2003 CHRYSLER CARAVAN high beam

HEADLAMP
DIAGNOSIS AND TESTING - HEADLAMP
When a vehicle experiences problems with the
headlamp system, verify the condition of the battery
connections, fuses, charging system, headlamp bulbs,
wire connectors, relay, high beam switch, dimmer
switch, and headlamp switch. Refer to the appropri-
ate wiring information.
Each vehicle is equipped with various lamp assem-
blies. A good ground is necessary for proper lighting
operation. Grounding is provided by the lamp socket
when it comes in contact with the metal body, or
through a separate ground wire.
When changing lamp bulbs check the socket for
corrosion. If corrosion is present, clean it with a wire
brush.
When it is necessary to remove components to ser-
vice another, it should not be necessary to apply
excessive force or bend a component to remove it.
Fig. 11 FOG LAMP UNIT ALIGNMENT - EXPORT
1 - HIGH INTENSITY AREA 4 - 200 MM
2 - CENTER OF VEHICLE 5 - 10 METERS
3 - HORIZONTAL CENTER OF FOG LAMP UNIT 6 - FRONT OF FOG LAMP UNIT
Fig. 12 FRONT POSITION LAMP
1 - TURN SIGNAL LAMP
2 - HIGH BEAM LAMP
3 - FRONT POSITION LAMP
4 - LOW BEAM LAMP
RSLAMPS/LIGHTING - EXTERIOR8L-11
FRONT POSITION LAMP - EXPORT (Continued)
ProCarManuals.com

CONDITION POSSIBLE CAUSES CORRECTION
HEADLAMPS DO NOT
ILLUMINATE.1. No voltage to headlamps. 1. Repair open headlamp circuit, refer to
Electrical, Wiring Information.
2. No Z343/Z344-ground at
headlamps.2. Repair circuit ground, refer to Electrical,
Wiring Information.
3. Broken connector terminal or
wire splice in headlamp circuit.3. Repair connector terminal or wire splice.
4. Faulty or burned out bulb. 4. Replace headlamp bulb(s).
5. Body Control Module
malfunction.5. Refer to appropriate Body Control Module
diagnostics.
6. PCI Bus Communication 6. Verify messages being transmitted by BCM
and received by FCM.
7. IPM/FCM Malfunction. 7. Refer to appropriate IPM/FCM diagnostics.
HEADLAMPS ON WITH
IGNITION IN RUN, WITH
HEADLAMP SWITCH
OFF.1. Faulty headlamp switch. 1. Replace headlamp switch (review BCM
logged faults).
2. Diagnostic tool indicates (4.7 -
5.0V) on headlamp switch input to
BCM.2. Inspect and repair terminals, connectors and
open circuits.
3. PCI Bus Communication. 3. Verify messages being transmitted by BCM
and received by FCM.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove headlamp unit retaining screws.
(3) Remove headlamp unit to expose back of unit.
(4) Remove wiring connector from bulb.
(5) Rotate headlamp bulb retaining ring counter-
clockwise.
(6) Pull headlamp bulb and remove from headlamp
unit (Fig. 13).
INSTALLATION
(1) Install headlamp bulb to the headlamp unit.
(2) Install headlamp bulb retaining ring.
(3) Connect wiring connector to bulb.
(4) Install the headlamp unit.
(5) Install headlamp unit retaining screws.
(6) Reconnect the battery negative cable.
HEADLAMP - EXPORT
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the headlamp unit.
(3) Remove the cover (high beam lamp) or rubber
boot (low beam lamp) to access bulbs (Fig. 14).
(4) Disconnect the wire harness connector.
(5) Disengage spring clip from headlamp.
(6) Pull headlamp bulb from back of headlamp
unit.
INSTALLATION
(1) Insert headlamp bulb into headlamp unit.
(2) Engage spring clip to headlamp.
(3) Connect wire harness connector.
(4) Install the cover (high beam lamp) or rubber
boot (low beam lamp) to headlamp unit.
(5) Install the headlamp unit.
(6) Connect the battery negative cable.
Fig. 13 HEADLAMP
1 - HEADLAMP
2 - HEADLAMP UNIT
RSLAMPS/LIGHTING - EXTERIOR8L-13
HEADLAMP (Continued)
ProCarManuals.com

