2002 CHRYSLER CARAVAN clock

AUTO TEMP CONTROL C1 - WHITE 13 WAY
CAV CIRCUIT FUNCTION
1 C161 20LB/WT DRIVER BLEND DOOR DRIVER (B)
2 C61 20DB/LG DRIVER BLEND DOOR DRIVER (A)
3 C133 20DB/WT PASSENGER BLEND DOOR DRIVER (B)
4 C33 20LB/BR PASSENGER BLEND DOOR DRIVER (A)
5 C132 20DB/YL RECIRCULATION DOOR DRIVER (B)
6 C32 20DB/TN RECIRCULATION DOOR DRIVER (A)
7 C135 20DB/GY MODE DOOR DRIVER (B)
8 C35 20LB/OR MODE DOOR DRIVER (A)
9 C53 20LB REAR MODE DOOR DRIVER (A)
10 C154 20LB/OR REAR MODE DOOR DRIVER (B)
11 C54 20LB/YL REAR BLEND DOOR DRIVER (A)
12 C169 20DB/OR REAR BLEND DOOR DRIVER (B)
13 - -
AUTO TEMP CONTROL C2 - BLACK 13 WAY
CAV CIRCUIT FUNCTION
1 C21 20DB/LG EVAPORATOR TEMPERATURE SENSOR SIGNAL
2 C121 20DB/DG SENSOR GROUND
3 E12 20OR/GY PANEL LAMPS DRIVER
4 A114 20GY/RD FUSED B(+) (I.O.D.)
5 F504 20GY/PK FUSED IGNITION SWITCH OUTPUT (RUN)
6 D25 20WT/VT PCI BUS
7 C56 20DB/LB BLOWER MOTOR CONTROL
8 C59 20DB/LB REAR BLOWER MOTOR CONTROL
9 D22 20WT/TN KDB CLOCK
10 D17 20WT/DG KDB DATA
11 Z24 18BK/OR GROUND
12 C200 20LB/DG TXV SOLENOID FEED
13 C900 18LB/VT WIPER DE-ICER DRIVER
AUTO TEMP CONTROL C3-4WAY
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
AUTOMATIC DAY/NIGHT MIRROR (PREMIUM/LUXURY) - BLACK 7 WAY
CAV CIRCUIT FUNCTION
1 F503 20BK/PK FUSED IGNITION SWITCH OUTPUT (RUN)
2 Z113 20BK GROUND
3 L1 20BK/WT BACK-UP LAMP FEED
4 P112 20BK/OR (EXCEPT
BUILT-UP-EXPORT)MIRROR B(+)
5 P114 20BK/LB (EXCEPT
BUILT-UP-EXPORT)MIRROR B(-)
6- -
7 L24 20BK/GY (EXCEPT
BUILT-UP-EXPORT)AUTOMATIC HEADLAMP SWITCH SENSOR
RS8W-80 CONNECTOR PIN-OUTS8W-80-9
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CENTER HIGH MOUNTED STOP LAMP - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 Z350 20BK/TN GROUND
2 L50 18WT/TN BRAKE LAMP SWITCH OUTPUT
CLOCKSPRING C1 - WHITE 6 WAY
CAV CIRCUIT FUNCTION
1 X920 20GY/OR RADIO CONTROL MUX RETURN
2 X20 20GY/WT RADIO CONTROL MUX
3 X3 20DG/VT HORN SWITCH SENSE
4 V37 20VT SPEED CONTROL SWITCH SIGNAL
5 K900 20DB/DG SPEED CONTROL SWITCH GROUND
6- -
CLOCKSPRING C2 - YELLOW 4 WAY
CAV CIRCUIT FUNCTION
1 R61 18LG/PK DRIVER SQUIB 2 LINE 1
2 R63 18LG/WT DRIVER SQUIB 2 LINE 2
3 R43 18LG/BR DRIVER SQUIB 1 LINE 1
4 R45 18LG/OR DRIVER SQUIB 1 LINE 2
CLOCKSPRING C3 - BLACK 4 WAY
CAV CIRCUIT FUNCTION
1- -
2 Z23 20BK/VT RIGHT SPEED CONTROL SWITCH GROUND
2 Z23 20BK/VT LEFT SPEED CONTROL SWITCH GROUND
3 V37 20DG/VT (EXCEPT
BUILT-UP-EXPORT)SPEED CONTROL SWITCH SIGNAL
3 V37 20DG/VT (EXCEPT
BUILT-UP-EXPORT)SPEED CONTROL SWITCH SIGNAL
3 V37 20VT/TN (BUILT-UP-EXPORT) SPEED CONTROL SWITCH SIGNAL
3 V37 20VT/TN (BUILT-UP-EXPORT) SPEED CONTROL SWITCH SIGNAL
4 X3 20DG/VT HORN SWITCH SENSE
CLOCKSPRING C4 - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 X20 20RD/BK RADIO CONTROL MUX
2 X920 20RD/DB RADIO CONTROL MUX RETURN
8W - 80 - 44 8W-80 CONNECTOR PIN-OUTSRS
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CLOCKSPRING C5 - YELLOW 4 WAY
CAV CIRCUIT FUNCTION
1 R45 18OR/LB DRIVER SQUIB 1 LINE 2
2 R43 18BK/LB DRIVER SQUIB 1 LINE 1
3 R63 18TN/LB DRIVER SQUIB 2 LINE 2
