2002 CHRYSLER CARAVAN power steering

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Left Cylinder Lock Switch BK At Switch N/S
Left Door Speaker BK At Speaker N/S
Left Fog Lamp WT At Lamp N/S
Left Front Door Ajar Switch BK At Switch N/S
Left Front Door Lock Motor/Ajar
SwitchBK Left Door N/S
Left Front Park/Turn Signal Lamp BK At Lamp 1, 5
Left Front Wheel Speed Sensor BK Left Fender Side Shield N/S
Left Full Open Switch BK Left Sliding Door N/S
Left Headlamp BK At Lamp 1, 5
Left Headlamp Leveling Motor WT At Motor N/S
Left High Beam Lamp BK At Lamp N/S
Left Instrument Panel Speaker BK At Speaker 15, 16, 22
Left Liftgate Flood Lamp GY At Lamp 42
Left Low Beam Lamp BK At Lamp N/S
Left Mid Reading Lamp GY At Lamp N/S
Left Park Lamp BK At Lamp N/S
Left Power Mirror BK At Mirror 22
Left Rear Lamp Assembly BK At Lamp 40
Left Rear Reading Lamp GY At Lamp N/S
Left Rear Speaker BK At Speaker 40
Left Rear Vent Motor NAT At Motor 39, 40
Left Rear Wheel Speed Sensor BK Center Rear of Floor Pan 40
Left Remote Radio Switch Steering Wheel N/S
Left Repeater Lamp GY Left Front Fender 4
Left Seat Airbag YL Left Seat N/S
Left Side Impact Airbag Control
ModuleYL/RD Left B Pillar 34
Left Sliding Door Control Module
C1BK Left Sliding Door N/S
Left Sliding Door Control Module
C2BK/RD Left Sliding Door N/S
Left Sliding Door Latch Sensing
SwitchBK Left Sliding Door N/S
Left Sliding Door Lock Motor BK Left Sliding Door N/S
Left Sliding Door Lock Motor/Ajar
SwitchBK Left Sliding Door N/S
Left Sliding Door Motor BK Left Sliding Door N/S
Left Speed Control Switch WT Steering Wheel N/S
Left Stop/Turn Signal Relay BK Left Quarter Panel N/S
Left Turn Signal Lamp OR AT Lamp N/S
Left Visor/Vanity Lamp BK At Lamp N/S
License Lamp DKGY At Lamp 42
Lift Pump Motor BK Left Rear Engine Compartment N/S
8W - 91 - 6 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
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CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Liftgate Ajar Switch (Manual
Release)BK At Latch 42
Liftgate Ajar Switch (Power
Release)BK Lower Liftgate 42
Liftgate Cinch/Release Motor BL Liftgate N/S
Liftgate Cylinder Lock Switch BK At Switch 42
Liftgate Left Pinch Sensor BK Left Side of Liftgate N/S
Liftgate Right Pinch Sensor BK Right Side of Liftgate N/S
Low Note Horn BK Left Frame Rail 5
Manifold Absolute Pressure Sensor BK On Intake 10
Mass Air Flow Sensor (Diesel) OR Top of Engine 11, 12
Memory Seat/Mirror Module C1 GY Under Driver Seat N/S
Memory Seat/Mirror Module C2 GY Under Driver Seat N/S
Memory Seat/Mirror Module C3 WT Under Driver Seat N/S
Memory Seat/Mirror Module C4 GY Under Driver Seat N/S
Memory Seat Front Vertical Motor RD Under Seat N/S
Memory Seat Front Vertical
Position SensorBK Under Seat N/S
Memory Seat Horizontal Motor BK Under Seat N/S
Memory Seat Horizontal Position
SensorBK Under Seat N/S
Memory Seat Rear Vertical Motor RD Under Seat N/S
Memory Seat Rear Vertical Position
SensorBK Under Seat N/S
Memory Seat Recliner Motor GN Under Seat N/S
Memory Seat Recliner Position
SensorBK Under Seat N/S
Memory Seat Switch BK At Switch Driver Door N/S
Message Center WT Rear of Message Center 15, 16, 23
Mode Door Actuator GY Left Side of HVAC N/S
Multi Function Switch BK At Steering Column 15, 16, 17, 18, 26
Output Speed Sensor GY Front of Transmission 14
Overhead Console BK Front of Console N/S
Oxygen Sensor 1/1 Upstream BK Rear of Engine 9, 10, 14
Oxygen Sensor 1/2 Downstream BK Rear of Engine 9, 10, 14
