2003 CHRYSLER CARAVAN ignition

RADIO C2 (CD CHANGER)-8WAY
CAV CIRCUIT FUNCTION
1 X40 20GY/WT AUDIO OUT RIGHT
2 E14 18OR/TN PANEL LAMPS DRIVER
3 D25 20WT/VT (EXCEPT EXPORT) PCI BUS
3 D25 20VT/YL (EXPORT) PCI BUS
4 X112 20RD IGNITION SWITCH OUTPUT
5 X41 20DG/WT AUDIO OUT LEFT
6 Z140 18BK/OR GROUND
7 Z141 18BK/TN GROUND
8 X160 20GY/YL B(+)
RADIO C2 (DVD/CD CHANGER)-9WAY
CAV CIRCUIT FUNCTION
1 X40 22GY/WT AUDIO OUT RIGHT
2 Z140 22BK/OR GROUND
3- -
4 D25 20WT/VT PCI BUS
5 X112 22RD IGNITION SWITCH OUTPUT
6 X41 22DG/WT AUDIO OUT LEFT
7- -
8- -
9 E14 20OR/TN PANEL LAMPS DRIVER
REAR A/C-HEATER UNIT (3 ZONE MTC) - LT. GREEN 10 WAY
CAV CIRCUIT FUNCTION
1 C53 22LB 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 Z135 12BK/LB REAR BLOWER MOTOR HIGH
7 C54 22LB/YL REAR BLEND DOOR DRIVER
8 C154 20LB/OR REAR COMMON DOOR DRIVER
9- -
10 - -
8W - 80 - 114 8W-80 CONNECTOR PIN-OUTSRS
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REAR AUTO TEMP CONTROL SWITCH (3 ZONE 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 (SWB) KDB CLOCK
3 D22 22WT/TN (LWB) KDB CLOCK
4 D17 20WT/DG (SWB) KDB DATA
4 D17 22WT/DG (LWB) KDB DATA
5 E10 20OR/DG PANEL LAMPS DRIVER
6- -
7- -
8- -
9- -
10 - -
11 - -
12 - -
13 - -
REAR BLOWER FRONT CONTROL SWITCH (3 ZONE MTC) - 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
REAR BLOWER MOTOR POWER MODULE C1 (3 ZONE ATC) - RED/BLACK 4 WAY
CAV CIRCUIT FUNCTION
1 C51 12DB/BR FUSED REAR BLOWER MOTOR RELAY OUTPUT
1 C51 18DB/BR FUSED REAR BLOWER MOTOR RELAY OUTPUT
2 C59 18DB/LB BLOWER MOTOR CONTROL
3 Z135 12BK/LB GROUND
4- -
RS8W-80 CONNECTOR PIN-OUTS8W - 80 - 115
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SENTRY KEY IMMOBILIZER MODULE - BLACK 6 WAY
CAV CIRCUIT FUNCTION
1- -
2 D25 20WT/VT PCI BUS
3- -
4 F20 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
5 Z120 22BK/WT GROUND
6 A114 20GY/RD (LHD) FUSED B(+) (I.O.D.)
6 A114 18GY/RD (RHD) FUSED B(+) (I.O.D.)
SIREN (UNITED KINGDOM) - BLACK 4 WAY
CAV CIRCUIT FUNCTION
1 D97 18WT/OR SIREN SIGNAL OUTPUT
2 D96 18WT/LB SIREN SIGNAL CONTROL
3 A600 18RD/LB SIREN SUPPLY
4 G944 18LB/BR SIREN SIGNAL RETURN
SOLENOID/PRESSURE SWITCH ASSY (EATX) - BLACK 8 WAY
CAV CIRCUIT FUNCTION
1 T47 18YL/DG 2-4 PRESSURE SWITCH SENSE
2 T50 18YL/TN LOW/REVERSE PRESSURE SWITCH SENSE
3 T9 18DG/TN OVERDRIVE PRESSURE SWITCH SENSE
4 T16 18YL/OR TRANSMISSION CONTROL RELAY OUTPUT
5 T59 18YL/LB UNDERDRIVE SOLENOID CONTROL
6 T60 18YL/GY OVERDRIVE SOLENOID CONTROL
7 T20 18DG/WT LOW/REVERSE SOLENOID CONTROL
8 T19 18YL/DB 2-4 SOLENOID CONTROL
SPEED CONTROL SERVO (GAS) - BLACK 4 WAY
CAV CIRCUIT FUNCTION
1 V36 18VT/YL (3.3L/3.8L) SPEED CONTROL VACUUM SOLENOID CONTROL
1 V36 18VT/YL (2.4L) S/C VACUUM CONTROL
2 V35 18VT/OR (2.4L) S/C VENT CONTROL
2 V35 18VT/OR (3.3L/3.8L) SPEED CONTROL VENT SOLENOID CONTROL
3 V30 20VT/WT SPEED CONTROL BRAKE SWITCH OUTPUT
4 Z155 18BK/LG GROUND
8W - 80 - 130 8W-80 CONNECTOR PIN-OUTSRS
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SUNROOF MODULE (EXCEPT EXPORT) - BLACK 12 WAY
CAV CIRCUIT FUNCTION
1 Q3 20OR/TN SUNROOF VENT
2 Q5 20OR/LB SUNROOF CLOSE
3 Q4 20OR/YL SUNROOF OPEN
4 F302 18GY/PK FUSED ACCESSORY RELAY OUTPUT
5 A115 14YL/RD FUSED B(+)
