2003 CHRYSLER CARAVAN brake fluid

8W-40 INSTRUMENT CLUSTER
Component Page
Airbag Control Module................ 8W-40-2
Body Control Module . . . 8W-40-2, 3, 4, 5, 6, 7, 8, 9,
10, 12, 13
Brake Fluid Level Switch............. 8W-40-10
Clockspring........................ 8W-40-11
Controller Antilock Brake.......... 8W-40-11, 15
Engine Control Module.......... 8W-40-9, 11, 15
Engine Coolant Temp Sensor....... 8W-40-7, 8, 9
Engine Oil Pressure Sensor........... 8W-40-15
Engine Oil Pressure Switch........... 8W-40-15
Front Control Module....... 8W-40-10, 11, 14, 15
Fuel Pump Module................... 8W-40-2
Fuse 24............................ 8W-40-2
G200..................... 8W-40-2, 12, 13, 14
G300............................. 8W-40-10
Instrument Cluster...... 8W-40-2, 3, 4, 5, 6, 7, 8,
9, 10, 12, 13, 14
Integrated Power Module........ 8W-40-2, 7, 8, 9,
10, 11, 14, 15
Left Front Door Ajar Switch............ 8W-40-3
Left Front Door Lock Motor/Ajar Switch . . 8W-40-3
Left Sliding Door Control Module........ 8W-40-4Component Page
Left Sliding Door Latch Sensing Switch . . . 8W-40-4
Left Sliding Door Lock Motor/Ajar
Switch.......................... 8W-40-4
Left Speed Control Switch............ 8W-40-11
Liftgate Ajar Switch.................. 8W-40-3
Liftgate Cinch/Release Motor........... 8W-40-3
Message Center.................. 8W-40-6, 14
Multi- Function Switch................ 8W-40-6
Parking Brake Switch............. 8W-40-12, 13
Powertrain Control Module..... 8W-40-7, 8, 11, 15
Right Front Door Ajar Switch........... 8W-40-3
Right Front Door Lock Motor/Ajar
Switch.......................... 8W-40-3
Right Sliding Door Control Module...... 8W-40-5
Right Sliding Door Latch Sensing Switch . . 8W-40-5
Right Sliding Door Lock Motor/Ajar
Switch.......................... 8W-40-5
Traction Control Switch........... 8W-40-7, 8, 9
Transmission Control Module........... 8W-40-8
Vehicle Speed Sensor............... 8W-40-7, 9
Washer Fluid Level Switch............ 8W-40-10
RS8W-40 INSTRUMENT CLUSTER8W-40-1
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8W-80 CONNECTOR PIN-OUTS
Component Page
A/C Compressor Clutch............... 8W-80-6
A/C Pressure Sensor.................. 8W-80-6
A/C-Heater Control C1 (MTC).......... 8W-80-6
A/C-Heater Control C2 (MTC).......... 8W-80-7
Accelerator Pedal Position Sensor
(Diesel).......................... 8W-80-7
Adjustable Pedals Module
(Except Export)................... 8W-80-7
Adjustable Pedals Relay
(Except Export)................... 8W-80-8
Adjustable Pedals Switch
(Except Export)................... 8W-80-8
Airbag Control Module (ORC).......... 8W-80-8
Ambient Temperature Sensor (Except
Base)........................... 8W-80-9
ATC Remote Sensor (ATC)............. 8W-80-9
Auto Temp Control C1................ 8W-80-9
Auto Temp Control C2................ 8W-80-9
Auto Temp Control C3............... 8W-80-10
Automatic Day/Night Mirror (Premium/
Luxury)........................ 8W-80-10
Autostick Switch (Except Export)....... 8W-80-10
Back-Up Lamp Switch (MTX).......... 8W-80-10
Battery Temperature Sensor (2.4L/
Diesel)......................... 8W-80-11
Blower Motor Resistor C1 (MTC)....... 8W-80-11
Blower Motor Resistor C2 (MTC)....... 8W-80-11
