2002 CHRYSLER CARAVAN relay

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Page 1848 of 2399

CHRYSLER CARAVAN 2002 Service Manual TRANSMISSION CONTROL
RELAY
DESCRIPTION
The transmission control relay (Fig. 336) is located
in the Intelligent Power Module (IPM), which is
located on the left side of the engine compartment
between t

Page 2245 of 2399

CHRYSLER CARAVAN 2002 Service Manual FRONT CONTROL PANEL
The front control panel and integral computer is
mounted in the instrument panel.
The instrument panel mounted control and inte-
gral computer contains:
²a power button which allo

FRONT CONTROL PANEL
The front control panel and integral computer is
mounted in the instrument panel.
The instrument panel mounted control and inte-
gral computer contains:
²a power button which allows the system to be
completely turned off.
²rear window defogger on/off switch.
²slide controls for completely independent side-to-
side temperature control of the discharge air. The full
range of temperature that the system can produce in
any mode is available on either side of the vehicle by
independently positioning the slide controls on the
instrument panel.
²air recirculation button. The Recirculate button
contains an LED that illuminates to show when the
function is in operation.
²an air conditioning button that allows the com-
pressor to be turned on/off. The Snowflake button
contains an LED that illuminates to shown when the
function is in operation.
²rotary knobs for front and rear fan speed selec-
tion.
²a rotary knob for mode control.
REAR CONTROL PANEL
A rear control panel centrally mounted on the
headliner has a rotary adjustment for temperature
and fan speed control of the rear unit by intermedi-
ate seat passengers when the front control rear knob
is set to the rear position.
DESCRIPTION - THREE ZONE AUTOMATIC
TEMPERATURE CONTROL
The Three-Zone Automatic Temperature Control
(ATC) allows occupants to select a comfort tempera-
ture, which is the perceived temperature level not
the actual passenger compartment air temperature.
The Three Zone Automatic Temperature Control
system includes a dust and odor air filter. The filter
element is the same size as the air conditioning evap-
orator to ensure ample capacity. A door at the base of
the heater and air conditioning housing below the
glove box provides easy access to the filter element.
The ATC computer utilizes integrated circuitry and
information carried on the Programmable Communi-
cations Interface (PCI) data bus network to monitor
many sensors and switch inputs throughout the vehi-
cle. In response to those inputs, the internal circuitry
and programming of the ATC computer allow it to
control electronic functions and features of the ATC
system. The inputs to the ATC computer are:
²Vehicle Speed/Engine RPM± The ATC com-
puter monitors engine RPM, vehicle speed and Man-
ifold Absolute Pressure information from the PCM.²Coolant Temperature± ATC computer moni-
tors Coolant temperature received from the PCM and
converts it to degrees Fahrenheit.
²Ambient Temperature± ATC computer moni-
tors Ambient temperature from the Compass Mini
Trip Computer (CMTC) and converts it to degrees
Fahrenheit.
²Engine Miscellaneous Sensor Status±ATC
computer monitors A/C disable information from the
PCM.
²Refrigerant Pressure± ATC computer moni-
tors Barometric Pressure, Intake Air Temperature,
High Side Pressure and Methanol Content as broad-
cast by the PCM.
²Door Ajar Status± The ATC computer moni-
tors Driver Front Door, Passenger Front Door, Left
Rear Door, Right Rear Door and Liftgate ajar infor-
mation, as identified by the Body Control Module
(BCM), to determine if all in-car temperatures should
be maintained.
²Dimming± The ATC computer monitors dim-
ming status from the BCM to determine the required
level of brightness and will dim accordingly.
²Vehicle Odometer± The ATC computer moni-
tors the vehicle odometer information from the BCM
to prevent flashing the VF tube icons if the manual
motor calibration or manual cool down tests have
failed. Flashing of the display icons will cease when
the vehicle odometer is greater than 3 miles.
²English Metric± The ATC computer monitors
the English/Metric information broadcast by the
CMTC. The set temp displays for both the front and
rear control heads will be set accordingly.
²Vehicle Identification Number± The ATC
computer monitors the last eight characters of the
VIN broadcast by the PCM and compares it to the
information stored in EEPROM. If it is different, the
new number will be stored over the old one and a
motor calibration shall be initiated.
²A/C System Information± The ATC computer
will send a message for Evaporator Temperature too
Low, Fan Blower Relay status, Evaporator Sensor
Failure, Rear Window Defogger Relay and A/C Select.
FRONT CONTROL PANEL
The front control panel and integral computer is
mounted in the instrument panel.
The instrument panel mounted control and inte-
gral computer contains:
²A power button which allows the system to be
completely turned off. The display is blank when the
system is off.
²Three rocker switches that select comfort tem-
peratures from 15É to 30É C (59É to 85É F), which are
shown in the vacuum-fluorescent digital control dis-
play. If the set temp is 59 and the down button is
24 - 2 HEATING & AIR CONDITIONINGRS
HEATING & AIR CONDITIONING (Continued)
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Page 2250 of 2399

