2002 CHRYSLER TOWN AND COUNTRY brakes

CONDITION POSSIBLE CAUSES CORRECTION
6. Freeze point of antifreeze not
correct. Mixture may be too rich.6. Check antifreeze. Adjust
antifreeze-to-water ratio as
required.
7. Coolant not flowing through
system.7. Check for coolant flow in
coolant tank with engine warm
and thermostat open. Coolant
should be observed flowing
through the tank. If flow is not
observed, determine reason for
lack of flow and repair as
necessary.
8. Radiator or A/C condensor fins
are dirty or clogged.8. Clean debris from radiator or
A/C condensor
9. Radiator core is corroded or
plugged.9. Have radiator re-cored or
replaced.
10. Aftermarket A/C installed without
proper A/C condensor.10. Install proper A/C
condensor.
11. Dragging Brakes. 11. Check and correct as
necessary.
12. Non-factory bug screen is being
used reducing airflow.12. Only a factory screen
should be used.
13. Thermostat partially or
completely shut. This is more
prevalent on high mileage vehicles.13. Check thermostat and
replace if necessary.
14. Cylinder head gasket leaking. 14. Check cylinder head gasket
for leaks.
15. Heater core leaking. 15. Check heater cor for leaks.
Repair as necessary.
TEMPERATURE GAUGE
READING IS
INCONSISTENT
(FLUCTUATES, CYCLES
OR IS ERRATIC)1. During cold weather operation,
with the heater blower in the high
position, the gauge reading may
drop slightly. Fluctuation is also
influenced by loads, outside
temperature and extended idle time
with diesel engines.1. A normal condition. No
correction is necessary.
2. Temperature gauge or engine
mounted gauge sensor defective or
shorted. Also, corroded or loose
wiring in this circuit.2. Check operation of gauge
and repair as necessary.
3. Gauge reading rises when vehicle
is brought to a stop after heavy use
(engine still running).3. A normal condition. No
correction needed. Gauge
should return to normal range
after vehicle is driven.
4. Gauge reading high after starting
a warm-iup (hot) engine.4. A normal condition. No
correction needed. Gauge
should return to normal after a
few minutes of engine
operation.
RGCOOLING 2.5L TURBO DIESEL7a-3
COOLING 2.5L TURBO DIESEL (Continued)
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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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When replacing a BCM there are three modules
available:
²Base
²Midline
²Highline
The Midline controller is used on vehicles that
have Power Door Locks and the Highline controller is
used for vehicles equipped with a Power Liftgate. If a
vehicle is equipped with the Vehicle Theft Security
System, the Midline/Highline controller becomes a
Premium when the theft feature is enabled.
CAUTION: Do not swap Body Control Modules
between vehicles or body controller's off the shelf.
The BCM has internal diagnostic capability that
assists in diagnosing the system error. When an
OPEN or a SHORT circuit exists, the diagnostic tool
can be used to read the BCM faults. The faults are
very descriptive in identifying the appropriate fea-
ture that has faulted.
The only two faults that the BCM logs that con-
clude the replacement of a BCM are faults;
²# 01 - Internal BCM failure (replace BCM)
²# 1F - J1850 Internal Hardware Failure (replace
BCM)
Otherwise the appropriate diagnostic procedures
for each of the features should be taken when the
BCM logs a fault.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the lower instrument panel silencer.
(3) Remove the knee blocker and reinforcement
(Refer to 23 - BODY/INSTRUMENT PANEL/KNEE
BLOCKER REINFORCEMENT - REMOVAL).
(4) Disconnect the five wire connectors from the
bottom of the Body Control Module (BCM).
(5) Move bulkhead wiring aside.
(6) Remove the screws holding the BCM to the
bulkhead.
(7) Remove the BCM from the mounting bracket.
INSTALLATION
(1) Install the BCM to the mounting bracket.
(2) Install the screws holding the BCM to the
bulkhead.
(3) Connect the five wire connectors to the bottom
of the Body Control Module (BCM).
(4) Install the knee blocker and reinforcement
(Refer to 23 - BODY/INSTRUMENT PANEL/KNEE
BLOCKER REINFORCEMENT - INSTALLATION).
(5) Install the lower instrument panel silencer.
(6) Connect the battery negative cable.
(7) Verify proper operation of BCM and its func-
tions.
CONTROLLER ANTILOCK
BRAKE
DESCRIPTION
The controller antilock brake (CAB) is a micropro-
cessor-based device which monitors the antilock
brake system (ABS) during normal braking and con-
trols it when the vehicle is in an ABS stop. The CAB
is mounted to the HCU as part of the integrated con-
trol unit (ICU) (Fig. 2). The CAB uses a 24-way elec-
trical connector on the vehicle wiring harness. The
power source for the CAB is through the ignition
switch in the RUN or ON position. The CAB is on
the PCI bus.
