2002 CHRYSLER CARAVAN manual transmission

CLEANING
Check the external cooler for debris on the cooling
fin surfaces. Clean as necessary. For internal clean-
ing/flushing procedures, (Refer to 7 - COOLING/
TRANSMISSION - STANDARD PROCEDURE).
INSPECTION
Inspect all hoses, tubes, clamps and connections for
leaks, cracks, or damage. Replace as necessary. Use
only approved transmission oil cooler hoses that are
molded to fit the space available.
Inspect external coolers for leaks, loose mounts, or
damage. Replace as necessary.
INSTALLATION
(1) Install transaxle oil cooler and mounting
screws (Fig. 2).
NOTE: When replacing the transmission oil cooler,
the cooler hoses must be replaced.
(2) Connect the new cooler hoses and install
clamps (Fig. 1).
(3) Install the radiator. (Refer to 7 - COOLING/
ENGINE/RADIATOR - INSTALLATION)
(4) Start engine. Check and adjust the fluid level
as necessary.
TRANSMISSION OIL COOLER
LINES
REMOVAL
(1) Using appropriate hose clamp pliers, release
tension on clamps and move off fittings.
NOTE: When the transaxle cooler lines are removed
from the rolled-groove type fittings at the cooler
and transaxle, damage to the inner wall of hose will
occur. To prevent potential leakage, the cooler
hoses must be replaced.
(2) Remove the hoses (Fig. 3) or (Fig. 4).
Fig. 1 TRANSMISSION COOLER HOSES
1 - TRANSAXLE COOLER HOSES
2 - FITTING - COOLER OUTLET
3 - FITTING - COOLER INLET
Fig. 2 Transmission Oil Cooler
1 - TRANSAXLE OIL COOLER
2 - SCREWS
3 - A/C CONDENSER (REAR SIDE)
Fig. 3 TRANS OIL COOLER LINES - 41TE
1 - FITTING - COOLER RETURN
2 - FITTING - COOLER SUPPLY
3 - HOSES - TRANSAXLE COOLER
4 - FITTING - COOLER OUTLET
5 - FITTING - COOLER INLET
RSTRANSMISSION7-39
TRANSMISSION OIL COOLER (Continued)
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INSTALLATION
NOTE: When the transaxle cooler lines are removed
from the rolled-groove type fittings at the cooler
and transaxle, damage to the inner wall of hose will
occur. To prevent potential leakage, the cooler
hoses must be replaced.
(1) Connect hoses to cooler and transaxle fittings
(Fig. 3) or (Fig. 4).
(2) Using appropriate pliers, position clamps over
fittings and release tension.
(3) Start engine and check transaxle fluid level.
Adjust fluid level as necessary.
Fig. 4 TRANSAXLE OIL COOLER LINES - 31TH
1 - FITTING - COOLER RETURN
2 - FITTING - COOLER SUPPLY
3 - HOSES - TRANSAXLE COOLER
4 - FITTING - COOLER OUTLET
5 - FITTING - COOLER INLET
7 - 40 TRANSMISSIONRS
TRANSMISSION OIL COOLER LINES (Continued)
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(9) Disconnect the wire connectors from the back
of the radio.
INSTALLATION
(1) Connect wire harness to back of radio.
(2) Install bolt holding ground strap to the radio (if
equipped).
(3) Connect antenna cable to back of radio.
(4) Position radio into instrument panel.
(5) Install screws holding radio to instrument
panel.
(6) Install center instrument panel trim.
(7) Install trim panel above cupholder.
(8) Install cupholder.
(9) Connect battery negative cable.
RADIO NOISE SUPPRESSION
COMPONENTS
DESCRIPTION
Radio noise suppression devices are factory-in-
stalled standard equipment on this vehicle. Radio
Frequency Interference (RFI) and ElectroMagnetic
Interference (EMI) can be produced by any on-board
or external source of electromagnetic energy. These
electromagnetic energy sources can radiate electro-
magnetic signals through the air, or conduct them
through the vehicle electrical system.
