2002 CHRYSLER CARAVAN coolant

(4) Remove the screw holding the PLG control
module to the D-pillar (Fig. 10).
(5) Remove the PLG control module from the vehi-
cle.
INSTALLATION
(1) Install the PLG control module on the D-pillar
and install retaining screw. Torque the screw to 14.5
in. lbs.
(2) Connect the wire harness connections on the
PLG control module. Be certain to slide connector
locks to the locked position.
(3) Install the D-pillar trim panel on the vehicle.
Refer to the Body section for the procedure.
(4) Connect the negative battery cable.
(5) Using an appropriate scan tool, check any
erase any PLG control module diagnostic trouble
codes.
(6) Verify PLG system operation. Cycle the PLG
through one complete open and close cycle, this will
allow the PLG control module to relearn its cycle
with the new components.
POWERTRAIN CONTROL
MODULE
DESCRIPTION
DESCRIPTION
The Powertrain Control Module (PCM) is a digital
computer containing a microprocessor (Fig. 11). The
PCM receives input signals from various switches
and sensors referred to as Powertrain Control Mod-
ule Inputs. Based on these inputs, the PCM adjusts
various engine and vehicle operations through
devices referred to as Powertrain Control Module
Outputs.
NOTE: PCM Inputs:
²Air Conditioning Pressure Transducer
²ASD Relay
²Battery Voltage
²Brake Switch
²Camshaft Position Sensor
²Crankshaft Position Sensor
²Distance Sensor (from transmission control mod-
ule)
²EGR Position Feedback
²Engine Coolant Temperature Sensor
²Heated Oxygen Sensors
Fig. 10 LIFTGATE CONTROL MODULE
1 - POWER LIFTGATE CONTROL MODULE
2 - MODULE RETAINING SCREWS
3 - D-PILLAR
4 - POWER LIFTGATE MOTOR
5 - MODULE ELECTRICAL CONNECTORS
Fig. 11 Powertrain Control Module (PCM)
1 - Battery
2 - Power Distribution Center
3 - Powertrain Control Module
RSELECTRONIC CONTROL MODULES8E-11
POWER LIFTGATE MODULE (Continued)
ProCarManuals.com

²Ignition sense
²Intake Air Temperature Sensor
²Knock Sensor
²Leak Detection Pump Feedback
²Manifold Absolute Pressure (MAP) Sensor
²Park/Neutral (from transmission control module)
²PCI Bus
²Power Steering Pressure Switch
²Proportional Purge Sense
²SCI Receive
²Speed Control
²Throttle Position Sensor
²Torque Management Input (From TCM)
²Transaxle Control Module (TCM)
²Transaxle Gear Engagement (From TCM)
²Vehicle Speed (from transmission control mod-
ule)
NOTE: PCM Outputs:
²Air Conditioning Clutch Relay
²Automatic Shut Down (ASD) and Fuel Pump
Relays
²Data Link Connector (PCI and SCI Transmit)
²Double Start Override
²EGR Solenoid
²Fuel Injectors
²Generator Field
²High Speed Fan Relay
²Idle Air Control Motor
²Ignition Coils
²Leak Detection Pump
²Low Speed Fan Relay
²MTV Actuator
²Proportional Purge Solenoid
²SRV Valve
²Speed Control Relay
²Speed Control Vent Relay
²Speed Control Vacuum Relay
²8 Volt Output
²5 Volt Output
Based on inputs it receives, the powertrain control
module (PCM) adjusts fuel injector pulse width, idle
speed, ignition timing, and canister purge operation.
The PCM regulates the cooling fans, air conditioning
and speed control systems. The PCM changes gener-
ator charge rate by adjusting the generator field.
The PCM adjusts injector pulse width (air-fuel
ratio) based on the following inputs.
²Battery Voltage
²Intake Air Temperature Sensor
²Engine Coolant Temperature
²Engine Speed (crankshaft position sensor)²Exhaust Gas Oxygen Content (heated oxygen
sensors)
²Manifold Absolute Pressure
²Throttle Position
The PCM adjusts engine idle speed through the
idle air control motor based on the following inputs.