CHRYSLER CARAVAN 2002 Service Manual If coolant flow is verified and the heater floor out-
let temperature is insufficient, a mechanical problem
may exist.
POSSIBLE LOCATION OR CAUSE OF INSUFFICIENT HEAT
²Obstructed cowl air intake.
²O

Page 2251 of 2399

CHRYSLER CARAVAN 2002 Service Manual CONTROLS - FRONT
TABLE OF CONTENTS
page page
A/C HEATER CONTROL
STANDARD PROCEDURE - HEATER-A/C
CONTROL CALIBRATION................8
REMOVAL.............................9
INSTALLATION.................

CONTROLS - FRONT
TABLE OF CONTENTS
page page
A/C HEATER CONTROL
STANDARD PROCEDURE - HEATER-A/C
CONTROL CALIBRATION................8
REMOVAL.............................9
INSTALLATION..........................9
A/C PRESSURE TRANSDUCER
DESCRIPTION - A/C PRESSURE
TRANSDUCER.......................10
OPERATION...........................10
DIAGNOSIS AND TESTING - A/C PRESSURE
TRANSDUCER.......................10
REMOVAL.............................11
INSTALLATION.........................11
BLEND DOOR ACTUATOR
DESCRIPTION.........................11
OPERATION...........................11
REMOVAL.............................12
INSTALLATION.........................12
BLOWER MOTOR RELAY
DESCRIPTION.........................13
OPERATION...........................13
DIAGNOSIS AND TESTING - BLOWER
MOTOR RELAY.......................14
REMOVAL.............................14
INSTALLATION.........................14
BLOWER MOTOR RESISTOR
DESCRIPTION.........................15
OPERATION...........................15
DIAGNOSIS AND TESTING - BLOWER
MOTOR RESISTOR....................15
REMOVAL.............................16
INSTALLATION.........................16
COMPRESSOR CLUTCH
DESCRIPTION.........................16
OPERATION...........................17
STANDARD PROCEDURE
STANDARD PROCEDURE - COMPRESSOR
CLUTCH AIR GAP.....................17STANDARD PROCEDURE - COMPRESSOR
CLUTCH BREAK-IN....................17
REMOVAL.............................17
INSPECTION - COMPRESSOR CLUTCH/COIL . 18
INSTALLATION.........................19
COMPRESSOR CLUTCH COIL
DIAGNOSIS AND TESTING - COMPRESSOR
CLUTCH COIL........................20
COMPRESSOR CLUTCH RELAY
DESCRIPTION.........................21
OPERATION...........................21
DIAGNOSIS AND TESTING - COMPRESSOR
CLUTCH RELAY......................22
REMOVAL.............................22
INSTALLATION.........................22
EVAPORATOR TEMPERATURE SENSOR
DESCRIPTION.........................22
OPERATION...........................23
REMOVAL.............................23
INSTALLATION.........................23
INFRARED TEMPERATURE SENSOR
DESCRIPTION.........................24
OPERATION...........................24
MODE DOOR ACTUATOR
DESCRIPTION.........................24
OPERATION...........................25
REMOVAL.............................25
INSTALLATION.........................25
POWER MODULE
DESCRIPTION.........................26
OPERATION...........................26
REMOVAL.............................26
INSTALLATION.........................27
RECIRCULATION DOOR ACTUATOR
DESCRIPTION.........................27
OPERATION...........................27
REMOVAL.............................28
INSTALLATION.........................28
A/C HEATER CONTROL
STANDARD PROCEDURE - HEATER-A/C
CONTROL CALIBRATION
The heater-A/C control module must be recali-
brated each time an actuator motor or the control
module is replaced. If the vehicle is so equipped, the
calibration procedure also includes rear HVAC posi-
tions for each actuator motor.(1) Turn the ignition switch to the On position.
(2) Simultaneously depress and hold the Power
and Recirculation buttons on the heater-A/C control
for at least five seconds. The manual heater-A/C con-
trol power Light Emitting Diode (LED) and Recircu-
lation LED, or the Automatic Temperature Control
(ATC) heater-A/C control Delay and Recirculation
graphics will begin to flash when the calibration pro-
cedure has begun.
24 - 8 CONTROLS - FRONTRS
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Page 2256 of 2399