OPERATION
The primary functions of the controller antilock
brake (CAB) are to:
²Monitor the antilock brake system for proper
operation.
²Detect wheel locking or wheel slipping tenden-
cies by monitoring the speed of all four wheels of the
vehicle.
²Control fluid modulation to the wheel brakes
while the system is in an ABS mode.
²Store diagnostic information.
²Provide communication to the DRBIIItscan tool
while in diagnostic mode.
²Illuminate the amber ABS warning indicator
lamp.
²(With traction control only) Illuminate the TRAC
ON lamp in the message center on the instrument
panel when a traction control event occurs.
Fig. 2 Integrated Control Unit (ICU)
1 - PUMP/MOTOR
2 - HCU
3 - PUMP/MOTOR CONNECTOR
4 - CAB
RSELECTRONIC CONTROL MODULES8E-5
BODY CONTROL MODULE (Continued)
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STANDARD PROCEDURE
STANDARD PROCEDURE - PINION FACTOR
SETTING
NOTE: This procedure must be performed if the
Transmission Control Module (TCM) has been
replaced with a NEW or replacement unit. Failure to
perform this procedure will result in an inoperative
or improperly calibrated speedometer.
The vehicle speed readings for the speedometer are
taken from the output speed sensor. The TCM must
be calibrated to the different combinations of equip-
ment (final drive and tires) available. Pinion Factor
allows the technician to set the Transmission Control
Module initial setting so that the speedometer read-
ings will be correct. To properly read and/or reset the
Pinion Factor, it is necessary to use a DRBIIItscan
tool.
(1) Plug the DRBIIItscan tool into the diagnostic
connector located under the instrument panel.
(2) Select the Transmission menu.
(3) Select the Miscellaneous menu.
(4) Select Pinion Factor. Then follow the instruc-
tions on the DRBIIItscan tool screen.
STANDARD PROCEDURE - QUICK LEARN
PROCEDURE
The quick learn procedure requires the use of the
DRBIIItscan tool. This program allows the elec-
tronic transaxle system to recalibrate itself. This will
provide the best possible transaxle operation.
NOTE: The quick learn procedure should be per-
formed if any of the following procedures are per-
formed:
²Transaxle Assembly Replacement
²Transmission Control Module Replacement
²Solenoid/Pressure Switch Assembly Replacement
²Clutch Plate and/or Seal Replacement
²Valve Body Replacement or Recondition
To perform the Quick Learn Procedure, the follow-
ing conditions must be met:
²The brakes must be applied
²The engine speed must be above 500 rpm
²The throttle angle (TPS) must be less than 3
degrees
²The shift lever position must stay until
prompted to shift to overdrive
²The shift lever position must stay in overdrive
after the Shift to Overdrive prompt until the
DRBIIItindicates the procedure is complete
²The calculated oil temperature must be above
60É and below 200É(1) Plug the DRBIIItscan tool into the diagnostic
connector. The connector is located under the instru-
ment panel.
(2) Go to the Transmission screen.
(3) Go to the Miscellaneous screen.
(4) Select Quick Learn Procedure. Follow the
instructions of the DRBIIItto perform the Quick
Learn Procedure.
REMOVAL
NOTE: If transmission control module is being
replaced with a new or replacement unit, the Pinion
Factor and Quick Learn procedures must be per-
formed. (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/TRANSMISSION CONTROL
MODULE - STANDARD PROCEDURE) (Refer to 8 -
ELECTRICAL/ELECTRONIC CONTROL MODULES/
TRANSMISSION CONTROL MODULE - STANDARD
PROCEDURE)
(1) Disconnect battery negative cable.
(2) Raise vehicle on hoist.
(3) Remove left front tire/wheel assembly.
(4) Pull back splash shield to gain access to TCM
location.
(5) Disconnect TCM 60-way connector (Fig. 16).
Fig. 16 Transmission Control Module 60-way
Connector
1 - TRANSMISSION CONTROL MODULE (TCM)
2 - 60-WAY CONNECTOR
RSELECTRONIC CONTROL MODULES8E-31
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INSTALLATION
CAUTION: Do not reuse the original brake lamp
switch. The switch can only be adjusted once. That
is during initial installation of the switch. If the
switch is not adjusted properly or has been
removed for some service, a new switch must be
installed and adjusted.
(1) Mount and adjust the NEW brake lamp switch
using the following procedure:
(a) Connect the wiring connector to the switch
and latch the locking tab.