4 R61 18OR/LB DRIVER SQUIB 2 LINE 1
CLUTCH PEDAL INTERLOCK SWITCH (MTX) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 T141 20YL/OR IGNITION SWITCH OUTPUT (START)
2 T751 20YL IGNITION SWITCH OUTPUT (START)
CLUTCH PEDAL INTERLOCK SWITCH JUMPER (ATX) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 T141 20YL/OR IGNITION SWITCH OUTPUT (START)
2 T751 20YL IGNITION SWITCH OUTPUT (START)
CLUTCH PEDAL UPSTOP SWITCH (DIESEL) - RED 2 WAY
CAV CIRCUIT FUNCTION
1 K119 20DB/LG CLUTCH PEDAL UPSTOP SWITCH SENSE
2 Z150 20BK/LG GROUND
RS8W-80 CONNECTOR PIN-OUTS8W-80-45
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RADIO CHOKE - LT. GRAY 2 WAY
CAV CIRCUIT FUNCTION
1 X1 16DG/BR NAME BRAND SPEAKER RELAY OUTPUT
2 X13 16DG/GY RADIO CHOKE OUTPUT
REAR A/C-HEATER UNIT (3 ZONE HVAC) - LT. GREEN 10 WAY
CAV CIRCUIT FUNCTION
1 C53 20LB REAR MODE DOOR DRIVER
2 C154 20LB/OR REAR COMMON DOOR DRIVER
3 C51 12LB/BR FUSED REAR BLOWER MOTOR RELAY OUTPUT
4 C152 16LB/LG REAR BLOWER MOTOR MED
5 C151 18LB/DG REAR BLOWER MOTOR LOW
6 C153 12DB/BR REAR BLOWER MOTOR HIGH
7 C54 20LB/YL REAR BLEND DOOR DRIVER
8 C154 20LB/OR REAR COMMON DOOR DRIVER
9- -
10 C200 20LB/DG TXV SOLENOID FEED
REAR AUTO TEMP CONTROL SWITCH (ATC) - BLACK 13 WAY
CAV CIRCUIT FUNCTION
1 F504 20GY/PK FUSED IGNITION SWITCH OUTPUT (RUN)
2 Z27 18BK/DG GROUND
3 D22 20WT/TN KDB CLOCK
4 D17 20WT/DG KDB DATA
5 E10 20OR/DG PANEL LAMPS DRIVER
6- -
7- -
8- -
9- -
10 - -
11 - -
12 - -
13 - -
REAR BLOWER FRONT CONTROL SWITCH (3 ZONE HVAC) - BLACK 8 WAY
CAV CIRCUIT FUNCTION
1- -
2 Z440 12BK/DG GROUND
3- -
4 C153 12DB/BR REAR BLOWER MOTOR HIGH
5- -
6 C152 16LB/LG REAR BLOWER MOTOR MED
7 C151 18LB/DG REAR BLOWER MOTOR LOW
8 C50 12DB/OR REAR BLOWER FRONT CONTROL FEED
RS8W-80 CONNECTOR PIN-OUTS8W-80-99
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CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
C325 BK Right Sliding Door 27
C326 YL At Driver Side Airbag N/S
C327 YL At Passenger Side Airbag N/S
C329 (Diesel) BK Left Rear Engine Compartment N/S
C330 (Diesel) LTGY Left Rear Engine Compartment N/S
C331 (Diesel) BK Left Rear Engine Compartment N/S
Cabin Heater Assist C1 (Diesel) BK Top of Engine 11, 12
Cabin Heater Assist C2 (Diesel) BK Top of Engine 11, 12
Camshaft Position Sensor (Gas) BK Rear of Cylinder Head
Right Side of EngineN/S
Camshaft Position Sensor (Diesel) BK Rear of Cylinder Head 11, 12
CD Changer Behind CD Changer N/S
Center Dome Lamp GY At Lamp N/S
Center High Mounted Stop Lamp BK At Lamp 42
Clockspring - C1 WT Steering Column 15, 16, 17, 18, 26
Clockspring - C2 YL Steering Column 15, 16, 17, 18, 26
Clockspring - C3 BK Steering Column N/S
Clockspring - C4 BK Steering Column N/S
Clockspring - C5 YL Steering Column N/S
Clutch Pedal Interlock Switch
(Diesel)RD At Switch/Driver Side 36
Clutch Pedal Upstop Switch
(Diesel)BK At Switch/Driver Side 36
Controller Anti-Lock Brake BK Right Side of Engine Compartment 9, 10, 12, 13, 14
Crank Case Ventilation Heater
(Diesel)BK Top of Cylinder Head 11