CHRYSLER CARAVAN 2002 Service Manual (5) Install and tighten the three screws that secure
the heater core shield to the left end of the heater/air
conditioner housing. Tighten the screws to 2 N´m (17
in. lbs.).
(6) Reinstall the silence

(5) Install and tighten the three screws that secure
the heater core shield to the left end of the heater/air
conditioner housing. Tighten the screws to 2 N´m (17
in. lbs.).
(6) Reinstall the silencer under the driver side end
of the instrument panel. (Refer to 23 - BODY/IN-
STRUMENT PANEL/INSTRUMENT PANEL
SILENCER - INSTALLATION).
(7) Reconnect the battery negative cable.
(8) Perform the heater-A/C control calibration pro-
cedure. (Refer to 24 - HEATING & AIR CONDITION-
ING/CONTROLS - FRONT/A/C-HEATER CONTROL
- STANDARD PROCEDURE - HEATER-A/C CON-
TROL CALIBRATION).
BLOWER MOTOR RELAY
DESCRIPTION
The blower motor relay (Fig. 6) is a International
Standards Organization (ISO) mini-relay. Relays con-
forming to the ISO specifications have common phys-
ical dimensions, current capacities, terminal
patterns, and terminal functions. The ISO mini-relay
terminal functions are the same as a conventional
ISO relay. However, the ISO mini-relay terminal pat-
tern (or footprint) is different, the current capacity is
lower, and the physical dimensions are smaller than
those of the conventional ISO relay. The blower
motor relay is located in the Intelligent Power Mod-
ule (IPM), which is in the engine compartment near
the battery. See the fuse and relay layout mapmolded into the inner surface of the IPM cover for
blower motor relay identification and location.
The black, molded plastic case is the most visible
component of the blower motor relay. Five male
spade-type terminals extend from the bottom of the
base to connect the relay to the vehicle electrical sys-
tem, and the ISO designation for each terminal is
molded into the base adjacent to each terminal.
OPERATION
The blower motor relay is an electromechanical
switch that uses a low current input from the Front
Control Module (FCM) to control the high current
output to the blower motor resistor (manual heater-
A/C control) or blower power module (ATC control).
The movable common feed contact point is held
against the fixed normally closed contact point by
spring pressure. When the relay coil is energized, an
electromagnetic field is produced by the coil wind-
ings. This electromagnetic field draws the movable
relay contact point away from the fixed normally
closed contact point, and holds it against the fixed
normally open contact point. When the relay coil is
de-energized, spring pressure returns the movable
contact point back against the fixed normally closed
contact point. The resistor or diode is connected in
parallel with the relay coil in the relay, and helps to
dissipate voltage spikes and electromagnetic interfer-
ence that can be generated as the electromagnetic
field of the relay coil collapses.
The blower motor relay terminals are connected to
the vehicle electrical system through a receptacle in
the Intelligent Power Module (IPM). The inputs and
outputs of the blower motor relay include:
²The common feed terminal (30) receives a bat-
tery current input from the battery through a B(+)
circuit at all times.
²The coil ground terminal (85) receives a ground
input through the front/rear blower motor relay con-
trol circuit only when the FCM electronically pulls
the control circuit to ground.
²The coil battery terminal (86) receives a battery
current input from the battery through a B(+) circuit
at all times.
²The normally open terminal (87) provides a bat-
tery current output to the blower motor resistor
(manual heater-A/C control) or blower power module
(automatic heater-A/C control) through a fuse in the
IPM on the fused front blower motor relay output cir-
cuit only when the blower motor relay coil is ener-
gized.
²The normally closed terminal (87A) is not con-
nected to any circuit in this application, but provides
a battery current output only when the blower motor
relay coil is de-energized.
Fig. 6 Blower Motor Relay
NUMBER IDENTIFICATION
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
RSCONTROLS - FRONT24-13
BLEND DOOR ACTUATOR (Continued)
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Page 2257 of 2399

