2002 CHRYSLER CARAVAN engine

PCM/SKIM PROGRAMMING
When a PCM (JTEC) and the SKIM are replaced
at the same time perform the following steps in
order:
(1) Program the new PCM (JTEC)
(2) Program the new SKIM
(3) Replace all ignition keys and program them to
the new SKIM.
ECM/SKIM PROGRAMMING
When an ECM (Bosch) and the SKIM are replaced
at the same time perform the following steps in
order:
(1) Program the new SKIM
(2) Program the new ECM (Bosch)
PROGRAMMING THE ECM (Bosch)
(1) To program the VIN, connect the DRB III and
turn the ignition on.
(2) Select Engine from the main menu. The DRB
III will require the VIN to be entered before continu-
ing.
(3) Select ENTER to update the VIN. The DRB III
will display the updated VIN.
(4) If the engine is equipped with air conditioning,
the ECM A/C function must be enabled. Enable the
ECM A/C function as follows:
²Using the DRB III select ENGINE, MISCELLA-
NEOUS, then ENABLE/DISABLE A/C
²Push 1 to enable A/C. DRB III screen should dis-
play A/C Activated.
PROGRAMMING THE PCM (JTEC)
The SKIS Secret Key is an ID code that is unique
to each SKIM. This code is programmed and stored
in the SKIM, PCM and transponder chip (ignition
keys). When replacing the PCM it is necessary to
program the secret key into the new PCM using the
DRB III. Perform the following steps to program the
secret key into the PCM.
(1) Turn the ignition switch on (transmission in
park/neutral).
(2) Use the DRB III and select THEFT ALARM,
SKIM then MISCELLANEOUS.
(3) Select PCM REPLACED (GAS ENGINE).
(4) Enter secured access mode by entering the
vehicle four-digit PIN.
(5) Select ENTER to update PCM VIN.
NOTE: If three attempts are made to enter secure
access mode using an incorrect PIN, secured
access mode will be locked out for one hour. To
exit this lockout mode, turn the ignition to the RUN
position for one hour then enter the correct PIN.
(Ensure all accessories are turned off. Also monitorthe battery state and connect a battery charger if
necessary).
(6) Press ENTER to transfer the secret key (the
SKIM will send the secret key to the PCM).
(7) Press Page Back to get to the Select System
menu and select ENGINE, JTEC (diesel only), MIS-
CELLANEOUS, and SRI MEMORY CHECK.
(8) The DRB III will ask, Is odometer reading
between XX and XX? Select the YES or NO button on
the DRB III. If NO is selected, the DRB III will read,
Enter odometer Reading. Enter
the odometer reading from the Instrument Panel and
press ENTER.
PROGRAMMING THE SKIM
(1) Turn the ignition switch on (transmission in
park/neutral).
(2) Use the DRB III and select THEFT ALARM,
SKIM then MISCELLANEOUS.
(3) Select PCM REPLACED (GAS ENGINE).
(4) Program the vehicle four-digit PIN into SKIM.
(5) Select COUNTRY CODE and enter the correct
country.
NOTE: Be sure to enter the correct country code. If
the incorrect country code is programmed into
SKIM, the SKIM must be replaced.
(6) Select YES to update VIN (the SKIM will learn
the VIN from the PCM).
(7) Press ENTER to transfer the secret key (the
PCM will send the secret key to the SKIM).
(8) Program ignition keys to SKIM.
NOTE: If the PCM and the SKIM are replaced at the
same time, all vehicle keys will need to be replaced
and programmed to the new SKIM.
PROGRAMMING IGNITION KEYS TO THE SKIM
(1) Turn the ignition switch on (transmission in
park/neutral).
(2) Use the DRB III and select THEFT ALARM,
SKIM then MISCELLANEOUS.
(3) Select PROGRAM IGNITION KEY'S.
(4) Enter secured access mode by entering the
vehicle four-digit PIN.
NOTE: A maximum of eight keys can be learned to
each SKIM. Once a key is learned to a SKIM it (the
key) cannot be transferred to another vehicle.
If ignition key programming is unsuccessful, the
DRB III will display one of the following messages:
Programming Not Attempted - The DRB III
attempts to read the programmed key status and
there are no keys programmed into SKIM memory.
RGELECTRONIC CONTROL MODULES8Ea-3
ENGINE CONTROL MODULE (Continued)
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Programming Key Failed (Possible Used Key From
Wrong Vehicle) - SKIM is unable to program key due
to one of the following:
²faulty ignition key transponder
²ignition key is programmed to another vehicle.