²Brake Switch
²Engine Coolant Temperature
²Engine Speed (crankshaft position sensor)
²Park/Neutral (transmission gear selection)
²Transaxle Gear Engagement
²Throttle Position
²Vehicle Speed (from Transmission Control Mod-
ule)
The PCM adjusts ignition timing based on the fol-
lowing inputs.
²Intake Air Temperature
²Engine Coolant Temperature
²Engine Speed (crankshaft position sensor)
²Knock Sensor
²Manifold Absolute Pressure
²Park/Neutral (transmission gear selection)
²Transaxle Gear Engagement
²Throttle Position
The automatic shut down (ASD) and fuel pump
relays are mounted externally, but turned on and off
by the powertrain control module through the same
circuit.
The camshaft and crankshaft signals are sent to
the powertrain control module. If the PCM does not
receive both signals within approximately one second
of engine cranking, it deactivates the ASD and fuel
pump relays. When these relays are deactivated,
power is shut off to the fuel injectors, ignition coils,
fuel pump and the heating element in each oxygen
sensor.
The PCM contains a voltage converter that
changes battery voltage to a regulated 8.0 volts. The
8.0 volts power the camshaft position sensor, crank-
shaft position sensor and vehicle speed sensor. The
PCM also provides a 5.0 volts supply for the engine
coolant temperature sensor, intake air temperature
sensor, manifold absolute pressure sensor and throt-
tle position sensor.
The PCM engine control strategy prevents reduced
idle speeds until after the engine operates for 320 km
(200 miles). If the PCM is replaced after 320 km (200
miles) of usage, update the mileage in new PCM. Use
the DRB scan tool to change the mileage in the PCM.
Refer to the appropriate Powertrain Diagnostic Man-
ual and the DRB scan tool.
8E - 12 ELECTRONIC CONTROL MODULESRS
POWERTRAIN CONTROL MODULE (Continued)
ProCarManuals.com

(M) Check Engine Lamp (MIL) will illuminate during engine operation if this Diagnostic Trouble Code was recorded.
(G) Generator Lamp Illuminated
GENERIC
SCAN TOOL
CODEDRB SCAN TOOL DISPLAY DESCRIPTION OF DIAGNOSTIC TROUBLE CODE
P0106 (M) Barometric Pressure Out of Range MAP sensor input voltage out of an acceptable range
detected during reading of barometric pressure at key-on.
P0107 (M) Map Sensor Voltage Too Low MAP sensor input below minimum acceptable voltage.
P0108 (M) Map Sensor Voltage Too High MAP sensor input above maximum acceptable voltage.
P0110 Intake Air Temp Sensor Stuck A rationality error has been detected for the intake air temp.
sensor.
P0111 (M) Intake Air Temp Sensor Performance Intake Air change less than 3É C in 200 Miles
P0112 (M) Intake Air Temp Sensor Voltage Low Intake air (charge) temperature sensor input below the
minimum acceptable voltage.
P0113 (M) Intake Air Temp Sensor Voltage High Intake air (charge) temperature sensor input above the
maximum acceptable voltage.
P0116 Engine Coolant Temp Performance A rationality error has been detected in the coolant temp
sensor.
P0117 (M) ECT Sensor Voltage Too Low Engine coolant temperature sensor input below the minimum
acceptable voltage.
P0118 (M) ECT Sensor Voltage Too High Engine coolant temperature sensor input above the
maximum acceptable voltage.
P0121 (M) TPS Voltage Does Not Agree With
MAPTPS signal does not correlate to MAP sensor signal.
P0122 (M) Throttle Position Sensor Voltage Low Throttle position sensor input below the acceptable voltage
range.
P0123 (M) Throttle Position Sensor Voltage High Throttle position sensor input above the maximum
acceptable voltage.