(b) Install the switch in its bracket by aligning
the index tab on the switch with the slot in the
mounting bracket.
(c) When the switch is fully seated in its
bracket, rotate the switch clockwise approximately
30É to lock the switch into place (Fig. 3).
(d) With the brake pedal in the fully released
position, move the lever on the back of the brake
lamp switch from the angled non-adjusted position
to the full vertical position as shown (Fig. 4). This
will adjust the brake lamp switch to the vehicle.
(2) Install silencer panel below steering column
knee blocker.
(3) Reconnect the battery negative terminal.
(4) Check the stop lamps to verify they are operat-
ing properly and not staying on when the pedal is in
the released position.
(5) Road test the vehicle to ensure proper opera-
tion of the brakes including ABS and speed control (if
equipped).
CENTER HIGH MOUNTED
STOP LAMP
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove two retaining screws (Fig. 5).
(3) Twist socket counter-clockwise and remove
from lamp.
(4) Pull bulb from socket (Fig. 6).
INSTALLATION
(1) Push bulb into socket.
(2) Install socket into the lamp unit.
(3) Install the retaining screws.
(4) Reconnect the battery negative cable.
CENTER HIGH MOUNTED
STOP LAMP UNIT
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the two retaining screws (Fig. 5).
(3) Disconnect the rear window washer hose.
(4) Remove bulb socket from lamp unit (Fig. 6).
INSTALLATION
(1) Install bulb socket to lamp unit.
(2) Reconnect the rear window washer hose.
Fig. 4 Adjustment Lever MovementFig. 5 CHMSL
1 - CHMSL UNIT
2 - LIFTGATE
8L - 6 LAMPS/LIGHTING - EXTERIORRS
BRAKE LAMP SWITCH (Continued)
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SPEED CONTROL
TABLE OF CONTENTS
page page
SPEED CONTROL
DESCRIPTION..........................1
OPERATION
OPERATION..........................1
OPERATION - INTERACTIVE SPEED
CONTROL (4 Speed EATX Only)...........2
DIAGNOSIS AND TESTING - ROAD TEST.....3
SPECIFICATIONS - TORQUE...............3
CABLE
DESCRIPTION..........................4
OPERATION............................4
REMOVAL.............................4
INSTALLATION..........................4
SERVO
DESCRIPTION..........................4OPERATION............................4
REMOVAL.............................4
INSTALLATION..........................5
SWITCH
DESCRIPTION..........................5
OPERATION............................5
REMOVAL.............................5
INSTALLATION..........................6
VACUUM RESERVOIR
DESCRIPTION..........................6
OPERATION............................6
REMOVAL.............................6
INSTALLATION..........................6
SPEED CONTROL
DESCRIPTION
The speed control system is electronically con-
trolled and vacuum operated. The electronic control
is integrated into the Powertrain Control Module.
The controls are located on the steering wheel. The
ON/OFF, and SET buttons are located on the left side
of the airbag module. The RESUME/ACCEL, CAN-
CEL and COAST buttons are located on the right
side of the airbag module (Fig. 1).The system is designed to operate at speeds above
30 mph (48 km/h).
WARNING: THE USE OF SPEED CONTROL IS NOT
RECOMMENDED WHEN DRIVING CONDITIONS DO
NOT PERMIT MAINTAINING A CONSTANT SPEED,
SUCH AS IN HEAVY TRAFFIC OR ON ROADS THAT
ARE WINDING, ICY, SNOW COVERED, OR SLIP-
PERY.
OPERATION
OPERATION
When speed control is activated by depressing the
ON switch, the PCM allows a set speed to be stored
in RAM for speed control. To store a set speed,
depress and release the SET switch while the vehicle
is moving at a speed between 25 and 85 mph. In
order for the speed control to engage, the brakes can-
not be applied, nor can the gear selector be indicat-
ing the transmission is in Park or Neutral. The speed
control can be disengaged manually by:
²Stepping on the brake pedal
²Depressing the OFF switch
²Depressing the CANCEL switch.
²Depressing the clutch pedal
²Operating in 1st or 2nd gear (autostick, if
equipped)
Fig. 1 SPEED CONTROL SWITCHES - Typical
RSSPEED CONTROL8P-1
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OPERATION
The Transmission Control Module (TCM) first
senses that the speed control is set. If the set speed
is exceeded by more than 4 mph (6.5 km/hr) and the
throttle is closed, the TCM causes the transaxle to
downshift to THIRD gear. After downshifting, the
automatic speed control resumes normal operation.