Crankshaft Position Sensor (Diesel) BK Rear of Engine 12
Crankshaft Position Sensor (Gas) BK Rear of Engine 9, 13
Data Link Connector WT Lower Instrument Panel Near Steering
Column35, 36
Diagnostic Junction Port BK Lower Instrument Panel Near Steering
Column35, 36
Dosing Pump BK Top of Engine N/S
Driver Airbag C1 BN Steering Column N/S
Driver Airbag C2 BK Steering Column N/S
Driver Blend Actuator (ATC) GY On HVAC N/S
Driver Blend Actuator (MTC) GY On HVAC N/S
Driver Door Courtesy Lamp GY At Lamp N/S
Driver Door Lock Switch BK At Switch N/S
Driver Heated Seat Back GN At Seat N/S
Driver Heated Seat Cushion BK At Seat N/S
Driver Heated Seat Module C1 GY Driver Heated Seat N/S
Driver Heated Seat Module C2 GY Driver Heated Seat Back N/S
Driver Heated Seat Module C3 GN At Seat N/S
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-3
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
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(4) The coil ground terminal (85) is connected to
the electromagnet in the relay. It receives battery
feed to energize the accessory relay when the ignition
switch is in the Accessory or On positions. Turn the
ignition switch to the On position. Check for battery
voltage at the fused ignition switch output (acc/run)
circuit cavity for relay terminal 85 in the IPM recep-
tacle for the accessory relay. If OK, go to Step 5. If
not OK, repair the open fused ignition switch output
(acc/run) circuit to the ignition switch as required.
(5) The coil battery terminal (86) is connected to
the electromagnet in the relay. The IPM cavity for
this terminal should have continuity to ground at all
times. If not OK, repair the open ground circuit to
ground as required.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the Integrated Power Module (IPM)
cover from the IPM.
(3) Remove the accessory relay from the IPM.
Refer to the IPM cover for relay location.
INSTALLATION
(1) Position the accessory relay in the proper
receptacle in the Integrated Power Module (IPM).
(2) Push in firmly on the accessory relay until the
terminals are fully seated in the terminal cavities in
the IPM receptacle.
(3) Install the IPM cover.
(4) Reconnect the battery negative cable.
INTEGRATED POWER MODULE
DESCRIPTION
The Integrated Power Module (IPM) is a combina-
tion of the Power Distribution Center (PDC) and the
Front Control Module (FCM). The IPM is located in
the engine compartment, next to the battery on this
model (Fig. 2). The power distribution center mates
directly with the Front Control Module (FCM) to
form the IPM Fuse and Relay Center. The power dis-
tribution center (PDC) is a printed circuit board
based module that contains fuses and relays, while
the front control module contains the electronics con-
trolling the IPM and other functions. This IPM con-
nects directly to the battery positive via a four pin
connector. The ground connection is via two other
connectors. The IPM provides the primary means of
voltage distribution and protection for the entire
vehicle.
