2002 CHRYSLER CARAVAN remote start

DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - SENTRY KEY
IMMOBILIZER SYSTEM
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO ELECTRICAL, RESTRAINTS,
WARNINGS, BEFORE ATTEMPTING COMPONENT
DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
NOTE: The following tests may not prove conclu-
sive in the diagnosis of this system. The most reli-
able, efficient, and accurate means to diagnose the
Sentry Key Immobilizer System involves the use of
a DRB IIITscan tool. Refer to the proper Body Diag-
nostic Procedures Manual.
The Sentry Key Immobilizer System (SKIS) and
the Programmable Communication Interface (PCI)
bus network should be diagnosed using a DRB IIIt
scan tool. The DRB IIItwill allow confirmation that
the PCI bus is functional, that the Sentry Key Immo-
bilizer Module (SKIM) is placing the proper messages
on the PCI bus, and that the Powertrain Control
Module (PCM) is receiving the PCI bus messages.
Refer to the proper Body Diagnostic Procedures man-
ual, and Wiring Diagrams for complete circuit
descriptions and diagrams.
(1) Check the fuses in the Integrated Power Mod-
ule (IPM). If OK, go to Step 2. If not OK, repair the
shorted circuit or component as required and replace
the faulty fuse.
(2) Disconnect and isolate the battery negative
remote cable from the remote terminal. Unplug the
wire harness connector at the SKIM. Check for con-
tinuity between the ground circuit cavity of the
SKIM wire harness connector and a good ground.
There should be continuity. If OK, go to Step 3. If not
OK, repair the open circuit to ground as required.
(3) Connect the battery negative cable. Check for
battery voltage at the fused B(+) circuit cavity of the
SKIM wire harness connector. If OK, go to Step 4. If
not OK, repair the open circuit to the fuse in the
IPM as required.
(4) Turn the ignition switch to the ON position.
Check for battery voltage at the fused ignition switch
output (run/start) circuit cavity of the SKIM wire
harness connector. If OK, use a DRB IIItscan tool
and the proper Body Diagnostic Procedures manual
to complete the diagnosis of the SKIS. If not OK,
repair the open circuit to the fuse in the IPM as
required.
DIAGNOSIS AND TESTING - VEHICLE THEFT
SECURITY SYSTEM
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. Using a DRB
IIItscan tool. Refer to the proper Body Diagnostic
Procedures Manual for test procedures.
HOOD AJAR SWITCH
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Using a small flat blade screwdriver, pry trig-
ger switch from the bracket on the left fender well.
(3) Disconnect the hood ajar switch from the wire
connector and remove from vehicle.
INSTALLATION
(1) Connect the hood ajar switch to the wire conec-
tor.
(2) Press the hood ajar switch into position on the
bracket located on the left inner fender well.
(3) Reconnect the battery negative cable.
(4) Close the hood and check for proper operation.
TRANSPONDER KEY
DESCRIPTION
The Sentry Key Immobilizer System (SKIS) uses a
transponder chip that is integral to each ignition key
(Fig. 1) to communicate with the Sentry Key Immo-
bilizer Module (SKIM). Ignition keys are supplied
with the vehicle when it is shipped from the factory.
The transponder chip is undermolded within the
head of the key. This undermold is hidden beneath
an overmolded rubber cap.