Park/Neutral Positon Switch BK Front of Transmission 10
Passenger Airbag YL Passenger Side of Instrument Panel 15, 18, 19 24
Passenger Blend Door Actuator On HVAC N/S
Passenger Door Courtesy Lamp BK At Lamp 37
Passenger Door Lock Switch BK At Switch 37
Passenger Folding Mirror Relay BL Right Kick Panel N/S
Passenger Heated Seat Back GN At Seat N/S
Passenger Heated Seat Cushion BK At Seat N/S
Passenger Heated Seat Module C1 GY At Heated Seat N/S
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-7
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
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CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Passenger Heated Seat Module C2 GY At Heated Seat Back N/S
Passenger Heated Seat Module C3 GN At Heated Seat N/S
Passenger Power Seat Front Riser
MotorRD Under Seat N/S
Passenger Power Seat Horizontal
MotorBK Under Seat N/S
Passenger Power Seat Rear Riser
MotorRD Under Seat N/S
Passenger Power Seat Recliner
MotorGN Under Seat N/S
Passenger Power Seat Switch GN At Switch N/S
Passenger Power Window Motor RD At Motor 37
Passenger Power Window Switch BK At Switch 37
Passenger Seatbelt Switch On Seat Harness N/S
Passenger Seatbelt Tensioner On Seat Harness N/S
Pedal Adjust Module At Module N/S
Pedal Adjust Switch At Switch N/S
Power Folding Mirror Switch BK Near Steering Column 26
Power Liftgate Module C1 BK Left Quarter 39, 40
Power Liftgate Module C2 BK/RD Left Quarter 39, 40
Power Liftgate Motor BK Left Quarter 40
Power Mirror Switch BK Rear of Switch 25
Power Outlet NAT Instrument Panel 15, 18, 20
Power Seat Circuit Breaker GY Under Seat N/S
Powertrain Control Module C1 GY/BK LT Fender Side Shield N/S
Powertrain Control Module C2 GY LT Fender Side Shield N/S
Power Window Circuit Breaker GY Left Side Kick Panel 35 36
Radiator Fan No.1 BK Left Side At Motor 1
Radiator Fan No.1 (Diesel) GY Left Side At Motor 2
Radiator Fan No.2 BK Right Side At Motor 1
Radiator Fan No.2 (Diesel) GY Right Side At Motor N/S
Radiator Fan Relay BK Top of Left Front Frame Rail 1
Radiator Fan Relay No. 1 (Diesel) BL Left Front Engine Compartment 2
Radiator Fan Relay No. 2 (Diesel) BL Left Front Engine Compartment 2
Radiator Fan Relay No. 3 (Diesel) BL Left Front Engine Compartment 2
Radio C1 GY Rear of Radio 15
Radio C2 BK Rear of Radio 15
Rear A/C-Heater Unit LT/GN Right Quarter Panel N/S
Rear Automatic Temperature
Control Switch (ATC)BK Rear of Switch 34
Rear Blower Front Control Switch BK Rear of Switch N/S
Rear Blower Motor Power Module
C1Right Quarter N/S
8W - 91 - 8 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
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CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Rear Blower Motor Power Module
C2Right Quarter N/S
Rear Blower Rear Control Switch
C1Overhead N/S
Rear Blower Rear Control Switch
C2Overhead N/S
Rear Power Outlet RD Left Quarter Panel 40
Rear Temperature Motor Right Quarter N/S
Rear Washer Pump Motor BK Right Fender Well 3
Rear Wiper Motor GY At Motor 42
Recirculation Door Actuator GY Right Side of HVAC N/S
Remote Keyless Entry Antenna
(JAPAN)BK Right Upper Instrument Panel 23
Remote Keyless Entry Module BK/RD Top Left of I.P. 15, 16
Right B-Pillar Switch GY Right B Pillar 33
Right Cinch/Release Motor GY Rear of Sliding Door 38
Right Combination Relay BK Left Quarter Panel N/S
Right Cylinder Lock Switch BK Right Front Door 37
Right Door Speaker BK/RD At Speaker N/S
Right Fog Lamp WT At Lamp 3