P0125 (M) Engine Coolant Temp Not Reached Time to enter Closed Loop Operation (Fuel Control) is
excessive.
P0128 Thermostat Rationality A rationality error has been detected for the thermostat
P0129 Barometic Pressure Out-of-Range low MAP sensor input voltage out of an acceptable range
detected during reading of barometric pressure.
P0130 1/1 O2 Sensor Heater Relay Circuit An open or shorted condition detected in the ASD or CNG
shutoff relay control ckt.
P0131 (M) 1/1 O2 Sensor Shorted To Ground Oxygen sensor input voltage maintained below normal
operating range.
P0132 (M) 1/1 O2 Sensor Shorted To Voltage Oxygen sensor input voltage maintained above normal
operating range.
P0133 (M) 1/1 O2 Sensor Slow Response Oxygen sensor response slower than minimum required
switching frequency.
P0134 (M) 1/1 O2 Sensor Stays at Center Neither rich or lean condition is detected from the oxygen
sensor input.
P0135 (M) 1/1 O2 Sensor Heater Failure Oxygen sensor heater element malfunction.
P0136 1/2 O2 Sensor Heater Relay Circuit An open or shorted condition detected in the ASD or CNG
shutoff relay control ckt.
P0137 (M) 1/2 O2 Sensor Shorted To Ground Oxygen sensor input voltage maintained below normal
operating range.
8E - 14 ELECTRONIC CONTROL MODULESRS
POWERTRAIN CONTROL MODULE (Continued)
ProCarManuals.com

(M) Check Engine Lamp (MIL) will illuminate during engine operation if this Diagnostic Trouble Code was recorded.
(G) Generator Lamp Illuminated
GENERIC
SCAN TOOL
CODEDRB SCAN TOOL DISPLAY DESCRIPTION OF DIAGNOSTIC TROUBLE CODE
P0850 Park/Natural Switch Performance A rationality error has been detected for park/neutral switch
performance.
P1105 Baro Read Solenoid Circuit Open or shorted condition detected in the baro read solenoid
control circuit.
P1115 General Temperature Rationality General temperature sensor rationality error.
P1192 (M) Inlet Air Temp. Circuit Low Inlet Air Temp. sensor input below acceptable voltage
P1193 (M) Inlet Air Temp. Circuit High Inlet Air Temp. sensor input above acceptable voltage.
P1194 PWM O2 Heater Performance Incorrect or irrational performance has been detected for the
PWM O2 heater circuit.
P1195 (M) 1/1 O2 Sensor Slow During Catalyst
MonitorA slow switching oxygen sensor has been detected in bank
1/1 during catalyst monitor test. (was P0133)
P1196 (M) 2/1 O2 Sensor Slow During Catalyst
MonitorA slow switching oxygen sensor has been detected in bank
2/1 during catalyst monitor test. (was P0153)
P1197 1/2 O2 Sensor Slow During Catalyst
MonitorA slow switching oxygen sensor has been detected in bank
1/2 during catalyst monitor test. (was P0139)
P1198 Radiator Temperature Sensor Volts
Too HighRadiator coolant temperature sensor input above the
maximum acceptable voltage.
P1199 Radiator Temperature Sensor Volts
Too LowRadiator coolant temperature sensor input below the
minimum acceptable voltage.
P1281 Engine is Cold Too Long Engine coolant temperature remains below normal operating
temperatures during vehicle travel (Thermostat).
P1282 Fuel Pump Relay Control Circuit An open or shorted condition detected in the fuel pump relay
control circuit.
P1288 Intake Manifold Short Runner Solenoid
CircuitAn open or shorted condition detected in the short runner
tuning valve circuit.
P1289 Manifold Tune Valve Solenoid Circuit An open or shorted condition detected in the manifold tuning
valve solenoid control circuit.
P1290 CNG Fuel System Pressure Too High Compressed natural gas system pressure above normal
operating range.