8 Keys Already Learned, Programming Not Done -
SKIM transponder ID memory is full.
(5) Obtain ignition keys to be programmed from
customer (8 keys maximum).
(6) Using the DRB III, erase all ignition keys by
selecting MISCELLANEOUS and ERASE ALL CUR-
RENT IGN. KEYS.
(7) Program all ignition keys.
Learned Key In Ignition - Ignition key transponder
ID is currently programmed in SKIM memory.
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove left front headlamp module (Refer to 8
- ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
HEADLAMP UNIT - REMOVAL).
(3) Remove lower headlamp assembly mounting
bolt (Fig. 2).(4) Remove ECM upper mounting bolts (Fig. 3).
(5) Lift ECM from radiator support.
(6) Disconnect ECM electrical connectors.
(7) Separate ECM from mounting bracket.
INSTALLATION
(1) Install ECM on mounting bracket.
(2) Connect ECM electrical connectors.
(3) Place ECM and bracket assembly in position on
radiator support.
(4) Install upper and lower mounting bolts.
(5) Install left headlamp module (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
HEADLAMP UNIT - INSTALLATION).
(6) Connect negative battery cable.
(7) Program ECM as necessary (Refer to 8 - ELEC-
TRICAL/ELECTRONIC CONTROL MODULES/EN-
GINE CONTROL MODULE - STANDARD
PROCEDURE).
Fig. 2 ENGINE CONTROL MODULE-LOWER
MOUNTING BOLT
1 - ENGINE CONTROL MODULE (ECM)
2 - INTEGRATED POWER MODULE
3 - ECM LOWER MOUNTING BOLT
Fig. 3 ENGINE CONTROL MODULE-UPPER
MOUNTING BOLTS
1 - BATTERY
2 - INTEGRATED POWER MODULE
3 - ENGINE CONTROL MODULE
4 - RADIATOR SUPPORT
5 - ECM UPPER MOUNTING BOLTS
6 - ECM ELECTRICAL CONNECTORS
8Ea - 4 ELECTRONIC CONTROL MODULESRG
ENGINE CONTROL MODULE (Continued)
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ENGINE SYSTEMS
TABLE OF CONTENTS
page page
BATTERY SYSTEM......................... 1
CHARGING.............................. 21STARTING............................... 28
BATTERY SYSTEM
TABLE OF CONTENTS
page page
BATTERY SYSTEM
DESCRIPTION..........................1
OPERATION............................2
DIAGNOSIS AND TESTING - BATTERY
SYSTEM.............................2
CLEANING.............................5
INSPECTION...........................5
SPECIFICATIONS........................6
SPECIAL TOOLS
BATTERY SYSTEM SPECIAL TOOLS.......7
BATTERY
DESCRIPTION..........................7
OPERATION............................9
DIAGNOSIS AND TESTING - BATTERY.......9
STANDARD PROCEDURE
STANDARD PROCEDURE - SPIRAL PLATE
BATTERY CHARGING..................10
STANDARD PROCEDURE -
CONVENTIONAL BATTERY CHARGING.....11
STANDARD PROCEDURE - OPEN-CIRCUIT
VOLTAGE TEST.......................13
STANDARD PROCEDURE - IGNITION-OFF
DRAW TEST.........................13
STANDARD PROCEDURE - CHECKING
BATTERY ELECTROLYTE LEVEL.........14REMOVAL - BATTERY...................14
INSTALLATION.........................15
BATTERY HOLDDOWN
DESCRIPTION.........................15
OPERATION...........................15
REMOVAL.............................15
INSTALLATION.........................16
BATTERY CABLES
DESCRIPTION.........................16
OPERATION...........................16
DIAGNOSIS AND TESTING - BATTERY CABLE . 16
REMOVAL.............................18
INSTALLATION.........................18
BATTERY TRAY
DESCRIPTION.........................18
OPERATION...........................19
REMOVAL.............................19
INSTALLATION.........................19
THERMOWRAP
DESCRIPTION.........................19
OPERATION...........................20
REMOVAL.............................20
INSTALLATION.........................20
BATTERY SYSTEM
DESCRIPTION
A single 12-volt battery system is standard factory-
installed equipment on this model. All of the compo-
nents of the battery system are located within the
engine compartment of the vehicle. The service infor-
mation for the battery system in this vehicle coversthe following related components, which are covered
in further detail elsewhere in this service manual:
²Battery- The storage battery provides a reli-
able means of storing a renewable source of electrical
energy within the vehicle.
