2002 CHRYSLER CARAVAN diagram

CONDITION POSSIBLE CAUSE CORRECTION
(5) FAULTY HORN SWITCH. (5) REPLACE DRIVER AIRBAG
MODULE TRIM COVER.
(6) FAULTY CLOCKSPRING. (6) REPLACE CLOCKSPRING.
(7) FAULTY FRONT
CONTROL MODULE.(7) REFER TO ELECTRONIC
CONTROL MODULES/FRONT
CONTROL MODULE.
FUSE BLOWS WHEN HORN SOUNDS (1) SHORT CIRCUIT IN
HORN OR HORN WIRING.(1) REMOVE HORN RELAY, CHECK
FOR SHORTED HORN OR HORN
WIRING. DISCONNECT HORN WIRE
HARNESS TO ISOLATE SHORT
AND REPAIR AS NECESSARY.
(2) FAULTY CLOCKSPRING. (2) REPLACE CLOCKSPRING.
FUSE BLOWS WITHOUT BLOWING
HORN(1) SHORT CIRCUIT. (1) REMOVE RELAY, INSTALL NEW
FUSE, IF FUSE DOES NOT BLOW
REPLACE HORN RELAY. IF FUSE
BLOWS WITH RELAY REMOVED,
CHECK FOR SHORT TO GROUND
WITH OHMMETER ON CIRCUIT
BETWEEN TERMINALS 30 & 86
AND THE FUSE TERMINAL. REPAIR
AS NECESSARY.
(2) FAULTY CLOCKSPRING. (2) REPLACE CLOCKSPRING.
HORN
DIAGNOSIS AND TESTING - HORN
HORN
(1) Disconnect wire connector at horn.
(2) Using a voltmeter, connect one lead to ground
terminal and the other lead to the positive wire ter-
minal (Fig. 1).
(3) Depress the horn switch, battery voltage
should be present.
(4) If no voltage, refer toHORNS WILL NOT
SOUND. If voltage is OK, go to step Step 5.
(5) Using ohmmeter, test ground wire for continu-
ity to ground.
(6) If no ground repair as necessary.
(7) If wires test OK and horn does not sound,
replace horn.
HORNS SOUND CONTINUOUSLY
CAUTION: Continuous sounding of horns may
cause relay to fail.The horn switch (membrane) sometimes can be the
cause without the switch being depressed.
(1) Remove the horn relay from the intelligent
power module.
(2) Using a continuity tester, test continuity from
the X3 cavity of the horn relay to ground. Refer to
the appropriate wiring information. The wiring infor-
mation includes wiring diagrams, proper wire and
connector repair procedures, details of wire harness
routing and retention, connector pin-out information
and location views for the various wire harness con-
nectors, splices and grounds.
(a) If continuity is detected, proceed to step Step
3.
(b) If NO continuity, replace the horn relay.
(3) Remove the airbag trim cover from the steering
wheel and disengage horn connector.
(4) Install horn relay into Integrated Power Mod-
ule (IPM).
(a) If horn does not sound, replace airbag trim
cover.
(b) If horn sounds, repair grounded X3 circuit
from IPM to clockspring in the steering column.
HORNS WILL NOT SOUND
Check horn fuse#8intheIPM. If fuse is blown,
check for a shorted switch in the airbag module. and
refer to FUSE BLOWN section. If fuse is OK, refer to
FUSE OK section.
RSHORN8H-3
HORN SYSTEM (Continued)
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NOTE: Always check the functionality of the cluster
by running the self test prior to troubleshooting.
INSTRUMENT CLUSTER DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
INSTRUMENT CLUSTER
INOPERATIVE. NO
RESPONSE FROM
INSTRUMENT CLUSTER.NO PCI BUS MESSAGES
FROM THE BCM.USE A DRB IIITSCAN TOOL TO CHECK THE BCM.
IF OK, LOOK FOR ANOTHER POSSIBLE CAUSE
FOR CLUSTER FAILURE. IF NOT OK, REFER TO
THE PROPER BODY DIAGNOSTIC PROCEDURES
MANUAL.