P1291 No Temp Rise Seen From Intake
HeatersEnergizing Heated Air Intake does not change intake air
temperature sensor an acceptable amount.
P1292 CNG Pressure Sensor Voltage Too
HighCompressed natural gas pressure sensor reading above
acceptable voltage.
P1293 CNG Pressure Sensor Voltage Too
LowCompressed natural gas pressure sensor reading below
acceptable voltage.
P1294 (M) Target Idle Not Reached Target RPM not achieved during drive idle condition.
Possible vacuum leak or IAC (AIS) lost steps.
P1295 No 5 Volts to TP Sensor Loss of a 5 volt feed to the Throttle Position Sensor has
been detected.
P1296 No 5 Volts to MAP Sensor Loss of a 5 volt feed to the MAP Sensor has been detected.
P1297 (M) No Change in MAP From Start To Run No difference is recognized between the MAP reading at
engine idle and the stored barometric pressure reading.
RSELECTRONIC CONTROL MODULES8E-21
POWERTRAIN CONTROL MODULE (Continued)
ProCarManuals.com

(M) Check Engine Lamp (MIL) will illuminate during engine operation if this Diagnostic Trouble Code was recorded.
(G) Generator Lamp Illuminated
GENERIC
SCAN TOOL
CODEDRB SCAN TOOL DISPLAY DESCRIPTION OF DIAGNOSTIC TROUBLE CODE
P2008 Short Runner Valve Solenoid Circuit An open or shorted condition detected in the short runner
tuning valve control circuit.
P2302 Ignition Coil Secondary #1 Circuit
P2305 Ignition Coil Secondary #2 Circuit
P2308 Ignition Coil Secondary #3 Circuit
P2311 Ignition Coil Secondary #4 Circuit
P2314 Ignition Coil Secondary #5 Circuit
P2317 Ignition Coil Secondary #6 Circuit
P2320 Ignition Coil Secondary #7 Circuit
P2323 Ignition Coil Secondary #8 Circuit
P2503 Charging System Voltage Low Charging system voltage below minimum acceptable voltage.
OPERATION - SENSOR RETURN - PCM INPUT
The sensor return circuit provides a low electrical
noise ground reference for all of the systems sensors.
The sensor return circuit connects to internal ground
circuits within the Powertrain Control Module (PCM).
OPERATION - SCI RECEIVE - PCM INPUT
SCI Receive is the serial data communication
receive circuit for the DRB scan tool. The Powertrain
Control Module (PCM) receives data from the DRB
through the SCI Receive circuit.
OPERATION - IGNITION SENSE - PCM INPUT
The ignition sense input informs the Powertrain
Control Module (PCM) that the ignition switch is in
the crank or run position.
OPERATION - PCM GROUND
Ground is provided through multiple pins of the
PCM connector. Depending on the vehicle there may
be as many as three different ground pins. There are
power grounds and sensor grounds.
The power grounds are used to control the ground
side of any relay, solenoid, ignition coil or injector.
The signal ground is used for any input that uses
sensor return for ground, and the ground side of any
internal processing component.
The SBEC III case is shielded to prevent RFI and
EMI. The PCM case is grounded and must be firmly
attached to a good, clean body ground.
Internally all grounds are connected together, how-
ever there is noise suppression on the sensor ground.
For EMI and RFI protection the case is also
grounded separately from the ground pins.
OPERATION
OPERATION - 8-VOLT SUPPLY - PCM OUTPUT
The PCM supplies 8 volts to the crankshaft posi-
tion sensor, camshaft position sensor.
OPERATION - 5 VOLT SUPPLY - PCM OUTPUT
The PCM supplies 5 volts to the following sensors:
²A/C pressure transducer
²Engine coolant temperature sensor
²Manifold absolute pressure sensor
²Throttle position sensor
²Linear EGR solenoid
²Battery temperature
²Knock sensor
STANDARD PROCEDURE - OBTAINING
DIAGNOSTIC TROUBLE CODES
BULB CHECK
Key on: Bulb illuminated until vehicle starts, as
long as all once per trip (readiness) monitors com-
pleted. If monitors havenotbeen completed, then:
Key on: bulb check for about 8 seconds, lamp then
flashes if once per trip (readiness) monitors havenot
been completed until vehicle is started, then MIL is
extinguished.