²Battery Cable- The battery cables connect the
battery terminal posts to the vehicle electrical sys-
tem.
RSENGINE SYSTEMS8F-1
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²Battery Holddown- The battery holddown
hardware secures the battery in the battery tray in
the engine compartment.
²Battery Thermowrap- The battery ther-
mowarp insulates the battery to protect it from
engine compartment temperature extremes.
²Battery Tray- The battery tray provides a
secure mounting location in the vehicle for the bat-
tery and an anchor point for the battery holddown
hardware.
For battery system maintenance schedules and
jump starting procedures, see the owner's manual in
the vehicle glove box. Optionally, refer to Lubrication
and Maintenance for the recommended battery main-
tenance schedules and for the proper battery jump
starting procedures. While battery charging can be
considered a maintenance procedure, the battery
charging procedures and related information are
located in the standard procedures section of this ser-
vice manual. This was done because the battery must
be fully-charged before any battery system diagnosis
or testing procedures can be performed. Refer to
Standard procedures for the proper battery charging
procedures.
OPERATION
The battery system is designed to provide a safe,
efficient, reliable and mobile means of delivering and
storing electrical energy. This electrical energy is
required to operate the engine starting system, as
well as to operate many of the other vehicle acces-
sory systems for limited durations while the engine
and/or the charging system are not operating. The
battery system is also designed to provide a reserve
of electrical energy to supplement the charging sys-
tem for short durations while the engine is running
and the electrical current demands of the vehicle
exceed the output of the charging system. In addition
to delivering, and storing electrical energy for the
vehicle, the battery system serves as a capacitor and
voltage stabilizer for the vehicle electrical system. It
absorbs most abnormal or transient voltages caused
by the switching of any of the electrical components
or circuits in the vehicle.
DIAGNOSIS AND TESTING - BATTERY SYSTEM
The battery, starting, and charging systems in the
vehicle operate with one another and must be tested
as a complete system. In order for the engine to start
and the battery to maintain its charge properly, all of
the components that are used in these systems must
perform within specifications. It is important that
the battery, starting, and charging systems be thor-
oughly tested and inspected any time a battery needs
to be charged or replaced. The cause of abnormal bat-
tery discharge, overcharging or early battery failure
must be diagnosed and corrected before a battery is
replaced and before a vehicle is returned to service.
The service information for these systems has been
separated within this service manual to make it eas-
ier to locate the specific information you are seeking.
However, when attempting to diagnose any of these
systems, it is important that you keep their interde-
pendency in mind.
The diagnostic procedures used for the battery,
starting, and charging systems include the most
basic conventional diagnostic methods, to the more
sophisticated On-Board Diagnostics (OBD) built into
the Powertrain Control Module (PCM). Use of an
induction-type milliampere ammeter, a volt/ohmme-
ter, a battery charger, a carbon pile rheostat (load
tester) and a 12-volt test lamp may be required. All
OBD-sensed systems are monitored by the PCM.
Each monitored circuit is assigned a Diagnostic Trou-
ble Code (DTC). The PCM will store a DTC in elec-
tronic memory for any failure it detects. Refer to
Charging System for the proper charging system on-
board diagnostic test procedures.
MICRO 420 ELECTRICAL SYSTEM TESTER
The Micro 420 automotive battery system tester is
designed to help the dealership technicians diagnose
the cause of a defective battery. Follow the instruc-
tion manual supplied with the tester to properly
diagnose a vehicle. If the instruction manual is not
available refer to the standard procedure in this sec-
tion, which includes the directions for using the
Micro 420 electrical system tester.
8F - 2 BATTERY SYSTEMRS
BATTERY SYSTEM (Continued)
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BATTERY SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
THE BATTERY SEEMS
WEAK OR DEAD WHEN
ATTEMPTING TO START
THE ENGINE.1. The electrical system
ignition-off draw is excessive.1. Refer to the IGNITION-OFF DRAW TEST
Standard Procedure for the proper test
procedures. Repair the excessive ignition-off
draw, as required.
2. The charging system is
faulty.2. Determine if the charging system is performing
to specifications. Refer to Charging System for
additional charging system diagnosis and testing
procedures. Repair the faulty charging system, as
required.
3. The battery is discharged. 3. Determine the battery state-of-charge using the
Micro 420 battery tester. Refer to the Standard
Procedures in this section for additional test
procedures. Charge the faulty battery, as
required.