Body Control Module C1.............. 8W-80-11
Body Control Module C2.............. 8W-80-12
Body Control Module C3.............. 8W-80-13
Body Control Module C4.............. 8W-80-14
Body Control Module C5.............. 8W-80-15
Boost Pressure Sensor (Diesel)......... 8W-80-15
Brake Fluid Level Switch............. 8W-80-16
Brake Lamp Switch................. 8W-80-16
Brake Transmission Shift Interlock Solenoid
(EATX) ......................... 8W-80-16
C100............................. 8W-80-16
C100............................. 8W-80-17
C101............................. 8W-80-17
C101............................. 8W-80-18
C102 (2.4L)........................ 8W-80-18
C102 (2.4L)........................ 8W-80-18
C102 (3.3L/3.8L).................... 8W-80-19
C102 (3.3L/3.8L).................... 8W-80-19
C103 (Diesel)...................... 8W-80-19
C103 (Diesel)...................... 8W-80-20
C106 (Export)...................... 8W-80-20
C106 (Export)...................... 8W-80-20
C107 (Export)...................... 8W-80-20
C107 (Export)...................... 8W-80-21
C110 (2.4L)........................ 8W-80-21Component Page
C110 (2.4L)........................ 8W-80-21
C111 (2.4L)........................ 8W-80-21
C111 (2.4L)........................ 8W-80-22
C200............................. 8W-80-22
C200............................. 8W-80-24
C201............................. 8W-80-26
C201............................. 8W-80-26
C202............................. 8W-80-26
C202............................. 8W-80-26
C203 (United Kingdom).............. 8W-80-27
C203 (United Kingdom).............. 8W-80-27
C204 (Premium).................... 8W-80-27
C204 (Premium).................... 8W-80-27
C300 (LHD)....................... 8W-80-28
C300 (LHD)....................... 8W-80-28
C300 (RHD Except Lowline)........... 8W-80-29
C300 (RHD Lowline)................ 8W-80-29
C300 (RHD)....................... 8W-80-29
C301 (Base/Power Locks)............. 8W-80-30
C301 (Base/Power Locks)............. 8W-80-30
C301 (LHD Premium/Memory)......... 8W-80-30
C301 (LHD Premium/Memory)......... 8W-80-30
C301 (RHD/LHD Premium Except
Memory)........................ 8W-80-31
C301 (RHD/LHD Premium Except
Memory)........................ 8W-80-31
C302 (Except RHD Memory).......... 8W-80-31
C302 (Except RHD Memory).......... 8W-80-31
C302 (RHD Memory)................ 8W-80-32
C302 (RHD Memory)................ 8W-80-32
C303 (LHD)....................... 8W-80-32
C303 (LHD)....................... 8W-80-33
C303 (RHD)....................... 8W-80-33
C303 (RHD)....................... 8W-80-33
C304............................. 8W-80-34
C304............................. 8W-80-34
C305............................. 8W-80-34
C305............................. 8W-80-34
C306............................. 8W-80-35
C306............................. 8W-80-35
C307 (Heated Seats)................. 8W-80-35
C307 (Heated Seats)................. 8W-80-35
C308............................. 8W-80-36
C308............................. 8W-80-36
C309............................. 8W-80-36
C309............................. 8W-80-37
C310 (Front Console)................ 8W-80-37
C310 (Front Console)................ 8W-80-37
C311 ............................. 8W-80-37