The molded plastic IPM housing includes a base
and cover. The IPM cover is easily opened or removed
for service access by squeezing the two marked coverlatches and has a fuse and relay layout map integral
to the inside surface of the cover. This IPM housing
base and cover are secured in place by an IPM
mounting bracket. This mounting bracket is designed
to allow the IPM to rotate counter-clockwise once the
locking tab is disengaged. The IPM mounting bracket
is secured in place by bolts threaded into the left
front wheel house.
Replaceable components of the IPM assembly are
broken down into the following components: the
Power Distribution Center (PDC) (without fuses or
relays), the IPM cover, the Front Control Module
(FCM), the IPM mounting bracket, IPM bracket
retaining clips and the IPM assembly which includes
the power distribution center, the cover and FCM.
Refer to the Front Control Module in the Elec-
tronic Control Module sectionof this service
manual for information on the FCM.
OPERATION
All of the current from the battery and the gener-
ator output enters the Integrated Power Module
(IPM) via a four- pin connector on the bottom of the
module. The IPM cover is unlatched and opened or
removed to access the fuses or relays. Internal con-
nections of all of the power distribution center cir-
cuits is accomplished by a combination of bus bars
and a printed circuit board. Refer to the Wiring sec-
Fig. 2 BATTERY THERMAL GUARD
1 - BATTERY THERMAL GUARD
2 - INTEGRATED POWER MODULE
3 - FRONT CONTROL MODULE
RS8W-97 POWER DISTRIBUTION SYSTEM8W-97-3
ACCESSORY RELAY (Continued)
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tion of the service manual for complete IPM circuit
schematics.
REMOVAL
(1) Disconnect the negative and positive battery
cables.
(2) Remove the battery thermal guard from the
vehicle. Refer to the Battery section for the proce-
dure.
(3) Remove the battery from the vehicle. Refer to
the Battery section for the procedure.
(4) Using a flat-bladed screwdriver, twist the Inte-
grated Power Module (IPM) bracket retaining latch
outward to free the intelligent power module from its
mounting bracket (Fig. 3).
(5) Rotate the IPM counter-clockwise to access and
disconnect the various electrical connectors (Fig. 4).
(6) Free the IPM from its mounting bracket by
removing the IPM bracket clips from the hinge. A
screwdriver slipped up from under the hinge will free
the clips.
INSTALLATION
(1) Snap the left side of the Integrated Power Mod-
ule (IPM) housing in its mounting bracket and con-
nect the various electrical connectors. Care must be
taken that the Connector Positive Assurance (CPA)
on the five-pin B+ connector is positively engaged to
prevent generating a Diagnostic Trouble Code (DTC).
NOTE: IPM electrical connectors are color coded to
ease location reference.(2) Being certain no wires are stressed or pinched,
rotate the IPM clock-wise until secured in mounting
bracket. An audible click may be heard.
(3) Install the battery in the vehicle. Refer to the
Battery section for the procedure.
(4) Install the battery thermal guard in the vehi-
cle. Refer to the Battery section for the procedure.
(5)
Connect the negative and positive battery cables.
(6) Using a diagnostic scan tool, check for any
stored diagnostic trouble codes and correct, check
that all vehicle options are operational before return-
ing the vehicle to service.
IOD FUSE
DESCRIPTION
All vehicles are equipped with an Ignition-Off
Draw (IOD) fuse that is removed from its normal
cavity in the Integrated Power Module (IPM) when
the vehicle is shipped from the factory. Dealer per-
sonnel are to remove the IOD fuse from the storage
location and install it into the IPM fuse cavity
marked IOD as part of the preparation procedures
performed just prior to new vehicle delivery.
The IPM has a molded plastic cover that can be
removed to provide service access to all of the fuses
and relays in the IPM. An integral latch and hinges
are molded into the IPM cover for easy removal. A
fuse layout map is integral to the underside of the
IPM cover to ensure proper fuse and relay identifica-
Fig. 3 RELEASING INTEGRATED POWER MODULE
FROM ITS MOUNTING BRACKET
Fig. 4 DISCONNECTING IPM
1 - INTEGRATED POWER MODULE FUSE & RELAY CENTER
8W - 97 - 4 8W-97 POWER DISTRIBUTION SYSTEMRS
INTEGRATED POWER MODULE (Continued)
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tion. The IOD fuse is a 15 ampere blade-type car-
tridge fuse and, when removed, it is stored in a fuse
cavity adjacent to the washer fuse within the IPM.
