNECTOR
2 - INPUT SPEED SENSOR CONNECTOR
3 - OUTPUT SPEED SENSOR CONNECTOR
4 - TRANSMISSION RANGE SENSOR CONNECTOR
Fig. 168 Coolant Recovery Bottle
1 - UPPER BOLT ATTACHING TO BATTERY TRAY
2 - COOLANT RECOVERY CONTAINER
3 - UPPER BOLT
4 - HOSE
5 - LOWER BOLT (QTY. 2)
6 - LEFT SIDE FRAME RAIL
RS41TE AUTOMATIC TRANSAXLE21 - 215
41TE AUTOMATIC TRANSAXLE (Continued)
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(6) Remove three (3) solenoid/pressure switch
assembly-to-transaxle case bolts (Fig. 315).
(7) Remove solenoid/pressure switch assembly and
gasket (Fig. 316). Use care to prevent gasket mate-
rial and foreign objects from become lodged in the
transaxle case ports.
INSTALLATION
NOTE: If solenoid/pressure switch assembly is
being replaced, it is necessary to perform the TCM
Quick Learn Procedure. (Refer to 8 - ELECTRICAL/
ELECTRONIC CONTROL MODULES/TRANSMISSION
CONTROL MODULE - STANDARD PROCEDURE)
(1) Install solenoid/pressure switch assembly and
new gasket to transaxle (Fig. 316).
(2) Install and torque three (3) bolts (Fig. 315) to
13 N´m (110 in. lbs.).
(3) Install input speed sensor (Fig. 314) and torque
to 27 N´m (20 ft. lbs.).
(4) Connect input speed sensor connector.
(5) Install solenoid/pressure switch 8-way connec-
tor and torque to 4 N´m (35 in. lbs.).
(6) Install air cleaner assembly.
(7) Connect battery negative cable.
(8) If solenoid/pressure switch assembly was
replaced, perform TCM Quick Learn procedure.
(Refer to 8 - ELECTRICAL/ELECTRONIC CON-
TROL MODULES/TRANSMISSION CONTROL
MODULE - STANDARD PROCEDURE)
SPEED SENSOR - INPUT
DESCRIPTION
The Input Speed Sensor is a two-wire magnetic
pickup device that generates AC signals as rotation
occurs. It is threaded into the transaxle case (Fig. 317) ,
sealed with an o-ring (Fig. 318), and is considered a pri-
mary input to the Transmission Control Module (TCM).
Fig. 315 Solenoid/Pressure Switch Assembly-to-
Case Bolts
1 - BOLTS
2 - SOLENOID AND PRESSURE SWITCH ASSEMBLY
Fig. 316 Solenoid/Pressure Switch Assembly and
Gasket
1 - SOLENOID/PRESSURE SWITCH ASSEMBLY
2 - GASKET
Fig. 317 Input Speed Sensor Location
1 - INPUT SPEED SENSOR
RS41TE AUTOMATIC TRANSAXLE21 - 281
SOLENOID/PRESSURE SWITCH ASSY (Continued)
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OPERATION
The Input Speed Sensor provides information on
how fast the input shaft is rotating. As the teeth of
the input clutch hub pass by the sensor coil (Fig.
319), an AC voltage is generated and sent to the
TCM. The TCM interprets this information as input
shaft rpm.The TCM compares the input speed signal with
output speed signal to determine the following:
²Transmission gear ratio
²Speed ratio error detection
²CVI calculation
The TCM also compares the input speed signal and
the engine speed signal to determine the following:
²Torque converter clutch slippage
²Torque converter element speed ratio
REMOVAL
(1) Disconnect battery negative cable.
(2) If necessary, disconnect and cap off transmis-
sion oil cooler lines.
(3) Disconnect input speed sensor connector.
(4) Unscrew and remove input speed sensor (Fig.
320).
(5) Inspect speed sensor o-ring (Fig. 321) and
replace if necessary.
Fig. 318 O-Ring Location
1 - INPUT SPEED SENSOR
2 - O-RING
Fig. 319 Sensor Relation to Input Clutch Hub
1 - INPUT SPEED SENSOR
2 - TRANSAXLE CASE
3 - INPUT CLUTCH HUB
Fig. 320 Input (Turbine) Speed Sensor
1 - INPUT SPEED SENSOR
21 - 282 41TE AUTOMATIC TRANSAXLERS
SPEED SENSOR - INPUT (Continued)
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INSTALLATION
(1) Verify o-ring is installed into position.
(2) Install and tighten input speed sensor to 27
N´m (20 ft. lbs.).
(3) Connect speed sensor connector.
(4) Connect battery negative cable.
SPEED SENSOR - OUTPUT
DESCRIPTION
The Output Speed Sensor is a two-wire magnetic
pickup device that generates an AC signal as rotation
occurs. It is threaded into the transaxle case (Fig.
322) , sealed with an o-ring (Fig. 323), and is consid-
ered a primary input to the Transmission Control
Module (TCM).
OPERATION
The Output Speed Sensor provides information on
how fast the output shaft is rotating. As the rear
planetary carrier park pawl lugs pass by the sensor
coil (Fig. 324), an AC voltage is generated and sent to
the TCM. The TCM interprets this information as
output shaft rpm.
The TCM compares the input and output speed
signals to determine the following:
²Transmission gear ratio
²Speed ratio error detection
²CVI calculation
Fig. 321 O-ring Location
1 - INPUT SPEED SENSOR
2 - O-RING
Fig. 322 Output Speed Sensor
1 - OUTPUT SPEED SENSOR
Fig. 323 O-Ring Location
1 - OUTPUT SPEED SENSOR
2 - O-RING
RS41TE AUTOMATIC TRANSAXLE21 - 283
SPEED SENSOR - INPUT (Continued)
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