C311 ............................. 8W-80-38
C312............................. 8W-80-38
C312............................. 8W-80-39
RS8W-80 CONNECTOR PIN-OUTS8W-80-1
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BRAKE FLUID LEVEL SWITCH - BLACK 2 WAY
CAV CIRCUIT FUNCTION
A B20 20DG/OR BRAKE FLUID LEVEL SWITCH SENSE
B Z420 20BK/OR GROUND
BRAKE LAMP SWITCH - BLACK 6 WAY
CAV CIRCUIT FUNCTION
1 A103 18GY/RD FUSED B(+)
2 L50 18WT/TN (GAS) BRAKE LAMP SWITCH OUTPUT
2 L50 18WT/TN (DIESEL) PRIMARY BRAKE SWITCH SIGNAL
3 V30 20VT/WT (GAS) SPEED CONTROL BRAKE SWITCH OUTPUT
4 V32 20VT/YL (GAS) SPEED CONTROL ON/OFF SWITCH SENSE
5 Z429 20BK/OR GROUND
6 B29 20DG/WT SECONDARY BRAKE SWITCH SIGNAL
BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID (EATX) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 K32 18DB/YL BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID
CONTROL
2 F2 18PK/YL FCM OUTPUT (UNLOCK-RUN-START)
C100 - BLACK (BODY SIDE)
CAV CIRCUIT
1 D21 20WT/DG
2 D123 20WT/BR
3 D20 20WT/LG (GAS)
3 K119 20DB/LG (DIESEL)
4-
5 Z111 18BK/WT
6 N1 16DB/OR (DIESEL)
6 T141 20YL/OR (EXPORT) (EXCEPT
DIESEL)
7 D15 20DG/YL (GAS)
7 N2 18DB/YL (DIESEL)
8 V32 20VT/YL (GAS)
8 K22 20OR/DB (DIESEL)
9 B29 20DG/WT
10 V37 20VT
11 K167 20BR/YL (DIESEL)
11 V30 20VT/WT (GAS)
12 K900 20DB/DG
13 B1 18DG/OR (ANTILOCK BRAKES)
14 B2 18DG/LB (ANTILOCK BRAKES)
8W - 80 - 16 8W-80 CONNECTOR PIN-OUTSRS
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INSTRUMENT CLUSTER - BLACK 13 WAY
CAV CIRCUIT FUNCTION
10 B25 16DG/WT (LHD EXCEPT EXPORT) PARK BRAKE SWITCH SENSE
11 G26 20VT/OR CHIME DRIVER
12 G150 20VT/BR INSTRUMENT CLUSTER WAKE UP SENSE
13 Z18 18BK/LB GROUND
INSTRUMENT PANEL SWITCH BANK - BLACK 13 WAY
CAV CIRCUIT FUNCTION
1- -
2- -
3 P8 22LG/WT (HEATED SEATS LHD
EXPORT)PASSENGER HEATED SEAT SWITCH
3 P7 20LG/DG (HEATED SEATS RHD) DRIVER HEATED SEAT SWITCH
3 P8 20LG/WT (HEATED SEATS LHD
EXCEPT EXPORT)PASSENGER HEATED SEAT SWITCH
4 F504 20GY/PK FUSED IGNITION SWITCH OUTPUT (RUN)
5 P7 20LG/DG (HEATED SEATS LHD) DRIVER HEATED SEAT SWITCH
5 P8 22LG/WT (HEATED SEATS RHD) PASSENGER HEATED SEAT SWITCH
6- -
7- -
8 L91 22WT/DB HAZARD SWITCH SENSE
9 W26 22BR/DB REAR WIPER SWITCH MUX
10 Z406 20BK/BR GROUND
11 G926 22VT/WT REAR WIPER SWITCH MUX RETURN
12 E14 20OR/TN PANEL LAMPS DRIVER
13 - -
INTEGRATED POWER MODULE C1 - LT. GREEN/RED 20 WAY
CAV CIRCUIT FUNCTION
1 F301 18VT/PK FUSED ACCESSORY RELAY OUTPUT
2- -
3- -
4 L43 18WT/DB LEFT LOW BEAM DRIVER
5 Z344 16BK/TN GROUND
6 L34 16WT/GY RIGHT HIGH BEAM DRIVER
7 W1 18BR/TN WASHER FLUID LEVEL SWITCH SENSE
8 L33 18WT/LG LEFT HIGH BEAM DRIVER
9 G31 18VT/LG (EXCEPT 2.4L/BASE) AMBIENT TEMPERATURE SENSOR SIGNAL
9 G31 18VT/LG (2.4L) AAT SIGNAL
10 L44 16WT/TN RIGHT LOW BEAM DRIVER
11 F300 18OR/PK FUSED ACCESSORY RELAY OUTPUT
12 - -
13 Z343 18BK/LG GROUND
14 - -
15 L78 18WT/OR FUSED PARK LAMP RELAY OUTPUT (RIGHT)
16 L77 18WT/BR FUSED PARK LAMP RELAY OUTPUT (LEFT)
17 - -
18 G931 18VT/BR (EXCEPT 2.4L/BASE) AMBIENT TEMPERATURE SENSOR RETURN
19 W20 18BR/YL REAR WASHER PUMP MOTOR CONTROL
20 W10 18BR FRONT WASHER PUMP MOTOR CONTROL
RS8W-80 CONNECTOR PIN-OUTS8W-80-75
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INTEGRATED POWER MODULE C7 - 20 WAY