CHRYSLER CARAVAN 2002 Service Manual 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 wel

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.
DIAGNOSIS AND TESTING - BLOWER MOTOR
RELAY
The front blower motor relay (Fig. 7) is located in
the Intelligent Power Module (IPM), which is in the
engine compartment near the battery. See the fuse
and relay layout map molded into the inner surface
of the IPM cover for front blower motor relay identi-
fication and location. Remove the relay from the IPM
to perform the following tests:
(1) A relay in the de-energized position should
have continuity between terminals 87A and 30, and
no continuity between terminals 87 and 30. If OK, go
to Step 2. If not OK, replace the faulty relay.
(2) Resistance between terminals 85 and 86 (elec-
tromagnet) should be 75 5 ohms. If OK, go to Step
3. If not OK, replace the faulty relay.
(3) Connect a battery to terminals 85 and 86.
There should now be continuity between terminals
30 and 87, and no continuity between terminals 87A
and 30. If OK, use a DRBIIItscan tool to perform
further diagnosis of the relay circuits. Refer to the
appropriate diagnostic information. If not OK,
replace the faulty relay.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Unlatch and remove the cover from the Intelli-
gent Power Module (IPM) (Fig. 8).
(3) See the fuse and relay layout map molded into
the inner surface of the IPM cover for front blower
motor relay identification and location.
(4) Remove the front blower motor relay from the
IPM by pulling the relay straight up.
INSTALLATION
(1) See the fuse and relay layout map molded into
the inner surface of the Intelligent Power Module
(IPM) cover for front blower motor relay identifica-
tion and location.
(2) Position the front blower motor relay to the
proper receptacle in the IPM.
(3) Align the front blower motor relay terminals
with the terminal cavities in the IPM relay recepta-
cle.
(4) Push down firmly on the front blower motor
relay until the terminals are fully seated in the ter-
minal cavities in the IPM receptacle.
(5) Install and latch the cover onto the IPM.
(6) Reconnect the battery negative cable.
Fig. 7 Blower Motor Relay - Terminal Legend
NUMBER IDENTIFICATION
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
Fig. 8 Intelligent Power Module
1 - BATTERY THERMAL GUARD
2 - INTELLIGENT POWER MODULE
3 - FRONT CONTROL MODULE
24 - 14 CONTROLS - FRONTRS
BLOWER MOTOR RELAY (Continued)
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Page 2260 of 2399

CHRYSLER CARAVAN 2002 Service Manual The compressor clutch plate and pulley unit, or the
clutch coil are available for separate service replace-
ment. The clutch coil zener diode is integral to the
clutch coil pigtail wire and connector