OPERATION
Each Sentry Key has a unique transponder identi-
fication code permanently programmed into it by the
manufacturer. Likewise, the SKIM has a unique
9Secret Key9code programmed into it by the manu-
facturer as well. When a Sentry Key is programmed
into the memory of the SKIM, the SKIM stores the
transponder identification code from the Sentry Key,
and the Sentry Key learns the9Secret Key9code from
the SKIM. Once the Sentry Key learns the9Secret
Key9code of the SKIM, it is also permanently pro-
grammed into the transponder's memory. Therefore,
blank keys for the SKIS must be programmed by the
RSVEHICLE THEFT SECURITY8Q-3
VEHICLE THEFT SECURITY (Continued)
ProCarManuals.com

Component Page
Mid Reading Lamps.................... 8W-44
Mode Door Actuator.................... 8W-42
Multi- Function Switch........... 8W-50, 52, 53
Output Speed Sensor................... 8W-31
Overhead Console..................... 8W-49
Oxygen Sensor 1/1 Upstream............. 8W-30
Oxygen Sensor 1/2 Downstream.......... 8W-30
Park Lamp Relay...................... 8W-10
Park Lamps.......................... 8W-50
Park/Turn Signal Lamps................ 8W-50
Parking Brake Switch.................. 8W-40
Passenger Airbag...................... 8W-43
Positive Temperature Coefficients......... 8W-10
Power Liftgate Module.................. 8W-61
Power Liftgate Motor................... 8W-61
Power Mirror Switch................... 8W-62
Power Mirrors........................ 8W-62
Power Outlet......................... 8W-41
Power Seat Circuit Breaker.............. 8W-10
Power Seat Front Riser Motors........... 8W-63
Power Seat Horizontal Motors............ 8W-63
Power Seat Horizontal Position Sensors.... 8W-63
Power Seat Rear Riser Motors............ 8W-63
Power Seat Rear Riser Position Sensors.... 8W-63
Power Seat Recliner Motors.............. 8W-63
Power Seat Switches................... 8W-63
Power Window Circuit Breaker........... 8W-10
Power Window Motors.................. 8W-60
Power Window Switches................ 8W-60
Powertrain Control Module.............. 8W-30
Radiator Fan Relays................... 8W-42
Radiator Fans........................ 8W-42
Radio Choke.......................... 8W-47
Radio............................... 8W-47
Reading Lamps....................... 8W-44
Rear A/C-Heater Unit.................. 8W-42
Rear Auto Temp Control Switch........... 8W-42
Rear Blower Front Control Switch......... 8W-42
Rear Blower Motor Power Module......... 8W-42
Rear Blower Motor Relay................ 8W-42
Rear Blower Motor..................... 8W-42
Rear Blower Rear Control Switch......... 8W-42
Rear Intrusion Sensor.................. 8W-39Component Page
Rear Lamp Assemblies.................. 8W-51
Rear Mode Motor...................... 8W-42
Rear Power Outlet..................... 8W-41
Rear Temperature Motor................ 8W-42
Rear Washer Pump Motor............... 8W-53
Rear Window Defogger Grid............. 8W-48
Recirculation Door Actuator.............. 8W-42
Remote Keyless Entry Antenna........... 8W-61
Remote Radio Switches................. 8W-47
Repeater Lamps....................... 8W-52
Seat Airbag.......................... 8W-43
Seat Belt Tensioners................... 8W-43
Sentry Key Immobilizer Module.......... 8W-39
Side Impact Airbag Control Modules....... 8W-43
Siren............................... 8W-39
Sliding Door Control Modules............ 8W-61
Sliding Door Latch Sensing Switches....... 8W-61
Sliding Door Lock Motor/Ajar Switches..... 8W-61
Sliding Door Lock Motors............... 8W-61
Sliding Door Motors.................... 8W-61