CAV CIRCUIT FUNCTION
1 C16 20DB/GY FUSED REAR WINDOW DEFOGGER RELAY OUTPUT
2 T751 20YL (GAS) FUSED IGNITION SWITCH OUTPUT (START)
2 T141 20YL/OR (DIESEL) FUSED IGNITION SWITCH OUTPUT (START)
3 D25 20WT/VT PCI BUS
4 L13 20WT/YL (EXPORT) HEADLAMP ADJUST SIGNAL
5 K32 18DB/YL (GAS) BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID
CONTROL
6- -
7 W7 20BR/GY FRONT WIPER PARK SWITCH SENSE
8 B20 20DG/OR BRAKE FLUID LEVEL SWITCH SENSE
9 F201 18PK/OR ORC RUN-START DRIVER
10 F214 18PK/LG (SIACM) SIACM RUN-START DRIVER
11 A106 20LB/RD FUSED B(+)
12 - -
13 F2 18PK/YL (GAS) FCM OUTPUT (UNLOCK-RUN-START)
14 - -
15 A114 16GY/RD FUSED B(+) (I.O.D.)
16 D123 20WT/BR FLASH PROGRAM ENABLE
17 L50 18WT/TN BRAKE LAMP SWITCH OUTPUT
18 X13 16DG/GY (PREMIUM 8 SPEAKER) NAME BRAND SPEAKER RELAY OUTPUT
19 X3 20DG/VT HORN SWITCH SENSE
20 F100 18PK/VT ORC RUN ONLY DRIVER
INTEGRATED POWER MODULE C8 - ORANGE 10 WAY
CAV CIRCUIT FUNCTION
1 W3 14BR/WT FRONT WIPER HIGH/LOW RELAY LOW SPEED
OUTPUT
2 N1 18DB/OR (GAS) FUEL PUMP RELAY OUTPUT
2 N1 16DB/OR (DIESEL) FUEL HEATER RELAY OUTPUT
3 A108 20LG/RD FUSED B(+)
4 A103 18GY/RD FUSED B(+)
5 L77 20WT/BR FUSED PARK LAMP RELAY OUTPUT (LEFT)
6 W4 14BR/OR FRONT WIPER HIGH/LOW RELAY HIGH SPEED
OUTPUT
7 C51 12LB/BR (3 ZONE ATC/MTC) FUSED REAR BLOWER MOTOR RELAY OUTPUT
8- -
9 L78 18WT/OR FUSED PARK LAMP RELAY OUTPUT (RIGHT)
10 L60 18WT/TN RIGHT FRONT TURN SIGNAL DRIVER
8W - 80 - 78 8W-80 CONNECTOR PIN-OUTSRS
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CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Right Sliding Door Lock
Motor/Ajar SwitchBK At Latch N/S
Right Sliding Door Motor BK At Sliding Door 44
Right Speed Control Switch BK At Steering Wheel N/S
Right Stop/Turn Signal Relay BK LT Quarter Panel N/S
Right Turn Signal Lamp OR At Lamp N/S
Right Visor/Vanity Lamp BK At Lamp N/S
Sentry Key Immobilizer Module BK At Steering Column 19, 20, 21, 22, 30
Siren (United Kingdom) BK Left Front Body N/S
Solenoid/Pressure Switch
Assembly (EATX)BK Side of Transmission 14, 18
Speed Control Servo BK Near Controller Antilock Brake 11, 18
Sunroof Module BK At Sunroof N/S
Sunroof Switch Nat Near Overhead Console N/S
Thatcham Alarm Module C1 BK Top Right Side of Instrument Panel
Near SpeakerN/S
Thatcham Alarm Module C1 WT Top Right Side of Instrument Panel
Near SpeakerN/S
Throttle Position Sensor GY On Throttle Body 10, 11, 17
Torque Converter Clutch Solenoid BK Front of Transmission 11
Traction Control Switch BK Rear of Swtich 20, 21, 30
Trailer Tow Connector BK Left Quarter Panel N/S
Transmission Control Module BK Left Engine Compartment 5
Transmission Range Sensor GY Top of Transmission 14, 18
Turbo boost Pressure Sensor On Cylinder Block 15
Vehicle Speed Sensor BK Rear of Transmission 10, 16
Washer Fluid Level Switch BK Bottom of Reservoir 3
Water in Fuel Sensor (Diesel) Left Rear Engine Compartment N/S
Wiper Module BK Left Side Cowl 6
GROUNDS
GROUND NUMBER LOCATION FIG.