4. The battery terminal
connections are loose or
corroded.4. Refer to Battery Cables for the proper battery
cable diagnosis and testing procedures. Clean
and tighten the battery terminal connections, as
required.
5. The battery has an
incorrect size or rating for
this vehicle.5. Refer to Battery System Specifications for the
proper size and rating. Replace an incorrect
battery, as required.
6. The battery is faulty. 6. Test the battery using the Micro 420 battery
tester. Refer to the Standard Procedures in this
section for additional test procedures. Replace
the faulty battery, as required.
7. The starting system is
faulty.7. Determine if the starting system is performing
to specifications. Refer to Starting System for the
proper starting system diagnosis and testing
procedures. Repair the faulty starting system, as
required.
8. The battery is physically
damaged.8. Inspect the battery for loose terminal posts or a
cracked and leaking case. Replace the damaged
battery, as required.
RSBATTERY SYSTEM8F-3
BATTERY SYSTEM (Continued)
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(4) Inspect the battery thermowrap for tears,
cracks, deformation or other damage. Replace any
battery thermal guard that has been damaged.
(5) Inspect the battery built-in test indicator sight
glass(if equipped) for an indication of the battery con-
dition. If the battery is discharged, charge as
required. Refer to Standard Procedures for the
proper battery built-in indicator test procedures. Also
refer to Standard Procedures for the proper battery
charging procedures.
SPECIFICATIONS
The battery Group Size number, the Cold Cranking
Amperage (CCA) rating, and the Reserve Capacity
(RC) rating or Ampere-Hours (AH) rating can be
found on the original equipment battery label. Be
certain that a replacement battery has the correct
Group Size number, as well as CCA, and RC or AH
ratings that equal or exceed the original equipment
specification for the vehicle being serviced. Battery
sizes and ratings are discussed in more detail below.
²Group Size- The outside dimensions and ter-
minal placement of the battery conform to standards
established by the Battery Council International
(BCI). Each battery is assigned a BCI Group Size
number to help identify a correctly-sized replace-
ment.
²Cold Cranking Amperage- The Cold Crank-
ing Amperage (CCA) rating specifies how much cur-
rent (in amperes) the battery can deliver for thirty
seconds at -18É C (0É F). Terminal voltage must not
fall below 7.2 volts during or after the thirty second
discharge period. The CCA required is generally
higher as engine displacement increases, depending
also upon the starter current draw requirements.
²Reserve Capacity- The Reserve Capacity (RC)
rating specifies the time (in minutes) it takes for bat-
tery terminal voltage to fall below 10.5 volts, at a
discharge rate of 25 amperes. RC is determined with
the battery fully-charged at 26.7É C (80É F). This rat-
ing estimates how long the battery might last after a
charging system failure, under minimum electrical
load.
²Ampere-Hours- The Ampere-Hours (AH) rat-
ing specifies the current (in amperes) that a battery
can deliver steadily for twenty hours, with the volt-
age in the battery not falling below 10.5 volts. This
rating is also sometimes identified as the twenty-
hour discharge rating.
BATTERY CLASSIFICATIONS & RATINGS
Part NumberBCI Group Size
ClassificationCold Cranking
AmperageReserve
CapacityAmpere -
HoursLoad Test
Amperage
4686158AB 34 500 110 Minutes 60 250
4727159AB 34 600 120 Minutes 66 300
4727242AB DIN H6 600 120 Minutes 66 300
5033235AA 34 700 95 Minutes 48 350
Fig. 3 Clean Battery Terminal Post - Typical
1 - TERMINAL BRUSH
2 - BATTERY CABLE
3 - BATTERY
8F - 6 BATTERY SYSTEMRS
BATTERY SYSTEM (Continued)
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SPECIAL TOOLS
BATTERY SYSTEM SPECIAL TOOLS
BATTERY
DESCRIPTION
There are three different batteries available on this
model. Vehicles equipped with a diesel engine utilize
a spiral wound plate designed battery with recombi-
nation technology. This is a maintenance-free battery
that is capable of delivering more power than a con-
ventional battery. This additional power is required
by a diesel engine during cold cranking. Vehicles
equipped with a gasoline engine utilize a conven-
tional battery. Refer to the following information for
detailed differences and descriptions of these batter-
ies.