The compressor clutch plate and pulley unit, or the
clutch coil are available for separate service replace-
ment. The clutch coil zener diode is integral to the
clutch coil pigtail wire and connector and, if faulty or
damaged, the clutch electromagnetic coil unit must
be replaced.
OPERATION
The compressor clutch components provide the
means to engage and disengage the compressor from
the engine serpentine accessory drive belt. When the
clutch coil is energized, it magnetically draws the
clutch plate into contact with the clutch pulley and
drives the compressor shaft. When the coil is not
energized, the pulley freewheels on the clutch hub
bearing, which is part of the pulley.
A zener diode is connected in parallel with the
clutch electromagnetic coil. This diode controls the
dissipation of voltage induced into the coil windings
by the collapsing of the electromagnetic fields that
occurs when the compressor clutch is disengaged.
The zener diode dissipates this induced voltage by
regulating a current path to ground. This arrange-
ment serves to protect other circuits and components
from potentially damaging voltage spikes in the vehi-
cle electrical system that might occur if the voltage
induced in the clutch coil windings could not be dis-
sipated.
The compressor clutch engagement is controlled by
several components: the heater-A/C controls in the
passenger compartment, the A/C pressure transducer
on the liquid line, the evaporator temperature sensor
on the expansion valve, the Powertrain Control Mod-ule (PCM) in the engine compartment, and the com-
pressor clutch relay in the Intelligent Power Module
(IPM). The PCM may delay compressor clutch
engagement for up to thirty seconds. (Refer to 8 -
ELECTRICAL/ELECTRONIC CONTROL MOD-
ULES/POWERTRAIN CONTROL MODULE -
DESCRIPTION - PCM OPERATION).
STANDARD PROCEDURE
STANDARD PROCEDURE - COMPRESSOR
CLUTCH AIR GAP
If a new clutch plate and/or clutch pulley are being
used, the air gap between the clutch plate and clutch
pulley must be checked using the following proce-
dure:
(1) Using feeler gauges, measure the air gap
between the clutch plate and the clutch pulley fric-
tion surfaces.
(2) If the air gap is not between 0.5 and 0.9 mm
(0.020 and 0.035 in.), add or subtract shims until the
desired air gap is obtained.
NOTE: The shims may compress after tightening
the compressor shaft bolt. Check the air gap in four
or more places on the clutch plate to verify that the
air gap is still correct. Spin the clutch pulley before
making the final air gap check.
STANDARD PROCEDURE - COMPRESSOR
CLUTCH BREAK-IN
After a new compressor clutch has been installed,
check that the compressor clutch coil is performing to
specifications. (Refer to 24 - HEATING & AIR CON-
DITIONING/CONTROLS - FRONT/COMPRESSOR
CLUTCH COIL - DIAGNOSIS AND TESTING). If
the clutch coil is performing to specifications, per-
form the compressor clutch break-in procedure. This
procedure (burnishing) will seat the opposing friction
surfaces and provide a higher compressor clutch
torque capability.
(1) Set the heater-A/C controls to the A/C mode,
with the blower switch in the highest speed position.
(2) Start the engine and hold the engine speed at
1500 to 2000 rpm.
(3) Cycle the compressor clutch On and Off about
twenty times (five seconds On, then five seconds Off).
REMOVAL
The refrigerant system can remain fully charged
during compressor clutch, pulley, or coil replacement.
Although the compressor assembly must be removed
from its mounting, the compressor clutch can be ser-
vice with the compressor in the vehicle.
Fig. 11 Compressor Clutch - Typical
1 - CLUTCH PLATE
2 - SHAFT KEY (SOME MODELS)
3 - PULLEY AND BEARING
4 - CLUTCH COIL
5 - CLUTCH SHIMS
6 - SNAP RING
7 - SNAP RING
RSCONTROLS - FRONT24-17
COMPRESSOR CLUTCH (Continued)
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Page 2263 of 2399

CHRYSLER CARAVAN 2002 Service Manual NOTE: A new snap ring must be used to secure the
clutch pulley to the compressor. The bevel side of
the snap ring must face outward.
(5) Using snap ring pliers (Special Tool C-4574 or
equivalent), ins