G100 Body Ground Near Powertrain Control Module N/S
G101 Above Starter 11, 13
G102 Left Headlamp Area 1
G103 Above Starter 11, 13
G200 Right Side of Instrument Panel 19, 23, 28
G201 Right Side of Instrument Panel 19, 23, 28
G202 Near Radio N/S
G300 Left B Pillar 31
G301 Right B Pillar 32, 38
G302 Left Rear Quarter 46
G400 Liftgate Ground N/S
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-11
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
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(7) Disconnect the manifold absolute pressure
(MAP) sensor electrical connector.
(8) Disconnect the vapor purge vacuum hose from
throttle body.
(9) Disconnect the PCV hose (Fig. 114).
(10) Remove the power steering reservoir attach-
ing bolts and only loosen the nut (Fig. 115). Lift res-
ervoir up to disengage lower mount from stud. Set
reservoir aside.Do notdisconnect hose.
(11) Disconnect the brake booster and leak detec-
tion pump (LDP) hoses from intake manifold (Fig.
116).
(12) Remove intake manifold bolts and remove the
manifold (Fig. 117).
(13) Cover the lower intake manifold with a suit-
able cover while the upper manifold is removed.
(14) Clean and inspect the upper intake manifold
(Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANI-
FOLD - CLEANING) and (Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD - INSPECTION).
CLEANING
(1) Discard gasket(s).
(2) Clean all sealing surfaces.
INSPECTION
Check manifold for:
²Damage and cracks.
Fig. 113 Intake Manifold Port Repair
1 - BRAKE BOOSTER PORT = 1/49±18 NPT PIPE TAP
1 - LDP/SPEED CONTROL PORT = 1/89±18 NPT PIPE TAP
2 - DRILL BIT = 7/169BRAKE BOOSTER PORT
2 - DRILL BIT = 11/329LDP/SPEED CONTROL PORT
3 - INTAKE MANIFOLD
Fig. 114 PCV & HOSE
1 - HOSE - PCV
2 - P C V VA LV E
Fig. 115 POWER STEERING FLUID RESERVOIR
1 - POWER STEERING RESERVOIR
2 - BOLT - RESERVOIR TO MANIFOLD
3 - NUT - RESERVOIR TO COIL BRACKET
9 - 146 ENGINE 3.3/3.8LRS
INTAKE MANIFOLD - UPPER (Continued)
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(4) Position steering so front wheels are straight
ahead.
CAUTION: Do not rotate steering wheel after disen-
gaging lower coupling from steering gear, damage
to air bag clock spring can result.
(5) Remove clinch bolt attaching steering column
coupling to steering gear shaft (Fig. 10).
(6) Remove steering column coupling from tele-
scoping steering gear shaft.
(7) Hoist vehicle and support on safety stands.
(8) Position a drain pan under power steering
pump and oil return hose coupling.
(9) Using a hose pinch-off pliers (C-4390), pinch
power steering oil return hose off between the cross-
member coupling and the pump.
(10) Loosen hose clamp at the cradle crossmember
coupling.
(11) Disconnect return hose from metal tube.
(12) While holding pressure relief valve nut on
back of power steering pump, Remove flare nut
attaching high pressure hose to back of pump.
(13) Remove high pressure hose from pump.
(14) Allow power steering fluid to drain into pan.
(15) Remove bolts attaching anti-lock brake sensor
leads to cradle crossmember.
(16) Position anti-lock brake leads out of the way.
(17) Disconnect stabilizer bar links from ends of
stabilizer bar.
(18) Disconnect lower ball joints from lower steer-
ing knuckles (Refer to 2 - SUSPENSION/FRONT/
LOWER BALL JOINT - REMOVAL).
(19) Remove the rear engine mount heat shield
(Fig. 11).
(20) Remove through bolt attaching rear engine
mount to cradle crossmember (Fig. 12).
(21) Using paint or grease pencil, mark outline of
cradle crossmember on frame rails to aid installation.
(22) Support cradle crossmember on suitable lift-
ing device (Fig. 14).
(23) Remove bolts attaching crossmember to front
frame rails (Fig. 13).
(24) Remove cradle crossmember from vehicle (Fig.
14).
Fig. 10 STEERING COUPLING
1 - STEERING SHAFT BOOT
2 - STEERING SHAFT
3 - CROSSMEMBER
4 - STEERING GEAR
5 - MOUNT
6 - TRANSAXLE
Fig. 11 REAR MOUNT HEAT SHIELD
1 - BOLT
2 - HEAT SHIELD
3 - CLIP
4 - REAR ENGINE MOUNT
13 - 10 FRAME & BUMPERSRS
FRONT CRADLE CROSSMEMBER (Continued)
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