2003 CHRYSLER CARAVAN brakes

(2) Using a brake pedal depressor, move and lock
the brake pedal to a position past the first inch of
pedal travel.This will prevent brake fluid from
draining out of the master cylinder when the
brake tubes are removed from the HCU.
(3) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(4) Remove the routing clip attaching the ICU wir-
ing harness to the ICU mounting bracket (Fig. 17).
CAUTION: Do not apply a 12 volt power source to
any terminals of the HCU connector when discon-
nected.
(5) Remove the 24-way connector (Fig. 17) from
the CAB. The 24-way connector is removed from the
CAB using the following procedure. Grasp the lock
on the 24-way connector (Fig. 17) and pull it as far
out as possible (Fig. 18). This will raise and unlock
the 24-way connector from the socket on the CAB.
CAUTION: Before removing the brake tubes from
the HCU, the HCU must be thoroughly cleaned. This
must be done to prevent dirt particles from falling
into the ports of HCU or entering the brake tubes.(6) Thoroughly clean all surfaces of the HCU, and
all brake tube nuts located on the HCU. Use only a
solvent such as Mopar Brake Parts Cleaner or an
equivalent to clean the HCU.
(7) Remove the brake tubes (6) from the inlet and
outlet ports on the HCU. (Fig. 19).
Fig. 17 CAB 24-Way Connector
1 - CAB WIRING HARNESS
2 - 24±WAY CONNECTOR
3 - FLOOR PAN
4 - HCU
5 - CAB
6 - HCU MOUNTING BRACKET
7 - CONNECTOR LOCK
Fig. 18 Unlocked 24-Way CAB Connector
1 - HCU
2 - CAB
3 - 24±WAY CONNECTOR
4 - CONNECTOR LOCK (UNLOCKED)
Fig. 19 Brake Tube Connections To HCU
1 - LEFT REAR WHEEL BRAKE TUBE
2 - SECONDARY BRAKE TUBE FROM MASTER CYLINDER
3 - LEFT FRONT WHEEL BRAKE TUBE
4 - CAB
5 - RIGHT REAR WHEEL BRAKE TUBE
6 - HCU MOUNTING BRACKET
7 - BRAKE TUBE TO HCU CONNECTION LOCATION LEGEND
8 - RIGHT FRONT WHEEL BRAKE TUBE
9 - PRIMARY BRAKE TUBE FROM MASTER CYLINDER
5 - 92 BRAKES - ABSRS
ICU (INTEGRATED CONTROL UNIT) (Continued)
ProCarManuals.com

(8) Remove the 3 bolts (Fig. 20) attaching the ICU
mounting bracket to the front suspension crossmem-
ber.
(9) Remove ICU and the mounting bracket as a
unit from the vehicle.
(10) Remove the 3 bolts (Fig. 21) mounting the
ICU to the mounting bracket. Separate the ICU from
the mounting bracket.
(11) For the procedure on separating and attaching
the CAB to the HCU, refer to DISASSEMBLY.DISASSEMBLY - ICU
(1) Remove the ICU from the vehicle. (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ICU (INTE-
GRATED CONTROL UNIT) - REMOVAL)
(2) Disconnect the pump/motor wiring harness
from the CAB (Fig. 22).
(3) Remove the 4 bolts (Fig. 23) attaching the CAB
to the HCU.
(4) Remove the CAB from the HCU (Fig. 24).
Fig. 20 ICU To Suspension Cradle Mounting Bolts
1 - HCU MOUNTING BRACKET BOLTS
2 - HCU MOUNTING BRACKET BOLT
3 - CAB
4 - HCU MOUNTING BRACKET
5 - HCU
Fig. 21 ICU Mounting Bolts
1 - HCU
2 - HCU MOUNTING BOLTS
3 - HCU MOUNTING BRACKET
Fig. 22 INTEGRATED CONTROL UNIT (ICU)
1 - PUMP/MOTOR
2 - HCU
3 - PUMP/MOTOR CONNECTOR
4 - CAB
Fig. 23 (TYPICAL) CAB Attaching Bolts
1 - MOUNTING BOLTS
2 - CAB
3 - HCU VALVE BLOCK
RSBRAKES - ABS5-93
ICU (INTEGRATED CONTROL UNIT) (Continued)
ProCarManuals.com