When the audio system converts RFI or EMI to an
audible acoustic wave form, it is referred to as radionoise. This undesirable radio noise is generally man-
ifested in the form of ªbuzzing,º ªhissing,º ªpopping,º
ªclicking,º ªcrackling,º and/or ªwhirringº sounds. In
most cases, RFI and EMI radio noise can be sup-
pressed using a combination of vehicle and compo-
nent grounding, filtering and shielding techniques.
This vehicle is equipped with factory-installed radio
noise suppression devices that were designed to min-
imize exposure to typical sources of RFI and EMI;
thereby, minimizing radio noise complaints.
Factory-installed radio noise suppression is accom-
plished primarily through circuitry or devices that
are integral to the factory-installed radios, audio
power amplifiers and other on-board electrical com-
ponents such as generators, wiper motors, blower
motors, and fuel pumps that have been found to be
potential sources of RFI or EMI.
OPERATION
There are two common strategies that can be used
to suppress Radio Frequency Interference (RFI) and
ElectroMagnetic Interference (EMI) radio noise. The
first suppression strategy involves preventing the
production of RFI and EMI electromagnetic signals
at their sources. The second suppression strategy
involves preventing the reception of RFI and EMI
electromagnetic signals by the audio system compo-
nents.
The use of braided ground straps in key locations
is part of the RFI and EMI prevention strategy.
These ground straps ensure adequate ground paths,
particularly for high current components such as
many of those found in the starting, charging, igni-
tion, engine control and transmission control sys-
tems. An insufficient ground path for any of these
high current components may result in radio noise
caused by induced voltages created as the high cur-
rent seeks alternative ground paths through compo-
nents or circuits intended for use by, or in close
proximity to the audio system components or circuits.
Preventing the reception of RFI and EMI is accom-
plished by ensuring that the audio system compo-
nents are correctly installed in the vehicle. Loose,
corroded or improperly soldered wire harness connec-
tions, improperly routed wiring and inadequate audio
system component grounding can all contribute to
the reception of RFI and EMI. A properly grounded
antenna body and radio chassis, as well as a shielded
antenna coaxial cable with clean and tight connec-
tions will each help reduce the potential for reception
of RFI and EMI.
Fig. 9 ANTENNA TO RADIO
1 - RADIO
2 - LOCKING ANTENNA CONNECTOR
3 - INSTRUMENT PANEL ANTENNA CABLE
8A - 10 AUDIORS
RADIO (Continued)
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ELECTRONIC CONTROL MODULES
TABLE OF CONTENTS
page page
ELECTRONIC CONTROL MODULES
STANDARD PROCEDURE - PCM/SKIM
PROGRAMMING.......................2
ADJUSTABLE PEDAL MODULE
DIAGNOSIS AND TESTING - ADJUSTABLE
PEDAL MODULE.......................3
REMOVAL.............................3
INSTALLATION..........................3
BODY CONTROL MODULE
DESCRIPTION..........................3
OPERATION............................3
REMOVAL.............................5
INSTALLATION..........................5
CONTROLLER ANTILOCK BRAKE
DESCRIPTION..........................5
OPERATION............................5
REMOVAL.............................6
INSTALLATION..........................6
DATA LINK CONNECTOR
DESCRIPTION..........................7
OPERATION............................7
FRONT CONTROL MODULE
DESCRIPTION..........................7
OPERATION............................7
DIAGNOSIS AND TESTING - FRONT
CONTROL MODULE....................8
REMOVAL.............................8
INSTALLATION..........................8
HEATED SEAT MODULE
DESCRIPTION..........................9
OPERATION............................9
DIAGNOSIS AND TESTING - HEATED SEAT
MODULE.............................9
REMOVAL.............................10