Right Front Door Ajar Switch BK At B Pillar N/S
Right Front Door Lock Motor/Ajar
SwitchBK Right Front Door 37
Right Front Park/Turn Signal Lamp BK At Lamp 1, 3
Right Front Wheel Speed Sensor GY Right Fender Side Shield 9, 12, 13
Right Full Open Switch BK Right Sliding Door 38
Right Headlamp BK At Lamp 1, 3
Right Headlamp Leveling Motor WT At Right Headlamp N/S
Right High Beam Lamp BK At Right Headlamp N/S
Right Instrument Panel Speaker BK At Speaker 15, 18, 19
Right Liftgate Flood Lamp BK At Lamp 42
Right Low Beam Lamp BK At Right Headlamp N/S
Right Mid Reading Lamp GY At Lamp N/S
Right Park Lamp BK AT Lamp N/S
Right Power Mirror BK At Mirror 15, 19, 23
Right Rear Lamp Assembly BK At Lamp 41
Right Rear Pillar Speaker BK At Speaker 41
Right Rear Reading Lamp GY At Lamp N/S
Right Rear Speaker BK/RD At Speaker 41
Right Rear Vent Motor NAT At Motor 41
Right Rear Wheel Speed Sensor BK Center Rear of Floor Pan 41
Right Remote Radio Switch BK At Steering Wheel N/S
Right Repeater Lamp GY Right Front Fender 33
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-9
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
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SPLICE NUMBER LOCATION FIG.
S177 In Right Headlamp Wiring Assembly N/S
S179 In Left Headlamp Wiring Assembly N/S
S187 (2.5L) Near T/O for Engine Control Module C1 11
S188 (2.5L) Near T/O for Radiator Fan Relay No.1 2
S201 In T/O to Instrument Panel Speaker 15, 21
S202 Near T/O for Instrument Panel Switch Bank 15, 21
S203 Near T/O for Instrument Panel Switch Bank 15, 21
S204 Near T/O to Instrument Panel Speaker 15, 21
S205 Near T/O for C201 15
S206 Near T/O for Instrument Cluster 15
S207 In A/C Unit Assembly N/S
S208 (RHD) Between T/O for Antenna Connector and T/O for Front
Cigar Lighter21
S209 (RHD) Between T/O for Front Cigar Lighter and T/O for Brake
Transmission Shift Interlock Solenoid21
S210 (RHD) Near T/O for C203 21
S211 In Steering Column Wiring Assembly N/S
S212 In Steering Column Wiring Assembly N/S
S302 In Floor Pan Track Wiring 31
S303 In T/O to Data Link Connector 31
S304 Near T/O for C307 32
S305 Near T/O for Memory Seat/Mirror Module - C2 N/S
S306 In Floor Pan Track Wiring 32
S307 Near T/O for Memory Power Seat Switch N/S
S308 In Floor Pan Track Wiring 31
S309 In Floor Pan Track Wiring 31
S310 Near T/O for C301 30
S311 In Floor Pan Track Wiring 29
S312 Near T/O for C320 N/S
S313 Near T/O for Power Liftgate Module 40
S314 In Floor Pan Track Wiring 29
S315 In Floor Pan Track Wiring 29
S316 In Floor Pan Track Wiring 29
S317 Near T/O for C101 30
S318 Near T/O for Power Seat Circuit Breaker N/S
S319 In Floor Pan Track Wiring 32
S320 Near T/O for C200 31
S321 In T/O to Data Link Connector 31
S322 Near T/O for C301 30
S323 In Floor Pan Track Wiring 31
S324 In Floor Pan Track Wiring 29
S325 In Floor Pan Track Wiring 29
S326 Near T/O for C101 30
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-13
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
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WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO RESTRAINTS BEFORE ATTEMPT-
ING ANY STEERING WHEEL, STEERING COLUMN,
SEAT OR INSTRUMENT PANEL COMPONENT DIAG-
NOSIS OR SERVICE. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
(1) Check the fused B(+) fuse in the Integrated
Power Module (IPM). 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 IPM. If OK, go to Step 3. If not OK, repair the
open fused B(+) circuit to the IPM fuse as required.