OBTAINING DTC'S USING DRB SCAN TOOL
(1) Connect the DRB scan tool to the data link
(diagnostic) connector. This connector is located in
the passenger compartment; at the lower edge of
instrument panel; near the steering column.
RSELECTRONIC CONTROL MODULES8E-25
POWERTRAIN CONTROL MODULE (Continued)
ProCarManuals.com

TRANSMISSION CONTROL
MODULE
DESCRIPTION
The Transmission Control Module (TCM) is located
behind the left fender and is fastened with three
screws to three clips in the left frame rail forward of
the suspension (Fig. 14).
OPERATION
The TCM is the controlling unit for all electronic
operations of the transaxle. The TCM receives infor-
mation regarding vehicle operation from both direct
and indirect inputs, and selects the operational mode
of the transaxle. Direct inputs are hardwired to, and
used specifically by the TCM. Indirect inputs origi-
nate from other components/modules, and are shared
with the TCM via the J1850 communication bus.Some examples ofdirect inputsto the TCM are:
²Battery (B+) voltage
²Ignition ªONº voltage
²Transmission Control Relay (Switched B+)
²Throttle Position Sensor
²Crankshaft Position Sensor (CKP)
²Transmission Range Sensor (TRS)
²Pressure Switches (L/R, 2/4, OD)
²Transmission Temperature Sensor (Integral to
TRS)
²Input Shaft Speed Sensor
²Output Shaft Speed Sensor
Some examples ofindirect inputsto the TCM are:
²Engine/Body Identification
²Manifold Pressure
²Target Idle
²Torque Reduction Confirmation
²Speed Control ON/OFF Switch
²Engine Coolant Temperature
²Ambient/Battery Temperature
²Brake Switch Status
²DRB Communication
Based on the information received from these var-
ious inputs, the TCM determines the appropriate
shift schedule and shift points, depending on the
present operating conditions and driver demand.
This is possible through the control of various direct
and indirect outputs.
Some examples of TCMdirect outputsare:
²Transmission Control Relay
²Solenoids (LR/CC, 2/4, OD and UD)
²Vehicle Speed (to PCM)
²Torque Reduction Request (to PCM)
An example of a TCMindirect outputis:
²Transmission Temperature (to PCM)
In addition to monitoring inputs and controlling
outputs, the TCM has other important responsibili-
ties and functions:
²Storing and maintaining Clutch Volume Indices
(CVI)
²
Storing and selecting appropriate Shift Schedules
²System self-diagnostics
²Diagnostic capabilities (with DRB scan tool)
Fig. 14 Transmission Control Module (TCM)
Location
1 - TRANSMISSION CONTROL MODULE (TCM)
8E - 28 ELECTRONIC CONTROL MODULESRS
ProCarManuals.com

SHIFT SCHEDULES
As mentioned earlier, the TCM has programming that
allows it to select a variety of shift schedules. Shift
schedule selection is dependent on the following:
²Shift lever position
²Throttle position
²Engine load²Fluid temperature
²Software level
As driving conditions change, the TCM appropri-
ately adjusts the shift schedule. Refer to the follow-
ing chart to determine the appropriate operation
expected, depending on driving conditions.