INSTALLATION.........................10
POWER LIFTGATE MODULE
DESCRIPTION.........................10
OPERATION...........................10
REMOVAL.............................10
INSTALLATION.........................11
POWERTRAIN CONTROL MODULE
DESCRIPTION
DESCRIPTION........................11DIAGNOSTIC TROUBLE CODE...........13
OPERATION - SENSOR RETURN - PCM
INPUT..............................25
OPERATION - SCI RECEIVE - PCM INPUT . . 25
OPERATION - IGNITION SENSE - PCM
INPUT..............................25
OPERATION - PCM GROUND............25
OPERATION
OPERATION - 8-VOLT SUPPLY - PCM
OUTPUT............................25
OPERATION - 5 VOLT SUPPLY - PCM
OUTPUT............................25
STANDARD PROCEDURE - OBTAINING
DIAGNOSTIC TROUBLE CODES..........25
REMOVAL.............................26
INSTALLATION.........................26
SENTRY KEY IMMOBILIZER MODULE
DESCRIPTION.........................26
OPERATION...........................27
REMOVAL.............................27
INSTALLATION.........................27
TRANSMISSION CONTROL MODULE
DESCRIPTION.........................28
OPERATION...........................28
STANDARD PROCEDURE
STANDARD PROCEDURE - PINION
FACTOR SETTING.....................31
STANDARD PROCEDURE - QUICK LEARN
PROCEDURE........................31
REMOVAL.............................31
INSTALLATION.........................32
MEMORY SEAT/MIRROR MODULE
DESCRIPTION.........................33
OPERATION...........................33
DIAGNOSIS AND TESTING - MEMORY
SEAT/MIRROR MODULE................33
REMOVAL.............................33
INSTALLATION.........................33
SLIDING DOOR CONTROL MODULE
DESCRIPTION.........................33
OPERATION...........................34
REMOVAL.............................34
INSTALLATION.........................34
RSELECTRONIC CONTROL MODULES8E-1
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ELECTRONIC CONTROL
MODULES
STANDARD PROCEDURE - PCM/SKIM
PROGRAMMING
NOTE: Before replacing the PCM for a failed driver,
control circuit or ground circuit, be sure to check
the related component/circuit integrity for failures
not detected due to a double fault in the circuit.
Most PCM driver/control circuit failures are caused
by internal component failures (i.e. relay and sole-
noids) and shorted circuits (i.e. pull-ups, drivers
and switched circuits). These failures are difficult to
detect when a double fault has occurred and only
one DTC has set.
When a PCM (SBEC) and the SKIM are replaced
at the same time perform the following steps in
order:
(1) Program the new PCM (SBEC)
(2) Program the new SKIM
(3) Replace all ignition keys and program them to
the new SKIM.
PROGRAMMING THE PCM (SBEC)
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 monitor
the 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, MISCELLANEOUS, 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.
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.
8E - 2 ELECTRONIC CONTROL MODULESRS
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(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.
ADJUSTABLE PEDAL MODULE
DIAGNOSIS AND TESTING - ADJUSTABLE
PEDAL MODULE
Refer to Appropriate Diagnostic Information.
REMOVAL
(1) Remove adjustable pedal assembly from vehi-
cle. (Refer to 5 - BRAKES/HYDRAULIC/MECHANI-
CAL/PEDAL - REMOVAL)
(2) Disconnect 2 wiring connectors from module
(Fig. 1).
(3) Remove cable from routing clips on module
(Fig. 1).
(4) Remove module mounting screws.
(5) Remove module.
INSTALLATION
(1) Install module on pedal assembly and install
mounting screws.
(2) Place cable in routing clips on module (Fig. 1).
(3) Connect 2 wiring connectors to module (Fig. 1).(4) Install adjustable pedal assembly. (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/PEDAL -
INSTALLATION)
BODY CONTROL MODULE
DESCRIPTION
The Body Control Module (BCM) is located in the
passenger compartment, attached to the bulkhead
underneath the left side of the instrument panel.