NOTE: A new snap ring must be used to secure the
clutch pulley to the compressor. The bevel side of
the snap ring must face outward.
(5) Using snap ring pliers (Special Tool C-4574 or
equivalent), install the external snap ring (bevel side
facing outward) that secures the clutch pulley to the
front cover of the compressor. Be certain that the
snap ring is fully and properly seated in the groove.
(6) If the original clutch plate and clutch pulley
are to be reused, reinstall the original shim(s) on the
compressor shaft against the shoulder. If a new
clutch plate and/or clutch pulley are being used,
install a trial stack of shims 1.0 mm (0.040 in.) thick
on the compressor shaft against the shoulder.
(7) Install the clutch plate onto the compressor
shaft.
(8) Install and tighten the compressor shaft nut. If
necessary, a band-type oil filter wrench or a strap
wrench can be placed around the clutch plate to aid
in bolt tightening. Tighten the bolt to 17.5 N´m (155
in. lbs.).
(9) If a new clutch plate and/or clutch pulley are
being installed, the air gap between the clutch plate
and clutch pulley must be checked. (Refer to 24 -
HEATING & AIR CONDITIONING/CONTROLS -
FRONT/COMPRESSOR CLUTCH - STANDARD
PROCEDURE - COMPRESSOR CLUTCH AIR GAP).
(10) On models with the 2.4L engine only, loosely
install the four screws that secure the compressor tothe mounting bracket on the engine. Tighten the
screws to 28 N´m (21 ft. lbs.).
(11) On models with the 3.3L and 3.8L engines
only, loosely install the three screws and one nut that
secure the compressor to the engine. Tighten each of
the fasteners using the following sequence to 54 N´m
(40 ft. lbs.).
²The upper screw at the rear of the compressor.
²The lower screw at the rear of the compressor.
²The lower screw at the front of the compressor.
²The upper nut at the front of the compressor.
(12) On models with the 3.3L and 3.8L engines
only, engage the retainer on the engine wire harness
compressor clutch coil take out with the bracket on
the top of the compressor.
(13) Reconnect the engine wire harness connector
for the compressor clutch coil to the coil pigtail wire
connector on the top of the compressor.
(14) Reinstall the serpentine accessory drive belt
onto the front of the engine. (Refer to 7 - COOLING/
ACCESSORY DRIVE/DRIVE BELTS - 2.4L -
INSTALLATION) or (Refer to 7 - COOLING/ACCES-
SORY DRIVE/DRIVE BELTS - 3.3L/3.8L - INSTAL-
LATION).
(15) Lower the vehicle.
(16) Reconnect the battery negative cable.
(17) If a new clutch plate and/or clutch pulley are
being installed, the new clutch components must be
burnished. (Refer to 24 - HEATING & AIR CONDI-
TIONING/CONTROLS - FRONT/COMPRESSOR
CLUTCH - STANDARD PROCEDURE - COMPRES-
SOR CLUTCH BREAK-IN).
COMPRESSOR CLUTCH COIL
DIAGNOSIS AND TESTING - COMPRESSOR
CLUTCH COIL
The air conditioning compressor clutch coil electri-
cal circuit is controlled by the Powertrain Control
Module (PCM) through the compressor clutch relay,
which is located in the Intelligent Power Module
(IPM) in the engine compartment near the battery.
Begin testing of a suspected compressor clutch coil
problem by performing the preliminary checks.
PRELIMINARY CHECKS
(1) If the compressor clutch will not engage, verify
the refrigerant charge level. (Refer to 24 - HEATING
& AIR CONDITIONING/PLUMBING - FRONT/RE-
FRIGERANT - DIAGNOSIS AND TESTING -
REFRIGERANT CHARGE LEVEL). If the refriger-
ant charge level is OK, go to Step 2. If the refriger-
ant charge level is not OK, adjust the refrigerant
charge as required.
Fig. 16 Install Clutch Pulley
1 - PULLEY ASSEMBLY
2 - WOOD BLOCK
24 - 20 CONTROLS - FRONTRS
COMPRESSOR CLUTCH (Continued)
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length coolant trip computer service indicator AUX warning light