SPREAD TERMINAL(S)
ON WIRING HARNESS
CLUSTER CONNECTOR.REMOVE CLUSTER FROM INSTRUMENT PANEL
AND CHECK WIRING HARNESS CONNECTOR FOR
SPREAD TERMINAL. IF OK, LOOK FOR ANOTHER
POSSIBLE CAUSE FOR THE CLUSTER FAILURE. IF
NOT OK, REPAIR CONNECTOR.
BCM IS NOT RECEIVING
PROPER INPUT FROM
THE IGNITION SWITCH.1. USE A DRB IIITSCAN TOOL TO VERIFY IGNITION
SWITCH STATUS INTO THE BCM. IF NOT OK, GO
TO STEP (2). IF OK, LOOK AT ANOTHER POSSIBLE
CAUSE OF FAILURE.
2. CHECK IGNITION SWITCH FUNCTION AND
WIRING.
INTERNAL CLUSTER
FAILURE.REPLACE CLUSTER.
WAKE UP CIRCUIT
FAULTY.VERIFY CONTINUITY OF WAKE UP CIRCUIT FROM
BCM TO MIC. CIRCUIT SHALL BE LOW WHENEVER
BCM IS AWAKE.
POWER OR GROUND
MISSING.IF NO RESPONSE FROM THE MIC, CHECK FOR
POWER AND GROUND AT THE MIC CONNECTOR.
REFER TO WIRING DIAGRAMS FOR CONNECTOR
CALL OUTS.
RSINSTRUMENT CLUSTER8J-3
INSTRUMENT CLUSTER (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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HEADLAMP LEVELING MOTOR
- EXPORT
DIAGNOSIS AND TESTING - HEADLAMP LEVELING MOTOR - EXPORT
HEADLAMP LEVELING MOTOR DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
ONE MOTOR DOES NOT
OPERATE.1. Poor electrical connection at
motor1. Check for proper electrical connection at
motor
2. No voltage at motor 2. Repair no voltage condition. Refer to
Wiring Diagrams
3. No ground at motor 3. Repair no ground condition. Refer to
Wiring Diagrams
4. Defective motor 4. Replace leveling motor
BOTH MOTORS DO NOT
OPERATE1. No voltage at or from headlamp
leveling switch1. Repair no voltage condition. Check for
proper headlamp leveling switch operation
2. No voltage at leveling motors 2. Repair no voltage condition. Refer to
Wiring Diagrams
3. No ground at leveling motors 3. Repair no ground condition. Refer to
Wiring Diagrams
4. Both motors defective 4. Replace both motors
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove headlamp unit.
(3) Disconnect electrical connector from headlamp
leveling motor.
(4) Remove the two mounting screws.
(5) Gently pry motor from headlamp unit (Fig. 14).
INSTALLATION
(1) Press motor into position.
(2) Install the two mounting screws.
(3) Connect the electrical connector to motor.
(4) Install the headlamp unit.
(5) Connect the battery negative cable.
Fig. 14 HEADLAMP LEVELING MOTOR - EXPORT
1 - HIGH BEAM HEADLAMP
2 - HEADLAMP LEVELING MOTOR
3 - LOW BEAM HEADLAMP
RSLAMPS/LIGHTING - EXTERIOR8L-15
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DIAGNOSIS AND TESTING - MULTI-FUNCTION
SWITCH
To test turn signal, headlamp beam select and opti-
cal horn portion of the multi-function switch:
(1) Remove the multi-function switch, refer to
Electrical, Lamps/Lighting - Exterior, Multi-Function
Switch, Removal, and Installation.
(2) Using an ohmmeter check the resistance read-
ings between multi-function switch pins. Refer to
Wiring Diagrams for proper pin numbers and the
MULTI-FUNCTION SWITCH RESISTANCE table.
MULTI-FUNCTION SWITCH RESISTANCE
SWITCH
POSITIONPIN NUMBER RESISTANCE
LEFT 2 AND 3 1.7V 5%
RIGHT 2 AND 3 1KV 5%
OPTICAL
HORN1 AND 3 4.87KV 5%
HI BEAM 1 AND 3 2.32KV 5%
REMOVAL
(1) Disconnect and isolate battery negative cable.
(2) Remove upper and lower steering column
shrouds. Refer to Steering, Column, Shroud,
Removal.
(3) Disconnect wire connector from back of multi-
function switch.
(4) Remove screws holding multi-function switch to
steering column adapter collar.