(3)
Open the power outlet door. Check for continuity
between the inside circumference of the power outlet
receptacle and a good ground. There should be continu-
ity. If OK, go to Step 4. If not OK, go to Step 5.
(4) Check for battery voltage at the insulated con-
tact located at the back of the power outlet recepta-
cle. If not OK, go to Step 5.
(5) Disconnect and isolate the battery negative
cable. Remove the appropriate bezel. Check for conti-
nuity between the ground circuit cavity of the power
outlet wire harness connector 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
power outlet wire harness connector. If OK, replace
the faulty power outlet receptacle. If not OK, repair
the open fused B(+) circuit to the IPM fuse as
required.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Look inside and note position of the retaining
bosses (Fig. 5).
(3) Using external snap ring pliers with 90 degree
tips. Insert pliers with tips against bosses and
squeeze forcing bosses out of base.
(4) Pull out the base through mounting ring by
gently rocking pliers. A tool can be made to do the
same. Refer to (Fig. 6).
(5) Disconnect the base wires.
(6) Set base aside. Remove light ring and discon-
nect wire.
INSTALLATION
(1) Position the mounting ring on the instrument
panel and feed the wires through the ring. Index the
cap and the mounting ring with the index tab at the9 o'clock position to the key in the instrument panel.
Install the ring.
(2) Connect the wires to the base. Orientate the
base alignment rib at the 11 o'clock position to mate
the groove in the mounting ring to the base.
(3) Push the base into the bezel until it locks in
place.
(4) Check operation of outlet or element and
install the 12 volt outlet cap.
Fig. 5 Outlet Base Removal
1 - RETAINING BOSSES-ENGAGE PLIERS HERE
2 - PARTIALLY REMOVED
3 - EXTERNAL SNAP-RING PLIERS
4 - PULL BASE OUT-THROUGH MOUNTING RING
Fig. 6 Tool For Outlet Removal
1 - 2.5MM (3/32 INS.)
2 - WELD
3 - 100MM (4 INS.)
4 - 22.25 TO 22.45MM (7/8 TO 57/64 INS.)
8W - 97 - 6 8W-97 POWER DISTRIBUTION SYSTEMRS
POWER OUTLET (Continued)
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(22) Remove engine front mount and bracket from
engine. (Refer to 9 - ENGINE/ENGINE MOUNTING/
FRONT MOUNT - REMOVAL)
(23) Remove structural collar. (Refer to 9 -
ENGINE/ENGINE BLOCK/STRUCTURAL COVER -
REMOVAL)
(24) Remove rear engine mount bracket. (Refer to
9 - ENGINE/ENGINE MOUNTING/REAR MOUNT -
REMOVAL)
(25) Mark flex plate to torque converter and
remove torque converter bolts.
(26) Pinch-off power steering supply hose at pump.
Remove hose from pump.
(27) Remove and set aside the power steering
pump and bracket. Do not disconnect pressure line.
(28) Lower vehicle.
(29) Remove A/C lines at compressor and cap open-
ings.
(30) Remove engine ground straps (strap at engine
right mount and at starter).
(31) Raise vehicle enough to allow engine dolly
Special Tool 6135, cradle Special Tool 6710 with
Posts Special Tool 6848 to be installed under vehicle
(Fig. 8).
(32) Loosen cradle posts to allow movement for
proper positioning. Locate two rear posts (right side
of engine) into the holes on the engine bedplate.