6 Z138 14BK/DB GROUND
7- -
8- -
9- -
10 - -
11 - -
12 - -
SUNROOF SWITCH (EXCEPT EXPORT) - NATURAL 4 WAY
CAV CIRCUIT FUNCTION
1 Q3 20OR/TN SUNROOF VENT
2 Q4 20OR/YL SUNROOF OPEN
3 Z137 20BK/DB GROUND
4 Q5 20OR/LB SUNROOF CLOSE
THATCHAM ALARM MODULE (UNITED KINGDOM) - BLACK 16 WAY
CAV CIRCUIT FUNCTION
1 A645 20RD/VT REAR INTRUSION SENSOR SIGNAL
2 G640 20DG/VT FRONT INTRUSION SENSOR SIGNAL
3 G22 20YL VTSS INDICATOR SUPPLY
4- -
5 D97 20WT/OR SIREN SIGNAL OUTPUT
6 D96 20WT/LB SIREN SIGNAL CONTROL
7 F20 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
8 G944 20LB/BR SIREN SIGNAL RETURN
9 G945 20VT/DG SENSOR GROUND
10 G946 20LG/VT SENSOR GROUND
11 G922 20GY VTSS INDICATOR DRIVER
12 - -
13 D25 20WT/VT PCI BUS
14 - -
15 L91 22WT/DB HAZARD SWITCH SENSE
16 A600 20RD/LB SIREN SUPPLY
RS8W-80 CONNECTOR PIN-OUTS8W - 80 - 131
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TRANSMISSION CONTROL MODULE (3.3L/3.8L) - BLACK 60 WAY
CAV CIRCUIT FUNCTION
1 T1 18DG/LB TRS T1 SENSE
2- -
3 T3 18DG/DB TRS T3 SENSE
4- -
5- -
6 K24 18BR/LB CRANKSHAFT POSITION SENSOR SIGNAL
7 D15 20DG/YL SCI TRANSMIT (TCM)
8 T751 18YL FUSED IGNITION SWITCH OUTPUT (START)
9 T9 18DG/TN OVERDRIVE PRESSURE SWITCH SENSE
10 T10 18DG/LG TORQUE MANAGEMENT REQUEST SENSE
11 F1 18PK/WT FCM OUTPUT (UNLOCK-RUN-START)
12 K22 18BR/OR THROTTLE POSITION SENSOR SIGNAL
13 T13 18DG/VT SPEED SENSOR GROUND
14 T14 18DG/BR OUTPUT SPEED SENSOR SIGNAL
15 T15 18YL/BR TRANSMISSION CONTROL RELAY CONTROL
16 T16 18YL/OR TRANSMISSION CONTROL RELAY OUTPUT
17 T16 18YL/OR TRANSMISSION CONTROL RELAY OUTPUT
18 - -
19 T19 18YL/DB 2-4 SOLENOID CONTROL
20 T20 18DG/WT LOW/REVERSE SOLENOID CONTROL
21 - -
22 - -
23 - -
24 - -
25 - -
26 - -
27 - -
28 - -
29 - -
30 - -
31 - -
32 - -
33 - -
34 - -
35 - -
36 - -
37 - -
38 - -
39 - -
40 - -
41 T41 18YL/DB TRS T41 SENSE
42 T42 18DG/YL TRS T42 SENSE
43 D25 18WT/VT PCI BUS
44 - -
45 - -
46 D123 20WT/OR FLASH PROGRAM ENABLE
47 T47 18YL/DG 2-4 PRESSURE SWITCH SENSE
48 - -
49 - -
50 T50 18YL/TN LOW/REVERSE PRESSURE SWITCH SENSE
51 K900 18DB/DG SENSOR GROUND
52 T52 18DG/WT INPUT SPEED SENSOR SIGNAL
53 Z132 16BK/YL GROUND
54 T54 18DG/OR TRANSMISSION TEMPERATURE SENSOR SIGNAL
55 T55 18YL/VT (AUTOSTICK) AUTOSTICK/OVERDRIVE OFF MUX INPUT
56 A104 18YL/RD FUSED B(+)
57 Z133 16BK/LG GROUND
58 N7 18DB/OG VEHICLE SPEED SENSOR SIGNAL
59 T59 18YL/LB UNDERDRIVE SOLENOID CONTROL
60 T60 18YL/GY OVERDRIVE SOLENOID CONTROL
RS8W-80 CONNECTOR PIN-OUTS8W - 80 - 133
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TRANSMISSION RANGE SENSOR (EATX) - DK. GRAY 10 WAY
CAV CIRCUIT FUNCTION
1- -
2- -
3 T13 18DG/VT SPEED SENSOR GROUND
4 T54 18DG/OR TRANSMISSION TEMPERATURE SENSOR SIGNAL
5 T41 18DG/GY (3.3L/3.8L) TRS T41 SENSE
6- -
7 T1 18DG/LB TRS T1 SENSE
8 T3 18DG/DB TRS T3 SENSE
9 T42 18DG/YL TRS T42 SENSE
10 T41 18YL/DB (3.3L/3.8L) PARK/NEUTRAL POSITION SWITCH SENSE (TRS T41)
10 T41 18DG/GY (2.4L) TRS T41 SENSE
VEHICLE SPEED SENSOR (MTX) - BLACK 3 WAY
CAV CIRCUIT FUNCTION
1 F855 20PK/YL (2.4L) 5 VOLT SUPPLY
1 F202 18PK/GY (DIESEL) FUSED IGNITION SWITCH OUTPUT (RUN-START)
2 K900 18DB/DG (2.4L) SENSOR GROUND
2 K900 20DB/DG (DIESEL) SENSOR GROUND
3 N7 18DB/OR (2.4L) VEHICLE SPEED SIGNAL