Solenoid/Pressure Switch Assy............ 8W-31
Speakers............................ 8W-47
Speed Control Servo................... 8W-33
Speed Control Switches................. 8W-33
Splice Information..................... 8W-70
Starter Motor Relay.................... 8W-21
Starter Motor......................... 8W-21
Stop/Turn Signal Relays................ 8W-54
Thatcham Alarm Module................ 8W-39
Throttle Position Sensor................ 8W-30
Torque Converter Clutch Solenoid......... 8W-31
Traction Control Switch................. 8W-35
Trailer Tow Connector.................. 8W-54
Transmission Control Module............ 8W-31
Transmission Range Sensor.............. 8W-31
Turn Signal Lamps.................... 8W-52
TXV Solenoid......................... 8W-42
Vehicle Speed Sensor................... 8W-30
Vent Motors.......................... 8W-60
Visor/Vanity Lamps.................... 8W-44
Washer Fluid Level Switch.............. 8W-53
Water In Fuel Sensor................... 8W-30
Wheel Speed Sensors................... 8W-35
8W - 02 - 2 8W-02 COMPONENT INDEXRS
ProCarManuals.com

Component Page
Headlamp Washer Pump Motor....... 8W-10-26, 52
Headlamp Washer Relay......... 8W-10-26, 52, 63
High Note Horn..................... 8W-10-36
Horn Relay................... 8W-10-17, 36, 59
Ignition Coil........................ 8W-10-42
Ignition Switch . . 8W-10-18, 25, 37, 45, 46, 48, 53, 54,
60
Instrument Cluster................ 8W-10-25, 51
Integrated Power Module . . . 8W-10-3, 4, 5, 13, 15, 16,
17, 18, 19, 20, 21, 22, 23,
24, 25, 26, 27, 28, 29, 30,
31, 32, 33, 36, 37, 38, 39,
40, 41, 42, 43, 44, 45, 46,
47, 48, 49, 51, 52, 53, 54,
55, 56, 57, 58, 59, 60, 61,
62, 63, 64, 65, 66, 68
Leak Detection Pump................. 8W-10-46
Left B-Pillar Switch.................. 8W-10-33
Left Combination Relay............... 8W-10-67
Left Fog Lamp................... 8W-10-15, 27
Left Front Park/Turn Signal
Lamp................... 8W-10-15, 28, 56, 65
Left Headlamp...................... 8W-10-57
Left Headlamp Leveling Motor..... 8W-10-29, 62, 65
Left High Beam Lamp................ 8W-10-58
Left Low Beam Lamp................. 8W-10-58
Left Park Lamp................... 8W-10-29, 65
Left Power Mirror.................... 8W-10-39
Left Rear Lamp Assembly . . . 8W-10-28, 29, 65, 66, 67
Left Repeater Lamp.................. 8W-10-51
Left Side Impact Airbag Control Module . . . 8W-10-62
Left Sliding Door Control Module........ 8W-10-52
Left Stop/Turn Signal Relay............ 8W-10-67
Left Turn Signal Lamp................ 8W-10-56
License Lamp................. 8W-10-28, 29, 65
Lift Pump Motor.................. 8W-10-23, 43
Lift Pump Relay.................. 8W-10-23, 43
Low Note Horn...................... 8W-10-36
Mass Air Flow Sensor................. 8W-10-44
Memory Seat/Mirror Module............ 8W-10-49
Message Center..................... 8W-10-51
Name Brand Speaker Relay....... 8W-10-20, 39, 59
Overhead Console.................... 8W-10-40
Oxygen Sensor 1/1 Upstream........... 8W-10-42
Oxygen Sensor 1/2 Downstream......... 8W-10-42
Park Lamp Relay............ 8W-10-15, 28, 29, 59
Park/Neutral Position Switch........... 8W-10-65
Passenger Door Lock Switch......... 8W-10-31, 33
Passenger Folding Mirror Relay . 8W-10-22, 24, 45, 47
Passenger Heated Seat Module.......... 8W-10-50
Passenger Power Seat Switch........... 8W-10-50
Passenger Power Window Switch........ 8W-10-31
Power Liftgate Module............. 8W-10-26, 52
Power Mirror Switch......... 8W-10-22, 24, 46, 47
Power Outlet....................... 8W-10-36
Component Page
Power Seat Circuit Breaker.......... 8W-10-25, 49