(5) Remove the multi-function switch.
INSTALLATION
(1) Position the switch on to the steering column.
(2) Install the two retaining screws.
(3) Connect the wire harness connector.
(4) Install the upper and lower steering column
shrouds. Refer to Steering, Column, Shroud, Installa-
tion.
(5) Connect the battery negative cable.
PARK/TURN SIGNAL LAMP
REMOVAL
(1) Disconnect and isolate battery negative cable.
(2) Remove headlamp retaining screws.
(3) Twist socket counter - clockwise and remove
(Fig. 26).
(4) Pull bulb from socket.
INSTALLATION
(1) Push bulb into socket.
(2) Twist socket into headlamp.(3) Install headlamp retaining screws.
(4) Reconnect battery negative cable.
PARK/TURN SIGNAL LAMP -
EXPORT
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the headlamp unit.
(3) Twist bulb socket and remove from headlamp
unit (Fig. 27).
(4) Twist bulb and remove from bulb socket.
Fig. 26 PARK/TURN SIGNAL LAMP
1 - PARK/TURN SIGNAL LAMP
2 - LAMP SOCKET
Fig. 27 PARK/TURN SIGNAL LAMP
1 - LOW BEAM HEADLAMP
2 - PARK/TURN SIGNAL LAMP
8L - 22 LAMPS/LIGHTING - EXTERIORRS
MULTI-FUNCTION SWITCH (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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ules push buttons located just rearward of the dis-
play screen in the overhead console. The three
universal transmitter push buttons are identified
with one, two or three light indicators so that they be
easily identified by sight or by feel.
Each of the three universal transmitter push but-
tons controls an independent radio transmitter chan-
nel. Each of these three channels can be trained to
transmit a different radio frequency signal for the
remote operation of garage door openers, motorized
gate openers, home or office lighting, security sys-
tems or just about any other device that can be
equipped with a radio receiver in the 286 to 399
MegaHertz (MHz) frequency range for remote opera-
tion. The universal transmitter is capable of operat-
ing systems using either rolling code or non-rolling
code technology.
The electronics module displays messages and a
small house-shaped icon with one, two or three dots
corresponding to the three transmitter buttons to
indicate the status of the universal transmitter. The
EVIC messages are:
²Cleared Channels- Indicates that all of the
transmitter codes stored in the universal transmitter
have been successfully cleared.
²Training- Indicates that the universal trans-
mitter is in its transmitter learning mode.
²Trained- Indicates that the universal transmit-
ter has successfully acquired a new transmitter code.
²Transmit- Indicates that a trained universal
transmitter button has been depressed and that the
universal transmitter is transmitting.
The universal transmitter cannot be repaired, and
is available for service only as a unit with the EVIC
or CMTC modules. If any of these components is
faulty or damaged, the complete EVIC or CMTC
module must be replaced.
OPERATION
The universal transmitter operates on a non-
switched source of battery current so the unit will
remain functional, regardless of the ignition switch
position. For more information on the features, pro-
gramming procedures and operation of the universal
transmitter, see the owner's manual in the vehicle
glove box.
DIAGNOSIS AND TESTING - UNIVERSAL
TRANSMITTER
If the universal transmitter is inoperative, but the
Electronic Vehicle Information Center (EVIC) or
Compass Mini-Trip Computer is operating normally,
see the owner's manual in the vehicle glove box for
instructions on training the universal transmitter.
Retrain the universal transmitter with a known good
transmitter as instructed in the owner's manual andtest the universal transmitter operation again. If the
unit is still inoperative, replace the faulty universal
transmitter and EVIC/CMTC module as a unit. If
both the universal transmitter and the EVIC/CMTC
module are inoperative, refer toOverhead Console
Diagnosis and Testingearlier in this group for fur-
ther diagnosis. For complete circuit diagrams, refer
toOverhead Consolein Wiring Diagrams.
AMBIENT TEMP SENSOR
DESCRIPTION
Ambient air temperature is monitored by the over-
head console through ambient temperature messages
received from the Front Control Module (FCM) over
the Programmable Communications Interface (PCI)
J1850 data bus circuit. The FCM receives a hard
wired input from the ambient temperature sensor.