The BCM utilizes integrated circuitry and informa-
tion carried on the Programmable Communications
Interface (PCI) data bus network along with many
hard wired inputs to monitor many sensor and
switch inputs throughout the vehicle. In response to
those inputs, the internal circuitry and programming
of the BCM allow it to control and integrate many
electronic functions and features of the vehicle
through both hard wired outputs and the transmis-
sion of electronic message outputs to other electronic
modules in the vehicle over the PCI data bus.
OPERATION
The Body Control Module (BCM) supplies vehicle
occupants with visual and audible information and
controls various vehicle functions. To provide and
receive information, the BCM is interfaced to the
vehicle's serial bus communications network, referred
to as the Programmable Communications Interface
(PCI) bus.
This network consists of the;
²Powertrain Control Module (PCM)
²Transmission Control Module (TCM)
²Mechanical Instrument Cluster (MIC)
²Occupant Restraint Controller (ORC)
²Compass/Mini-Trip Computer (CMTC)
²Electronic Vehicle Information Center (EVIC)
²Controller Antilock Brake (CAB)
²HVAC Control Module
²Sliding Door Control Modules (driver and pas-
senger side doors)
²Power Liftgate Module (PLG)
²Audio system equipped with RAZ, RBU, RBK,
and RBB radios.
²Side Impact Airbag Control Module (SIACM)
²Memory Seat Module (MSM)
²Sentry Key Immobilizer Module (SKIM)
The BCM is operational when battery power is
supplied to the module.
The BCM provides the following features:
²Power Door Locks
²Automatic Door Locks
²Battery Protection - The BCM will automatically
turn off all exterior lamps after 3 minutes, and all
Fig. 1 Adjustable Pedal Module
1 - CABLE
2 - ADJUSTABLE PEDAL MODULE
3 - WIRING CONNECTORS
4 - ADJUSTABLE PEDAL ASSEMBLY
RSELECTRONIC CONTROL MODULES8E-3
ELECTRONIC CONTROL MODULES (Continued)
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(9) Connect a DRBIIItto the vehicle and initialize
the system.
DATA LINK CONNECTOR
DESCRIPTION
The data link connector is located inside the vehi-
cle, below instrument panel next to the center col-
umn (Fig. 5).
OPERATION
The data link connector (diagnostic connector)
links the DRB scan tool with the Powertrain ControlModule (PCM). Refer to On-Board Diagnostics in the
General Diagnosis section of this group.
FRONT CONTROL MODULE
DESCRIPTION
The Front Control Module (FCM) is a micro con-
troller based module located in the engine compart-
ment. This FCM mates to the power distribution
center to form the Integrated Power Module (IPM).
The IPM connects directly to the battery and pro-
vides the primary means of circuit protection and
power distribution for all vehicle electrical systems.
The FCM controls power to some of these vehicle sys-
tems electrical and electromechanical loads based on
inputs received from hard wired switch inputs and
data received on the Programmable Communications
Interface (PCI) data bus.
For information on the IPM, (Refer to 8 - ELEC-
TRICAL/POWER DISTRIBUTION/INTEGRATED
POWER MODULE - DESCRIPTION)
OPERATION
As messages are sent over the Programmable Com-
munications Interface (PCI) data bus, the Front Con-
trol Module (FCM) reads these messages and controls
power to some of the vehicles electrical systems by
completing the circuit to ground (low side driver) or
completing the circuit to 12 volt power (high side
driver).