Power Window Circuit Breaker....... 8W-10-16, 31
Power Window Switch................. 8W-10-34
Powertrain Control
Module.... 8W-10-18, 21, 22, 37, 41, 42, 45, 46, 55
PTC4 .......................... 8W-10-20, 39
PTC7 .................... 8W-10-16, 17, 18, 36
Radiator Fan Relay............. 8W-10-26, 51, 55
Radiator Fan Relay No. 1........... 8W-10-13, 44
Radiator Fan Relay No. 2......... 8W-10-26, 44, 51
Radiator Fan Relay No. 3.............. 8W-10-44
Radio.......................... 8W-10-32, 40
Radio Choke..................... 8W-10-20, 39
Rear A/C-Heater Unit.............. 8W-10-19, 38
Rear Blower Motor Power Module..... 8W-10-19, 38
Rear Blower Motor Relay...... 8W-10-19, 20, 38, 63
Rear Power Outlet.............. 8W-10-16, 31, 32
Rear Washer Pump Motor........ 8W-10-16, 31, 68
Rear Window Defogger Grid......... 8W-10-20, 39
Rear Wiper Motor.................... 8W-10-33
Remote Keyless Entry Module........... 8W-10-40
Right B-Pillar Switch................. 8W-10-33
Right Combination Relay.............. 8W-10-67
Right Fog Lamp.................. 8W-10-15, 27
Right Front Park/Turn Signal
Lamp................... 8W-10-15, 28, 56, 60
Right Headlamp..................... 8W-10-57
Right Headlamp Leveling Motor.... 8W-10-29, 60, 62
Right High Beam Lamp............... 8W-10-58
Right Low Beam Lamp................ 8W-10-58
Right Park Lamp................. 8W-10-29, 60
Right Power Mirror................... 8W-10-39
Right Rear Lamp Assembly.... 8W-10-15, 28, 29, 66
Right Repeater Lamp................. 8W-10-51
Right Side Impact Airbag Control Module . . 8W-10-62
Right Sliding Door Control Module....... 8W-10-52
Right Stop/Turn Signal Relay........... 8W-10-67
Right Turn Signal Lamp............... 8W-10-56
Sentry Key Immobilizer
Module............... 8W-10-40, 46, 48, 53, 54
Solenoid/Pressure Switch Assy.......... 8W-10-41
Starter Motor............... 8W-10-13, 14, 18, 37
Starter Motor Relay.......... 8W-10-18, 37, 53, 54
Thatcham Alarm Module...... 8W-10-46, 48, 54, 68
Torque Converter Clutch Solenoid........ 8W-10-46
Trailer Tow Connector.............. 8W-10-28, 65
Transmission Control
Module............ 8W-10-18, 21, 37, 41, 61, 62
Transmission Control Relay.......... 8W-10-21, 41
Transmission Range Sensor............. 8W-10-65
TXV Solenoid....................... 8W-10-38
Vehicle Speed Sensor................. 8W-10-43
Washer Fluid Level Switch............. 8W-10-60
Wiper Module................. 8W-10-16, 30, 59
8W - 10 - 2 8W-10 POWER DISTRIBUTIONRS
ProCarManuals.com

AIRBAG CONTROL MODULE (ORC) - YELLOW/RED 23 WAY
CAV CIRCUIT FUNCTION
1 R54 18LB/YL PASSENGER SEAT BELT TENSIONER LINE 2
2 R56 18LB/DG PASSENGER SEAT BELT TENSIONER LINE 1
3 R62 18LB/PK PASSENGER SQUIB 2 LINE 2
4 R64 18LB/WT PASSENGER SQUIB 2 LINE 1
5 R42 18LB/BR PASSENGER SQUIB 1 LINE 2
6 R44 18LB/OR PASSENGER SQUIB 1 LINE 1
7 R53 18LG/YL DRIVER SEAT BELT TENSIONER LINE 2
8 R55 18LG/DG DRIVER SEAT BELT TENSIONER LINE 1
9 R61 18LG/PK DRIVER SQUIB 2 LINE 1
10 R63 18LG/WT DRIVER SQUIB 2 LINE 2
11 R43 18LG/BR DRIVER SQUIB 1 LINE 1
12 R45 18LG/OR DRIVER SQUIB 1 LINE 2
13 - -
14 F201 18PK/OR FCM OUTPUT (ORC RUN-START DRIVER)
15 F100 18PK/VT FCM OUTPUT (ORC RUN ONLY DRIVER)
16 Z12 18BK/OR GROUND
17 R59 18LG/TN DRIVER SEAT BELT SWITCH LINE 1
18 R57 18LG/GY DRIVER SEAT BELT SWITCH LINE 2
19 R60 18DB/LB PASSENGER SEAT BELT SWITCH LINE 1
20 R58 18LB/GY PASSENGER SEAT BELT SWITCH LINE 2
21 D25 18WT/VT PCI BUS
22 - -
23 - -
AMBIENT TEMP SENSOR (EXCEPT BASE) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 G31 18VT/LG AMBIENT TEMPERATURE SENSOR SIGNAL