Locate the two front posts (left side of engine) on the
oil pan rails (Fig. 8). Lower vehicle and position cra-
dle mounts until the engine is resting on mounts.
Tighten mounts to cradle frame. This will keep
mounts from moving when removing or installing
engine and transmission.
(33) Install safety straps around the engine to cra-
dle. Tighten straps and lock.
(34) Lower vehicle so the weight ofONLY THE
ENGINE AND TRANSMISSIONare on the cradle.
(35) Remove engine and transmission mount bolts.
(36) Raise vehicle slowly. It may be necessary to
move the engine/transmission assembly with the
dolly to allow for removal around the body.
Fig. 6 Crossmember Cradle Plate
1 - CRADLE PLATE
Fig. 7 Catalytic Converter to Exhaust Manifold
1 - CATALYTIC CONVERTER
2 - BOLT
3 - GASKET
4 - FLAG NUT
9 - 14 ENGINE 2.4LRS
ENGINE 2.4L (Continued)
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INSTALLATION - ENGINE ASSEMBLY
(1) Position engine and transmission assembly
under vehicle and slowly lower the vehicle over the
engine and transmission.
(2) Align engine and transmission mounts to
attaching points. Install mounting bolts at the right
(Fig. 9) and left mounts (Fig. 10).
(3) Remove safety straps.
(4) Slowly raise vehicle enough to remove the
engine dolly and cradle Special Tools 6135 and 6710.
(5) Install rear mount bracket and rear mount
through bolt. (Refer to 9 - ENGINE/ENGINE
MOUNTING/REAR MOUNT - INSTALLATION)
(6) Install the flex plate to torque converter bolts.
(7) Install structural collar. (Refer to 9 - ENGINE/
ENGINE BLOCK/STRUCTURAL COVER - INSTAL-
LATION)
(8) Install front mount bracket and front mount
through bolt. (Refer to 9 - ENGINE/ENGINE
MOUNTING/FRONT MOUNT - INSTALLATION)
(9) Connect exhaust system to manifold (Fig. 7).
(10) Install crossmember cradle plate (Fig. 6).
(11) Install new oil filter.
(12) Install power steering pump and bracket.(13) Connect power steering supply line to pump
and remove pinch-off pliers.
(14) Connect A/C compressor hoses to compressor.
(15) Install accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION)
(16) Install axle shafts. (Refer to 3 - DIFFEREN-
TIAL & DRIVELINE/HALF SHAFT - INSTALLA-
TION)
(17) Install accessory drive belt splash shield.
(18) Install front wheels and tires.
(19) Remove plugs from transmission cooler hoses
and install transaxle oil cooler line service splice kit.
Refer to instructions included with kit.
(20) Connect the transaxle shift linkage and elec-
trical connectors.
(21) Connect heater hoses (Fig. 5).
(22) Install ground straps.
(23) Connect all engine and throttle body electrical
connections.
(24) Connect all vacuum lines.
(25) Connect the throttle cables.
(26) Connect the fuel line. (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY/QUICK CONNECT FIT-
TING - STANDARD PROCEDURE)
(27) Connect radiator lower and upper hoses.
(28) Install radiator fans. (Refer to 7 - COOLING/
ENGINE/RADIATOR FAN - INSTALLATION)
(29) Fill cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(30) Connect battery cables.
(31) Install air cleaner and inlet hose.
Fig. 9 RIGHT MOUNT TO RAIL AND ENGINE
1 - BOLT - MOUNT TO RAIL 68 N´m (50 ft. lbs.)
2 - BOLT - MOUNT TO ENGINE 54 N´m (40 ft. lbs.)
3 - BOLT - MOUNT TO RAIL (HORIZONTAL) 68 N´m (50 ft. lbs.)
4 - RIGHT ENGINE MOUNT
5 - RIGHT FRAME RAIL
Fig. 10 LEFT MOUNT TO FRAME BRACKET
1 - FRAME BRACKET
2 - FRAME RAIL - LEFT
3 - BOLT
4 - TRANSAXLE MOUNT
9 - 16 ENGINE 2.4LRS
ENGINE 2.4L (Continued)
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