SPIRAL PLATE BATTERY - DIESEL ENGINE
Spiral plate technology takes the elements of tradi-
tional batteries - lead and sulfuric acid - to the next
level. By tightly winding layers of spiral grids and
acid-permeated vitreous separators into cells, the
manufacturer has developed a battery with more
power and service life than conventional batteries the
same size. The spiral plate battery is completely, per-
manently sealed. Through gas recombination, hydro-
gen and oxygen within the battery are capturedduring normal charging and reunited to form the
water within the electrolyte, eliminating the need to
add distilled water. Therefore, these batteries have
non-removable battery vent caps (Fig. 4). Watercan-
notbe added to this battery.
The acid inside an spiral plate battery is bound
within the vitreous separators, ending the threat of
acid leaks. This feature allows the battery to be
installed in any position anywhere in the vehicle.
Spiral plate technology is the process by which the
plates holding the active material in the battery are
wound tightly in coils instead of hanging flat, like
conventional batteries. This design has a lower inter-
nal resistance and also increases the active material
surface area.
WARNING: NEVER EXCEED 14.4 VOLTS WHEN
CHARGING A SPIRAL PLATE BATTERY. PERSONAL
INJURY AND/OR BATTERY DAMAGE MAY RESULT.
Due to the maintanance-free design, distilled water
cannot be added to this battery. Therefore, if more
than 14.4 volts are used during the spiral plate bat-
tery charging process, water vapor can be exhausted
through the pressure-sensitive battery vents and lost
for good. This can permanently damage the spiral
plate battery. Never exceed 14.4 volts when charging
a spiral plate battery. Personal injury and/or battery
damage may result.
MICRO 420 BATTERY TESTER
Fig. 4 MAINTENANCE-FREE DIESEL ENGINE
BATTERY
RSBATTERY SYSTEM8F-7
BATTERY SYSTEM (Continued)
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CONVENTIONAL BATTERY - GASOLINE ENGINE
Low-maintenance batteriesare used on vehicles
equipped with a gasoline engine, these batteries have
removable battery cell caps (Fig. 5). Watercanbe
added to this battery. Under normal service, the com-
position of this battery reduces gassing and water
loss at normal charge rates. However these batteries
may require additional distilled water after years of
service.
Maintenance-free batteriesare standard facto-
ry-installed equipment on this model. Male post type
terminals made of a soft lead material protrude from
the top of the molded plastic battery case (Fig. 6)to
provide the means for connecting the battery to the
vehicle electrical system. The battery positive termi-
nal post is visibly larger in diameter than the nega-
tive terminal post, for easy identification. The letters
POSandNEGare also molded into the top of the
battery case adjacent to their respective positive and
negative terminal posts for additional identification
confirmation.
This battery is designed to provide a safe, efficient
and reliable means of storing electrical energy in a
chemical form. This means of energy storage allows
the battery to produce the electrical energy required
to operate the engine starting system, as well as to
operate many of the other vehicle accessory systemsfor limited durations while the engine and/or the
charging system are not operating. The battery is
made up of six individual cells that are connected in
series. Each cell contains positively charged plate
groups that are connected with lead straps to the
positive terminal post, and negatively charged plate
groups that are connected with lead straps to the
negative terminal post. Each plate consists of a stiff
mesh framework or grid coated with lead dioxide
(positive plate) or sponge lead (negative plate). Insu-
lators or plate separators made of a non-conductive
material are inserted between the positive and nega-
tive plates to prevent them from contacting or short-
ing against one another. These dissimilar metal
plates are submerged in a sulfuric acid and water
solution called an electrolyte.
Some factory-installed batteries have a built-in test
indicator (hydrometer). The color visible in the sight
glass of the indicator will reveal the battery condi-
tion. For more information on the use of the built-in
test indicator, refer toStandard ProceduresThe
chemical composition of the metal coated plates
within the low-maintenance battery reduces battery
gassing and water loss, at normal charge and dis-
charge rates. Therefore, the battery should not
require additional water in normal service. If the
electrolyte level in this battery does become low, dis-
tilled water must be added. However, rapid loss of
Fig. 5 BATTERY CELL CAP REMOVAL/
INSTALLATION - LOW-MAINTANANCE GASOLINE
ENGINE BATTERY
1 - BATTERY CELL CAP
2 - BATTERY CASE
Fig. 6 Maintenance-Free Battery
1 - POSITIVE POST
2 - VENT
3 - CELL CAP
4 - VENT
5 - CELL CAP
6 - VENT
7 - NEGATIVE POST
8 - INDICATOR EYE (if equipped)
9 - ELECTROLYTE LEVEL
10 - PLATE GROUPS
11 - MAINTENANCE-FREE BATTERY
8F - 8 BATTERY SYSTEMRS
BATTERY (Continued)
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