2 G931 18VT/BR AMBIENT TEMPERATURE SENSOR RETURN
ATC REMOTE SENSOR (ATC)-4WAY
CAV CIRCUIT FUNCTION
1 F600 20LB/PK PROTECTED IGNITION
2 D40 20WT/LB KDB NO. 2 CLOCK
3 C905 20BR/LB SENSOR RETURN
4 D18 20WT/YL KDB NO. 2 DATA
8W - 80 - 8 8W-80 CONNECTOR PIN-OUTSRS
ProCarManuals.com

RIGHT REAR WHEEL SPEED SENSOR - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 B2 18DG/LB RIGHT REAR WHEEL SPEED SENSOR 12 VOLT
SUPPLY
2 B1 18DG/OR RIGHT REAR WHEEL SPEED SENSOR SIGNAL
RIGHT REMOTE RADIO SWITCH - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 X20 20RD/BK RADIO CONTROL MUX
2 X920 20RD/DB RADIO CONTROL MUX RETURN
RIGHT REPEATER LAMP (BUILT-UP-EXPORT) - GRAY 2 WAY
CAV CIRCUIT FUNCTION
1 A701 18BR/RD FUSED B(+) (HAZARD)
2 L162 20WT/VT RIGHT SIDE REPEATER LAMP FEED
RIGHT SEAT AIRBAG - YELLOW 2 WAY
CAV CIRCUIT FUNCTION
1 R32 18LB/OR (EXCEPT
BUILT-UP-EXPORT)RIGHT SEAT SQUIB LINE 1
1 R34 18WT/BK (BUILT UP EXPORT) RIGHT SEAT SQUIB LINE 2
2 R34 18LB/WT (EXCEPT
BUILT-UP-EXPORT)RIGHT SEAT SQUIB LINE 2
2 R32 18DG/WT (BUILT UP EXPORT) RIGHT SEAT SQUIB LINE 1
RIGHT SIDE IMPACT AIRBAG CONTROL MODULE - YELLOW/RED 7 WAY
CAV CIRCUIT FUNCTION
1 R32 18LB/OR RIGHT SEAT SQUIB LINE 1
2 R34 18LB/WT RIGHT SEAT SQUIB LINE 2
3- -
4 D25 20WT/VT PCI BUS
5 F214 18PK/LG FCM OUTPUT (SIACM RUN-START DRIVER)
6- -
7 Z104 18BK/LG GROUND
8W - 80 - 108 8W-80 CONNECTOR PIN-OUTSRS
ProCarManuals.com

DESCRIPTION - PUMP (2.5L DIESEL)
Hydraulic pressure for the operation of the power
steering gear is provided by a belt driven power
steering pump. The power steering pump is mounted
front lower right corner of the engine (Fig. 13).
The pump has a supply fitting for fluid coming
from the reservoir and a pressure port for exiting
fluid that is headed for the steering gear.
OPERATION
The power steering pump is a constant displace-
ment vane type pump. The 2.4L pump has an inte-
gral fluid reservoir and there is a secondary remote
non-flow reservoir which acts only as a fluid fill and
check point. The 3.3L/3.8L pump houses very little
fluid and is therefore supplied by a remote flow
through reservoir.
WARNING
WARNING: POWER STEERING FLUID, ENGINE
PARTS AND EXHAUST SYSTEM MAY BE
EXTREMELY HOT IF ENGINE HAS BEEN RUNNING.
DO NOT START ENGINE WITH ANY LOOSE OR DIS-
CONNECTED HOSES. DO NOT ALLOW HOSES TO
TOUCH HOT EXHAUST MANIFOLD OR CATALYST.
WARNING: FLUID LEVEL SHOULD BE CHECKED
WITH THE ENGINE OFF TO PREVENT PERSONAL
INJURY FROM MOVING PARTS.
CAUTION
CAUTION: When the system is open, cap all open
ends of the hoses, power steering pump fittings or
power steering gear ports to prevent entry of for-
eign material into the components.
STANDARD PROCEDURE - POWER STEERING
PUMP INITIAL OPERATION
WARNING: FLUID LEVEL SHOULD BE CHECKED
AND ADJUSTED WITH ENGINE OFF TO PREVENT
INJURY FROM MOVING ENGINE COMPONENTS.
CAUTION: Use only MoparTAutomatic Transmis-
sion Fluid (MS-9602) in power steering system. Use
of other MoparTpower steering fluids (MS5931 and
MS9933) should be avoided to ensure peak perfor-
mance of the power steering system under all oper-
ating conditions. Do not overfill.
Read the fluid level through the side of the power
steering fluid reservoir. The fluid level should indi-
cateªFILL RANGEºwhen the fluid is at a temper-
ature of approximately 21ÉC to 27ÉC (70ÉF to 80ÉF).
(1) Wipe the filler cap and area clean, then remove
the cap.
Fig. 1 POWER STEERING PUMP (2.4L)
1 - PULLEY
2 - BRACKET
3 - PRESSURE FITTING
4 - RETURN FITTING
5 - SUPPLY FITTING
Fig. 2 POWER STEERING PUMP (3.3L/3.8L)
1 - SUPPLY FITTING
2 - PRESSURE FITTING
3 - PULLEY
RSPUMP19-37
PUMP (Continued)
ProCarManuals.com