ASSEMBLY - ICU
(1) Install the CAB (Fig. 24) on the HCU.
(2) Install the 4 bolts mounting the CAB (Fig. 23)
to the HCU. Tighten the CAB mounting bolts to a
torque of 2 N´m (17 in. lbs.).
(3) Plug the pump/motor wiring harness into the
CAB.
(4) Install the ICU in the vehicle and bleed the
base and ABS hydraulic systems. (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ICU (INTE-
GRATED CONTROL UNIT) - INSTALLATION)
INSTALLATION
INSTALLATION - LHD
(1) Place the ICU in its bracket below the master
cylinder. Start the upper mounting bolt to hold it in
place.
(2) Inside the vehicle, install the remaining 2
mounting bolts attaching the ICU to the mounting
bracket (Fig. 16). Tighten all 3 mounting bolts to a
torque of 11 N´m (97 in. lbs.).
(3) Install the dash seal and three mounting
screws (Fig. 15).
(4) If equipped, install the silencer on top of the
dash seal (Fig. 15).
(5) Connect the steering shaft coupling and install
the pinch bolt (Fig. 15). Tighten the pinch bolt to 28
N´m (250 in. lbs.).
(6) Remove the steering wheel holder.
CAUTION: Because of the flexible section in the pri-
mary and secondary brake tubes, the brake tubes
must be held in proper orientation when tightened
and torqued. These tubes must not contact eachother or other vehicle components when installed.
Also, after the brake tubes are installed on the HCU,
ensure all spacer clips are reinstalled on the brake
tubes.
(7) Install the primary and secondary brake tubes
into their correct port locations on the HCU valve
block (Fig. 14). Tighten the tube nuts to a torque of
17 N´m (145 in. lbs.).
CAUTION: When installing the chassis brake tubes
on the HCU valve block, they must be located cor-
rectly in the valve block to ensure proper ABS oper-
ation.
NOTE: The chassis brake tube attachment locations
to the HCU, are marked on the bottom of the CAB.
(8) Install the (4) chassis brake tubes into their
correct port locations on the HCU valve block as
shown (Fig. 14). Tighten the tube nuts to a torque of
17 N´m (145 in. lbs.).
NOTE: Before installing the 24±way connector in
the CAB be sure the seal is properly installed in the
connector.
(9) Install the 24±way connector on the CAB by,
first, positioning the 24±way connector in the socket
of the CAB and carefully pushing it down as far as
possible. Once connector is fully seated by hand into
the CAB socket, push down on connector lock. This
will pull the connector into the socket of the CAB
and lock it in the installed position.
(10) Install any routing clips on the brake tubes.
(11) Remove the brake pedal holder.
(12) Install the speed control servo with its mount-
ing nuts.
(13) Connect the wiring harness to the speed con-
trol servo.
(14) Install the battery tray (Refer to 8 - ELEC-
TRICAL/BATTERY SYSTEM/TRAY - INSTALLA-
TION).
(15) Install the screw securing the coolant filler
neck to the battery tray.
(16) Reconnect the vacuum hose connector at the
tank built into the battery tray.
(17) Install the battery (Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/BATTERY - INSTALLA-
TION).
(18) Install the battery shield.
(19) Remove the brake pedal holder.
(20) Connect negative cable back on negative post
of the battery.
(21) Bleed the Base and ABS brake hydraulic sys-
tems (Refer to 5 - BRAKES - STANDARD PROCE-
DURE).
Fig. 24 (TYPICAL) Remove/Install CAB
1 - CAB
2 - HCU VALVES
3 - HCU VALVE BLOCK
5 - 94 BRAKES - ABSRS
ICU (INTEGRATED CONTROL UNIT) (Continued)
ProCarManuals.com