To ensure that an upshift is appropriate after the set
speed is reached, the TCM waits until the speed con-
trol system opens the throttle at least 6 degrees
before upshifting to OVERDRIVE again.
If the driver applies the brakes, canceling auto-
matic speed control operation with the transaxle still
in THIRD gear, the TCM maintains this gear until
the driver opens the throttle at least 6 degrees to
avoid an inappropriate upshift. The upshift is also
delayed for 2.5 seconds after reaching the 6 degrees
throttle opening in anticipation that the driver might
open the throttle enough to require THIRD gear.
This will avoid unnecessary and disturbing transmis-
sion cycling. If the automatic speed control RESUME
feature is used after braking, the upshift is delayed
until the set speed is achieved to reduce cycling and
provide better response.
DIAGNOSIS AND TESTING - ROAD TEST
Perform a vehicle road test to verify reports of
speed control system malfunction. The road test
should include attention to the speedometer. Speed-
ometer operation should be smooth and without flut-
ter at all speeds.
Flutter in the speedometer indicates a problem
which might cause surging in the speed control sys-tem. The cause of any speedometer problems should
be corrected before proceeding. Refer to the Instru-
ment Cluster for speedometer diagnosis.
If a road test verifies an inoperative system, and
the speedometer operates properly, check for:
²A Diagnostic Trouble Code (DTC). If a DTC
exists, conduct tests per the Powertrain Diagnostic
Procedures manual.
²A misadjusted brake (stop) lamp switch. This
could also cause an intermittent problem.
²Loose or corroded electrical connections at the
servo. Corrosion should be removed from electrical
terminals and a light coating of Mopar Multipurpose
Grease, or equivalent, applied.
²Leaking vacuum reservoir.
²Loose or leaking vacuum hoses or connections.
²Defective one-way vacuum check valve.
²Secure attachment at both ends of the speed
control servo cable.
²Smooth operation of throttle linkage and throttle
body air valve.
²Conduct electrical test at PCM.
²Failed speed control servo. Do the servo vacuum
test.
CAUTION: When test probing for voltage or conti-
nuity at electrical connectors, care must be taken
not to damage connector, terminals or seals. If
these components are damaged, intermittent or
complete system failure may occur.
SPECIFICATIONS - TORQUE
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Servo Mounting Bracket Nuts 14 10.3 123.9
Servo Mounting Bracket Bolts 14 10.3 123.9
Servo Mounting Nuts 6.7 60
RSSPEED CONTROL8P-3
SPEED CONTROL (Continued)
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WIRING
TABLE OF CONTENTS
page page
WIRING DIAGRAM INFORMATION....... 8W-01-1
COMPONENT INDEX.................. 8W-02-1
POWER DISTRIBUTION............... 8W-10-1
GROUND DISTRIBUTION.............. 8W-15-1
BUS COMMUNICATIONS.............. 8W-18-1
CHARGING SYSTEM.................. 8W-20-1
STARTING SYSTEM.................. 8W-21-1
FUEL/IGNITION SYSTEM.............. 8W-30-1
TRANSMISSION CONTROL SYSTEM..... 8W-31-1
VEHICLE SPEED CONTROL............ 8W-33-1
ANTILOCK BRAKES................... 8W-35-1
VEHICLE THEFT SECURITY SYSTEM..... 8W-39-1
INSTRUMENT CLUSTER............... 8W-40-1
HORN/CIGAR LIGHTER/POWER OUTLET . . 8W-41-1
AIR CONDITIONING-HEATER........... 8W-42-1
AIRBAG SYSTEM.................... 8W-43-1
INTERIOR LIGHTING.................. 8W-44-1
BODY CONTROL MODULE............. 8W-45-1MESSAGE CENTER................... 8W-46-1
AUDIO SYSTEM..................... 8W-47-1
REAR WINDOW DEFOGGER............ 8W-48-1
OVERHEAD CONSOLE................. 8W-49-1
FRONT LIGHTING.................... 8W-50-1
REAR LIGHTING..................... 8W-51-1
TURN SIGNALS...................... 8W-52-1
WIPERS............................ 8W-53-1
TRAILER TOW....................... 8W-54-1
POWER WINDOWS................... 8W-60-1
POWER DOOR LOCKS................ 8W-61-1
POWER MIRRORS................... 8W-62-1
POWER SEATS...................... 8W-63-1
SPLICE INFORMATION................ 8W-70-1
CONNECTOR PIN-OUTS............... 8W-80-1
CONNECTOR/GROUND/SPLICE
LOCATION........................ 8W-91-1
POWER DISTRIBUTION SYSTEM........ 8W-97-1 RSWIRING
8W-1
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