OPERATION
The term ignition-off draw identifies a normal con-
dition where power is being drained from the battery
with the ignition switch in the Off position. The IOD
fuse feeds the memory and sleep mode functions for
some of the electronic modules in the vehicle as well
as various other accessories that require battery cur-
rent when the ignition switch is in the Off position,
including the clock. The only reason the IOD fuse is
removed is to reduce the normal IOD of the vehicle
electrical system during new vehicle transportation
and pre-delivery storage to reduce battery depletion,
while still allowing vehicle operation so that the
vehicle can be loaded, unloaded and moved as needed
by both vehicle transportation company and dealer
personnel.
The IOD fuse is removed from the IPM fuse cavity
when the vehicle is shipped from the assembly plant.
Dealer personnel must install the IOD fuse when the
vehicle is being prepared for delivery in order to
restore full electrical system operation. Once the
vehicle is prepared for delivery, the IOD function of
this fuse becomes transparent and the fuse that has
been assigned the IOD designation becomes only
another Fused B(+) circuit fuse. The IOD fuse serves
no useful purpose to the dealer technician in the ser-
vice or diagnosis of any vehicle system or condition,
other than the same purpose as that of any other
standard circuit protection device.
The IOD fuse can be used by the vehicle owner as
a convenient means of reducing battery depletion
when a vehicle is to be stored for periods not to
exceed about thirty days. However, it must be
remembered that removing the IOD fuse will not
eliminate IOD, but only reduce this normal condition.
If a vehicle will be stored for more than about thirty
days, the battery negative cable should be discon-
nected to eliminate normal IOD; and, the battery
should be tested and recharged at regular intervals
during the vehicle storage period to prevent the bat-
tery from becoming discharged or damaged. Refer to
Battery Systemfor additional service information.
REMOVAL
(1) Turn the ignition switch to the Off position.
(2) Unlatch and open the cover of the intelligent
power module.
(3) Remove the IOD fuse from fuse location
markedIODof the Integrated Power Module (IPM).
(4) Store the removed IOD fuse by installing it in
the unused fuse storage markedSPAREof the IPM.
(5) Close and latch the IPM.
INSTALLATION
(1) Be certain the ignition switch is in the Off posi-
tion.
(2) Unlatch and open the cover of the Integrated
Power Module (IPM).
(3) Remove the stored 15 amp IOD fuse from fuse
storage markedSPAREof the IPM.
(4) Use a thumb to press the IOD fuse firmly down
into IPM fuse cavity markedIOD.
(5) Close and latch the IPM cover.
POWER OUTLET
DESCRIPTION
Accessory power outlets are standard equipment on
this model. Two power outlets are installed in the
instrument panel center lower bezel, which is located
near the bottom of the instrument panel center stack
area. Two additional power outlets are also incorpo-
rated into the vehicle, one on the left rear C-pillar
trim and the other in the center console, if equipped.
The power outlets bases are secured by a snap fit in
the appropriate bezels. A hinged plug flips closed to
conceal and protect the power outlet base when the
power outlet is not being used.
The power outlet receptacle unit and the power
outlet plugs are each available for service replace-
ment.
OPERATION
The power outlet base or receptacle shell is con-
nected to ground, and an insulated contact in the
bottom of the shell is connected to battery current.
The power outlet on the instrument panel marked
with a battery receives battery voltage from a fuse in
the Integrated Power Module (IPM) at all times. The
other power outlet on the instrument panel marked
with a key receives battery voltage only when the
key is in the on position.
The power outlet located in the center console
receives battery voltage all the time when positioned
between thefront seatsand key-on voltage when
positioned between therear seats. The power outlet
located on the C-pillar receives battery voltage only
when the key is in the on position.
DIAGNOSIS AND TESTING
DIAGNOSIS & TESTING - POWER OUTLET
For complete circuit diagrams, refer toCigar
Lighter/Power Outletin Wiring Diagrams.
RS8W-97 POWER DISTRIBUTION SYSTEM8W-97-5
IOD FUSE (Continued)
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