(22) Road test vehicle to ensure proper operation
of the base and antilock brake systems.
INSTALLATION - RHD
(1) Install the ICU on the mounting bracket (Fig.
21). Install the 3 bolts (Fig. 21) attaching the ICU to
the mounting bracket. Tighten the 3 mounting bolts
to a torque of 11 N´m (97 in. lbs.).
CAUTION: The ICU mounting bracket to front sus-
pension cradle mounting bolts have a unique corro-
sion protection coating and a special aluminum
washer. For this reason, only the original, or origi-
nal equipment Mopar replacement bolts can be
used to mount the ICU bracket to the front suspen-
sion crossmember.
(2) Install the ICU and its mounting bracket as an
assembly on the front suspension crossmember.
Install the 3 bolts attaching the ICU bracket to the
crossmember (Fig. 20). Tighten the 3 mounting bolts
to a torque of 28 N´m (250 in. lbs.).
CAUTION: Because of the flexible section in the pri-
mary and secondary brake tubes, and the brake
tubes between the HCU and the proportioning
valve, the brake tubes must be held in proper ori-
entation when tightened and torqued. These tubes
must not contact each other or other vehicle com-
ponents when installed. Also, after the brake tubes
are installed on the HCU, ensure all spacer clips are
reinstalled on the brake tubes.
CAUTION: When installing the chassis brake tubes
on the HCU valve block, they must be located cor-
rectly in the valve block to ensure proper ABS oper-
ation. Refer to (Fig. 19) for the correct chassis
brake tube locations.
NOTE: The chassis brake tube attachment locations
to the HCU, are marked on the bottom of the ICU
mounting bracket.
(3) Install the 6 chassis brake tubes into their cor-
rect port locations on the HCU valve block as shown
in (Fig. 19). Tighten the tube nuts to a torque of 17
N´m (145 in. lbs.).
NOTE: Before installing the 24-way connector in the
CAB be sure the seal is properly installed in the
connector.(4) Install the 24-way connector (Fig. 17) on the
CAB using the following procedure. Position the
24-way connector in the socket of the CAB and care-
fully push it down as far as possible. When connector
is fully seated by hand into the CAB socket, push in
the connector lock (Fig. 18). This will pull the connec-
tor into the socket of the CAB and lock it in the
installed position.
NOTE: The CAB wiring harness must be clipped to
the ICU mounting bracket. This will ensure the wir-
ing harness is properly routed and does not contact
the brake tubes or the body of the vehicle.
(5) Clip the cab wiring harness (Fig. 17) to the
ICU mounting bracket.
(6) Install the routing clips (Fig. 25) on the brake
tubes.
(7) Lower the vehicle.
(8) Connect negative cable back on negative post of
the battery.
(9) Bleed the base and ABS hydraulic systems.
(Refer to 5 - BRAKES - STANDARD PROCEDURE)
(10) Road test vehicle to ensure proper operation
of the base and antilock brake systems.
Fig. 25 Brake Tube Routing Clips
1 - ROUTING CLIP
2 - HCU
3 - BRAKE TUBES
4 - ROUTING CLIP
RSBRAKES - ABS5-95
ICU (INTEGRATED CONTROL UNIT) (Continued)
ProCarManuals.com

ENGINE
DIAGNOSIS AND TESTING - ENGINE COOLING
SYSTEM
Establish what driving condition caused the cooling
system complaint. The problem may be caused by an
abnormal load on the system such as the following:
prolonged idle, very high ambient temperature, slight
tail wind at idle, slow traffic speed, traffic jam, high
speed, steep grade.
DRIVING TECHNIQUES
To avoid overheating the cooling system:
(1) Idle with A/C off when temperature gauge is at
end of normal range.
(2) Do not increase engine speed for more air flow
and coolant flow because the electric motor fan sys-
tems are not responsive to engine RPM. The added
cooling from higher coolant flow rate is more than
offset by increased heat rejection (engine heat added
to coolant).
TRAILER TOWING
Consult the owner's manual under Trailer Towing
and do not exceed specified limits.
VISUAL INSPECTION
If the cooling system problem is not caused by a
driving condition, perform a visual inspection to
determine if there was a recent service or accident
repair, including the following:
²Loose/damaged water pump drive belt
²Incorrect cooling system refilling (trapped air or
low level)
²Brakes possibly dragging
²Damaged hoses
²Loose/damaged hose clamps
²Damaged/incorrect engine thermostat
²Damaged cooling fan motor, fan blade and fan
shroud
²Damaged head gasket
²Damaged water pump
²Damaged radiator
²Damaged coolant recovery system
²Damaged heater core
²Open/shorted electrical circuits
If the visual inspection reveals none of the above
as cause for a cooling system complaint, refer to the
following diagnostic charts.
COOLING SYSTEM DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
PRESSURE CAP IS BLOWING
OFF STEAM AND/OR COOLANT.
TEMPERATURE GAUGE READING
MAY BE ABOVE NORMAL BUT
NOT HIGH. COOLANT LEVEL MAY
BE HIGH IN COOLANT RESERVE/
OVERFLOW TANK.1. Pressure relief valve in radiator
cap is defective, or was not
properly seated.1. Check condition of radiator cap
and cap seal. (Refer to 7 -
COOLING/ENGINE/RADIATOR
PRESSURE CAP - DIAGNOSIS
AND TESTING) Replace cap as
necessary.
2. Incorrect cap was installed. 2. Replace cap as necessary.
3. Incorrect coolant mixture. 3. Check concentration level of the
coolant. (Refer to 7 - COOLING/
ENGINE/COOLANT - DIAGNOSIS
AND TESTING) Adjust the ethylene
glycol-to-water ratio as required.
COOLANT LOSS TO THE
GROUND WITHOUT PRESSURE
CAP BLOWOFF. GAUGE IS
READING HIGH OR HOT.1. Coolant leaks in radiator, cooling
system hoses, water pump or
engine.1. Pressure test and repair as
necessary. (Refer to 7 - COOLING -
DIAGNOSIS AND TESTING)
7 - 14 ENGINERS
ProCarManuals.com