3 N7 20DB/OR (DIESEL) VEHICLE SPEED SENSOR SIGNAL
WASHER FLUID LEVEL SWITCH - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 Z401 20BK/TN (EXPORT) GROUND
1 Z401 18BK/TN (EXCEPT EXPORT) GROUND
2 W1 18BR/TN WASHER FLUID LEVEL SWITCH SENSE
WATER IN FUEL SENSOR (DIESEL) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 F853 20RD WATER IN FUEL SENSOR SIGNAL
2 K900 18RD SENSOR GROUND
WIPER MODULE - DK. GRAY 4 WAY
CAV CIRCUIT FUNCTION
1 W3 14BR/WT FRONT WIPER HIGH/LOW RELAY LOW SPEED OUTPUT
2 W7 20BR/GY FRONT WIPER PARK SWITCH SENSE
3 W4 14BR/OR FRONT WIPER HIGH/LOW RELAY HIGH SPEED OUTPUT
4 Z103 14BK/WT GROUND
8W - 80 - 134 8W-80 CONNECTOR PIN-OUTSRS
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CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Engine Coolant Temperature
Sensor (Diesel)BL On Cylinder Block 15
Engine Oil Pressure Sensor
(Diesel)BK Rear of Engine 16
Engine Oil Pressure Switch (Gas) LTGN On Cylinder Block 12
EVAP/Purge Solenoid BK Right Motor Mount 10, 17
Evaporator Temperature Sensor BK Right Side of HVAC N/S
Floor Console Lamp BK At Lamp N/S
Floor Console Power Outlet RD At Front Console N/S
Front Blower Module C1 (ATC) BK On HVAC N/S
Front Blower Module C2 (ATC) BK On HVAC N/S
Front Cigar Lighter RD/NAT Rear of Lighter 19, 22, 24
Front Intrusion Sensor BK At Sensor N/S
Front Reading Lamps/Switch BK At Switch N/S
Front Washer Pump Motor BK Right Fender Well 3
Fuel Heater (Diesel) BK Left Rear Engine Compartment N/S
Fuel Injector No.1 BK At Fuel Injector N/S
Fuel Injector No.1 (Diesel) BK At Fuel Injector 15
Fuel Injector No.2 BK At Fuel Injector N/S
Fuel Injector No.2 (Diesel) BK At Fuel Injector 15
Fuel Injector No.3 BK At Fuel Injector N/S
Fuel Injector No.3 (Diesel) BK At Fuel Injector 15
Fuel Injector No.4 BK At Fuel Injector N/S
Fuel Injector No.4 (Diesel) BK At Fuel Injector 15
Fuel Injector No.5 BK At Fuel Injector N/S
Fuel Injector No.6 BK At Fuel Injector N/S
Fuel Pressure Sensor (Diesel) BK Top Left of Engine 15
Fuel Pressure Solenoid (Diesel) Right Front Engine 15
Fuel Pump Module LTGY Side of Fuel Tank 33
Generator BK Rear of Generator 11, 15, 17, 18
Glow Plug Relay (Diesel) BK Near Battery N/S
Headlamp Switch BK Rear of Switch 19, 20, 29
Headlamp Washer Pump Motor At Motor 3
High Note Horn BK Left Frame Rail 5
High Pressure Fuel Pump
(Diesel)Rear of Pump 15
Hood Ajar Switch BK Left Fender 6
Idle Air Control Motor (2.4L) BK On Throttle Body 10, 11
Idle Air Control Motor (3.3/3.8L) BK On Throttle Body 17
Ignition Coil 2.4L BK Top of Valve Cover 10, 11
Ignition Coil 3.3L, 3.8L DKGY Top of Engine 18
Ignition Switch BK Rear of Switch at Steering Column 19, 20, 21, 22, 30
Inlet Air Temperature Sensor BK Top Left of Engine 9, 10, 11
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-5
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
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SPECIAL TOOLS
POWER DISTRIBUTION SYSTEMS
ACCESSORY RELAY
DESCRIPTION
The accessory relay is an electromechanical device
that switches fused battery current to the accessory
powered vehicle circuits when the ignition switch is
turned to the Accessory or On positions. The delay