The following functions arecontrolledby the
Front Control Module:
²Accessory Relay Actuation
²Brake Transmission Shift Interlock Functions
(BTSI)
²Diesel Cabin Heater (Diesel Engine Vehicles)
²Electronic Back Light (EBL) Rear Defogger
²Electronic Transaxle (Gasoline engine Vehicles)
²Front and Rear Blower Motor Relay Actuation
²Front Fog Lamp Relay Actuation
²Front Washer Motor
²Front Windshield Wiper ªHIº & ªLOº Relay
Actuation
²Front Windshield Wiper ªONº Relay Actuation
²Headlamp Power with Voltage Regulation
²Horn Relay Actuation
²Headlamp Washer Relay Actuation
²Name Brand Speaker (NBS) Relay Actuation
²Occupant Restraint Controller Voltage
²Park Lamp Relay Actuation
²Rear Washer Motor
²Side Airbag Voltage
The following inputs areReceived/Monitoredby
the Front Control Module:
²Ambient Temperature Sensing
Fig. 4 CAB Mounting Screws
1 - HCU
2 - MOUNTING SCREWS
3 - CAB
Fig. 5 DATA LINK CONNECTOR
RSELECTRONIC CONTROL MODULES8E-7
CONTROLLER ANTILOCK BRAKE (Continued)
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seat switch. Refer toDiagnosis and Testing
Heated Seat Switchin Heated Seats for heated
seat switch diagnosis and testing procedures. If the
heated seat switch checks OK, proceed as follows.
(1) Check the heated seat element (Refer to 8 -
ELECTRICAL/HEATED SEATS/HEATED SEAT
ELEMENT - DIAGNOSIS AND TESTING).
(2) Check the heated seat sensor (Refer to 8 -
ELECTRICAL/HEATED SEATS/HEATED SEAT
SENSOR - DIAGNOSIS AND TESTING).
(3) Check the heated seat switch (Refer to 8 -
ELECTRICAL/HEATED SEATS/DRIVER HEATED
SEAT SWITCH - DIAGNOSIS AND TESTING).
NOTE: Refer to Wiring for the location of complete
heated seat system wiring diagrams and connector
pin-out information.
(4) Using a voltmeter, backprobe the appropriate
heated seat module connector, do not disconnect.
Check for voltage at the appropriate pin cavities. 12v
should be present. If OK go to Step 5, if Not, Repair
the open or shorted voltage supply circuit as
required.
(5) Using a ohmmeter, backprobe the appropriate
heated seat module connector, do not disconnect.
Check for proper continuity to ground on the ground
pin cavities. Continuity should be present. If OK
replace the heated seat module with a known good
unit and retest system, if Not OK, Repair the open or
shorted ground circuit as required.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the appropriate front seat from the
vehicle (Refer to 23 - BODY/SEATS/SEAT - REMOV-
AL).
(3) Unsnap the module from the seat cushion pan.
(4) Disconnect the module wire harness connec-
tors.
INSTALLATION
(1) Connect the module wire harness connectors.
(2) Snap the module on the seat cushion pan.
(3) Install the appropriate front seat in the vehicle
(Refer to 23 - BODY/SEATS/SEAT - INSTALLA-
TION).
(4) Connect and isolate the negative battery cable.
POWER LIFTGATE MODULE
DESCRIPTION
Vehicles equipped with a power liftgate (PLG) uti-
lize a PLG control module. This module is located on
the vehicles left side D-pillar just below the motorassembly (Fig. 9) and contains a microprocessor,
which is used to communicate to the vehicles body
control module. The PLG control module receives and
monitors logic inputs from all the PLG system
switches except for the outside handle switch. This
module also contains the software technology to
detect liftgate obstructions and stop and / or reverse
the door accordingly.
OPERATION
The PLG control module contains the electronic cir-
cuitry and software used to control the sequence of
events for the PLG system. This module comunicates
on the PCI bus circuit with the vehicles body control
module to monitor many different inputs and outputs
such as door lock status, transmission gear selector
position and vehicle speed. Refer to PLG system
operation for more information.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove left D-pillar trim panel from the vehi-
cle. Refer to Body for the procedure.
(3) Disconnect the wire harness connections from
the PLG motor assembly (Fig. 10).
Fig. 9 LIFTGATE CONTROL MODULE
1 - POWER LIFTGATE CONTROL MODULE
2 - MODULE RETAINING SCREWS
3 - D-PILLAR
4 - POWER LIFTGATE MOTOR
5 - MODULE ELECTRICAL CONNECTORS
8E - 10 ELECTRONIC CONTROL MODULESRS
HEATED SEAT MODULE (Continued)
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