The ambient temperature sensor is a variable resis-
tor mounted to a bracket that is secured with a screw
to the right side of the headlamp mounting module
grille opening, behind the radiator grille and in front
of the engine compartment.
Refer toFront Control Modulein Electronic
Control Modules. For complete circuit diagrams, refer
to the appropriate wiring information. The ambient
temperature sensor cannot be adjusted or repaired
and, if faulty or damaged, it must be replaced.
OPERATION
The ambient temperature sensor is a variable
resistor that operates on a five-volt reference signal
sent to it by the Front Control Module. The resis-
tance in the sensor changes as temperature changes,
changing the temperature sensor signal circuit volt-
age to the Front Control Module. Based upon the
resistance in the sensor, the Front Control Module
senses a specific voltage on the temperature sensor
signal circuit, which it is programmed to correspond
to a specific temperature. The Front Control Module
then sends the proper ambient temperature mes-
sages to the EVIC, CMTC over the PCI J1850 data
bus.
The thermometer function is supported by the
ambient temperature sensor, a wiring circuit, the
Front Control Module, the Programmable Communi-
cations Interface (PCI) data bus, and a portion of the
Electronics module. If any portion of the ambient
temperature sensor circuit fails, the Front Control
Module will self-diagnose the circuit.
The ambient temperature sensor circuit can also be
diagnosed by referring toDiagnosis and Testing -
Ambient Temperature Sensor, and Diagnosis
and Testing - Ambient Temperature Sensor Cir-
cuit. If the temperature sensor and circuit are con-
8M - 10 MESSAGE SYSTEMSRS
UNIVERSAL TRANSMITTER (Continued)
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firmed to be OK, but the temperature display is
inoperative or incorrect, refer toDiagnosis and
Testing - Overhead Consolein this group. For
complete circuit diagrams, refer to the appropriate
wiring information.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - AMBIENT
TEMPERATURE SENSOR
(1) Turn the ignition switch to the Off position.
Disconnect and isolate the battery negative cable.
Disconnect the ambient temperature sensor wire har-
ness connector.
(2) Measure the resistance of the ambient temper-
ature sensor. At ±40É C (±40É F), the sensor resis-
tance is 336.6 kilohms. At 60É C (140É F), the sensor
resistance is 2.49 kilohms. The sensor resistance
should read between these two values. If OK, refer to
Diagnosis and Testing - Ambient Temperature
Sensor Circuitin this group. If not OK, replace the
faulty ambient temperature sensor.
DIAGNOSIS AND TESTING - AMBIENT
TEMPERATURE SENSOR CIRCUIT
(1) Turn the ignition switch to the Off position.
Disconnect and isolate the battery negative cable.
Disconnect the ambient temperature sensor wire har-
ness connector and the Front Control Module wire
harness connector.
(2) Connect a jumper wire between the two termi-
nals in the body half of the ambient temperature sen-
sor wire harness connector.
(3) Check for continuity between the sensor return
circuit and the ambient temperature sensor signalcircuit cavities of the Front Control Module wire har-
ness connector. There should be continuity. If OK, go
to Step 4. If not OK, repair the open sensor return
circuit or ambient temperature sensor signal circuit
to the ambient temperature sensor as required.
(4) Remove the jumper wire from the body half of
the ambient temperature sensor wire harness con-
nector. Check for continuity between the sensor
return circuit cavity of the Front Control Module
wire harness connector and a good ground. There
should be no continuity. If OK, go to Step 5. If not
OK, repair the shorted sensor return circuit as
required.
(5) Check for continuity between the ambient tem-
perature sensor signal circuit cavity of the Front
Control Module wire harness connector and a good
ground. There should be no continuity. If OK, refer to
Diagnosis and Testing - Overhead Consolein
this group. If not OK, repair the shorted ambient
temperature sensor signal circuit as required.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Raise and support vehicle on safety stands.
(3) From behind front bumper fascia, remove
screw holding sensor to radiator closure panel.
(4) Remove sensor from vehicle.
INSTALLATION
(1) Position the sensor in the vehicle.
(2) From behind the front bumper fascia, install
the screw holding sensor to radiator closure panel.
(3) Connect the battery negative cable.
RSMESSAGE SYSTEMS8M-11
AMBIENT TEMP SENSOR (Continued)
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