(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. 1). 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.
²(with traction control only) Illuminate the TRAC
OFF lamp when the amber ABS warning indicator
lamp illuminates.
The CAB constantly monitors the antilock brake
system for proper operation. If the CAB detects a
fault, it will turn on the amber ABS warning indica-
tor lamp and disable the antilock braking system.
The normal base braking system will remain opera-
tional.
NOTE: If the vehicle is equipped with traction con-
trol, the TRAC OFF lamp will illuminate anytime the
amber ABS warning indicator lamp illuminates.
The CAB continuously monitors the speed of each
wheel through the signals generated by the wheel
speed sensors to determine if any wheel is beginning
to lock. When a wheel locking tendency is detected,
the CAB commands the CAB command coils to actu-
ate. The coils then open and close the valves in the
HCU that modulate brake fluid pressure in some or
all of the hydraulic circuits. The CAB continues to
control pressure in individual hydraulic circuits until
a locking tendency is no longer present.
The CAB contains a self-diagnostic program that
monitors the antilock brake system for system faults.
When a fault is detected, the amber ABS warning
indicator lamp is turned on and the fault diagnostic
trouble code (DTC) is then stored in a diagnostic pro-
gram memory. A latched fault will disable certain
system functionality for the current ignition cycle. An
unlatched fault will disable certain system function-
ality until the fault condition disappears. These
DTC's will remain in the CAB memory even after the
ignition has been turned off. The DTC's can be read
and cleared from the CAB memory by a technician
using the DRBIIItscan tool. If not cleared with a
DRBIIItscan tool, the fault occurrence and DTC will
Fig. 1 Integrated Control Unit (ICU)
1 - PUMP/MOTOR
2 - HCU
3 - PUMP/MOTOR CONNECTOR
4 - CAB
RSELECTRONIC CONTROL MODULES8E-5
BODY CONTROL MODULE (Continued)
ProCarManuals.com

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 PCM/
TCM 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
²Powertrain/Transmission 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
REMOVAL - SBEC CONTROLLER
(1) Disconnect the negative battery cable.
(2) Remove the battery shield, refer to the Battery
section for more information.
(3) Remove the 2 upper PCM bracket bolts (Fig.
11).(4) Remove the 2 PCM connectors.
(5) Remove the headlamp, refer to the Lamps sec-
tion for more information.
(6) Remove the lower PCM mounting bolt (Fig. 12).
(7) Remove PCM.
Fig. 11 PCM
1 - Attaching Bolts
Fig. 12 PCM LOWER BOLT
8E - 16 ELECTRONIC CONTROL MODULESRS
POWERTRAIN CONTROL MODULE (Continued)
ProCarManuals.com

STANDARD PROCEDURE
STANDARD PROCEDURE - PINION FACTOR
SETTING
NOTE: This procedure must be performed if the
PCM/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 PCM/TCM
must be calibrated to the different combinations of
equipment (final drive and tires) available. Pinion
Factor allows the technician to set the Powertrain/
Transmission Control Module initial setting so that
the speedometer readings 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 PCM/
TCM 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
²Powertrain/Transmission 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 complete²The 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. 18).
(6) Remove three (3) TCM-to-rail screws and
remove TCM from vehicle (Fig. 19).
Fig. 18 Transmission Control Module 60-way
Connector
1 - TRANSMISSION CONTROL MODULE (TCM)
2 - 60-WAY CONNECTOR
RSELECTRONIC CONTROL MODULES8E-23
TRANSMISSION CONTROL MODULE (Continued)
ProCarManuals.com