Schedule Condition Expected Operation
Extreme ColdOil temperature at start-up below
-16É FPark, Reverse, Neutral and 2nd
gear only (prevents shifting which
may fail a clutch with frequent
shifts)
ColdOil temperature at start-up above
-12É F and below 36É F± Delayed 2-3 upshift
(approximately 22-31 mph)
± Delayed 3-4 upshift (45-53 mph)
± Early 4-3 costdown shift
(approximately 30 mph)
± Early 3-2 coastdown shift
(approximately 17 mph)
± High speed 4-2, 3-2, 2-1 kickdown
shifts are prevented
± No EMCC
WarmOil temperature at start-up above
36É F and below 80 degree F± Normal operation (upshift,
kickdowns, and coastdowns)
± No EMCC
HotOil temperature at start-up above
80É F± Normal operation (upshift,
kickdowns, and coastdowns)
± Full EMCC, no PEMCC except to
engage FEMCC (except at closed
throttle at speeds above 70-83 mph)
OverheatOil temperature above 240É F or
engine coolant temperature above
244É F± Delayed 2-3 upshift (25-32 mph)
± Delayed 3-4 upshift (41-48 mph)
± 3rd gear FEMCC from 30-48 mph
± 3rd gear PEMCC from 27-31 mph
Super OverheatOil temperature above 260É F ± All9Overheat9shift schedule
features apply
± 2nd gear PEMCC above 22 mph
± Above 22 mph the torque
converter will not unlock unless the
throttle is closed or if a wide open
throttle 2nd PEMCC to 1 kickdown
is made
8E - 30 ELECTRONIC CONTROL MODULESRS
TRANSMISSION CONTROL MODULE (Continued)
ProCarManuals.com

ELECTRONIC CONTROL MODULES
TABLE OF CONTENTS
page page
ENGINE CONTROL MODULE
DESCRIPTION..........................1
OPERATION............................1
STANDARD PROCEDURE - PCM/ECM/SKIM
PROGRAMMING - DIESEL...............2REMOVAL.............................4
INSTALLATION..........................4
ENGINE CONTROL MODULE
DESCRIPTION
The ECM is located in the left front corner of the
engine compartment attached to the radiator support
(Fig. 1).
OPERATION
The ECM has been programmed to monitor differ-
ent circuits of the diesel fuel injection system. Thismonitoring is called on-board diagnostics. Certain cri-
teria must be met for a diagnostic trouble code to be
entered into the ECM memory. The criteria may be a
range of: engine rpm, engine temperature, time or
other input signals to the ECM. If all of the criteria
for monitoring a system or circuit are met, and a
problem is sensed, then a DTC will be stored in the
ECM memory. It is possible that a DTC for a moni-
tored circuit may not be entered into the ECM mem-
ory, even though a malfunction has occurred. This
may happen when the monitoring criteria have not
been met. The ECM compares input signal voltages
from each input device with specifications (the estab-
lished high and low limits of the input range) that
are programmed into it for that device. If the input
voltage is not within the specifications and other
trouble code criteria are met, a DTC will be stored in
the ECM memory.
ECM OPERATING MODES
As input signals to the ECM change, the ECM
adjusts its response to the output devices. For exam-
ple, the ECM must calculate a different fuel quantity
and fuel timing for engine idle condition than it
would for a wide open throttle condition. There are
several different modes of operation that determine
how the ECM responds to the various input signals.
Ignition Switch On (Engine Off)
When the ignition is turned on, the ECM activates
the glow plug relay for a time period that is deter-
mined by engine coolant temperature, atmospheric
temperature and battery voltage.
Engine Start-Up Mode
The ECM uses the engine temperature sensor and
the crankshaft position sensor (engine speed) inputs
to determine fuel injection quantity.
Normal Driving Modes
Engine idle, warm-up, acceleration, deceleration
and wide open throttle modes are controlled based on
all of the sensor inputs to the ECM. The ECM uses
Fig. 1 ENGINE CONTROL MODULE LOCATION-
TYPICAL
1 - BATTERY
2 - IPM (INTEGRATED POWER MODULE)
3 - ECM (ENGINE CONTROL MODULE)
4 - RETAINING BOLT
5 - RADIATOR SUPPORT
6 - CLUTCH CABLE BRACKET (LHD)
7 - CLUTCH CABLE BRACKET RETAINING BOLT (LHD)
RGELECTRONIC CONTROL MODULES8Ea-1
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