feature will maintain power to the accessories for 45
seconds after the ignition is shut off or until a door is
opened. This allows sufficient time to close windows
and park the windshield wipers. The accessory relay
is located in the Integrated Power Module (IPM) in
the engine compartment.
The accessory relay is a International Standards
Organization (ISO) relay. Relays conforming to the
ISO specifications have common physical dimensions,
current capacities, terminal patterns, and terminal
functions.
The accessory relay cannot be repaired or adjusted
and, if faulty or damaged, it must be replaced.
OPERATION
The ISO relay consists of an electromagnetic coil, a
resistor or diode, and three (two fixed and one mov-
able) electrical contacts. The movable (common feed)
relay contact is held against one of the fixed contacts
(normally closed) by spring pressure. When the elec-
tromagnetic coil is energized, it draws the movable
contact away from the normally closed fixed contact,
and holds it against the other (normally open) fixed
contact.
When the electromagnetic coil is de-energized,
spring pressure returns the movable contact to the
normally closed position. The resistor or diode is con-
nected in parallel with the electromagnetic coil in therelay, and helps to dissipate voltage spikes that are
produced when the coil is de-energized.
DIAGNOSIS AND TESTING
DIAGNOSIS & TESTING - ACCESSORY RELAY
The accessory relay (Fig. 1) is located in the Inte-
grated Power Module (IPM), in the engine compart-
ment. For complete circuit diagrams, refer toWiring
Diagrams.
(1) Remove the accessory relay from the IPM.
Refer toAccessory Relayin the Removal and
Installation section of this group for the procedure.
(2) A relay in the de-energized position should
have continuity between terminals 87A and 30, and
no continuity between terminals 87 and 30. If OK, go
to Step 3. If not OK, replace the faulty relay.
(3) Resistance between terminals 85 and 86 (elec-
tromagnet) should be 75   5 ohms. If OK, go to Step
4. If not OK, replace the faulty relay.
(4) Connect a battery to terminals 85 and 86.
There should now be continuity between terminals
30 and 87, and no continuity between terminals 87A
and 30. If OK, perform the Relay Circuit Test that
follows. If not OK, replace the faulty relay.
DIAGNOSIS & TESTING - RELAY CIRCUIT TEST
(1) The relay common feed terminal cavity (30) of
the IPM is connected to battery voltage and should
be hot at all times. Check for battery voltage at the
fused B(+) circuit cavity in the IPM receptacle for the
accessory relay. If OK, go to Step 2. If not OK, repair
the fused B(+) circuit to the IPM fuse as required.
(2) The relay normally closed terminal (87A) is
connected to terminal 30 in the de-energized position,
but is not used for this application. Go to Step 3.
(3) The relay normally open terminal (87) is con-
nected to the common feed terminal (30) in the ener-
gized position. This terminal supplies battery voltage
Terminal Pick Kit 6680
Fig. 1 Accessory Relay
8W - 97 - 2 8W-97 POWER DISTRIBUTION SYSTEMRS
POWER DISTRIBUTION SYSTEM (Continued)
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