HEADLAMP LEVELING MOTOR
- EXPORT
DIAGNOSIS AND TESTING - HEADLAMP
LEVELING MOTOR - EXPORT
HEADLAMP LEVELING MOTOR DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
ONE MOTOR DOES NOT
OPERATE.1. Poor electrical connection at
motor1. Check for proper electrical connection at
motor
2. No voltage at motor 2. Repair no voltage condition. Refer to
Wiring Diagrams
3. No ground at motor 3. Repair no ground condition. Refer to
Wiring Diagrams
4. Defective motor 4. Replace leveling motor
BOTH MOTORS DO NOT
OPERATE1. No voltage at or from headlamp
leveling switch1. Repair no voltage condition. Check for
proper headlamp leveling switch operation
2. No voltage at leveling motors 2. Repair no voltage condition. Refer to
Wiring Diagrams
3. No ground at leveling motors 3. Repair no ground condition. Refer to
Wiring Diagrams
4. Both motors defective 4. Replace both motors
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove headlamp unit.(3) Disconnect electrical connector from headlamp
leveling motor.
(4) Remove the two mounting screws.
(5) Gently pry motor from headlamp unit (Fig. 15).
Fig. 14 HEADLAMP UNIT
1 - HIGH BEAM LAMP
2 - HEADLAMP LEVELING MOTOR
3 - LOW BEAM LAMP
4 - TURN LAMP
8L - 14 LAMPS/LIGHTING - EXTERIORRS
HEADLAMP - EXPORT (Continued)
ProCarManuals.com

INSTALLATION
(1) Press motor into position.
(2) Install the two mounting screws.
(3) Connect the electrical connector to motor.
(4) Install the headlamp unit.
(5) Connect the battery negative cable.
HEADLAMP LEVELING
SWITCH - EXPORT
DESCRIPTION
Some vehicles are equipped with a remote head-
lamp leveling system. This system allows the driver
to adjust the vertical headlamp aim from the interior
of the vehicle to compensate for passenger or cargo
load.
The headlamp leveling switch is located next to the
headlamp switch on the instrument panel (Fig. 16).
If the headlamp leveling switch is faulty or damaged,
the headlamp switch must be replaced.
DIAGNOSIS AND TESTING - HEADLAMP
LEVELING SWITCH - EXPORT
The headlamp leveling switch is located next to the
headlamp switch on the instrument panel. (Refer to 8
- ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
HEADLAMP SWITCH - DIAGNOSIS AND TEST-
ING) for diagnosis of the headlamp leveling switch. If
the headlamp leveling switch is faulty, the headlamp
switch must be replaced.
HEADLAMP SWITCH
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - HEADLAMP
SWITCH
Using a Digital Multi-meter, perform the HEAD-
LAMP SWITCH CONTINUITY test and refer to (Fig.
17).
If the Headlamp Switch is not within specifications
replace the switch.
Fig. 15 HEADLAMP LEVELING MOTOR - EXPORT
1 - HIGH BEAM HEADLAMP
2 - HEADLAMP LEVELING MOTOR
3 - LOW BEAM HEADLAMP
Fig. 16 HEADLAMP LEVELING SWITCH
1 - POWER MIRROR SWITCH
2 - HEADLAMP SWITCH
3 - INTERIOR DIMMER
4 - HEADLAMP LEVELING SWITCH
Fig. 17 HEADLAMP SWITCH CONNECTOR
RSLAMPS/LIGHTING - EXTERIOR8L-15
HEADLAMP LEVELING MOTOR - EXPORT (Continued)
ProCarManuals.com

HEADLAMP
SWITCH
POSITION13-WAY
CONNECTOR
TERMINALRESISTANCE
HEADLAMP
LEVELING
SWITCH
POSITION13-WAY
CONNECTOR
TERMINALRESISTANCE
01 TO 7 3238 - 3456V
1 TO 2 3181 - 3400V
1 1 TO 7 1195 - 1225V
2 1 TO 7 746 - 765V
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the Instrument Panel Lower Steering
Column Cover. Refer to Body, Instrument Panel,
Lower Steering Column Cover, Removal.
(3) Reach up behind the left side of the instrument
panel and depress spring clip on top or bottom of
headlamp switch. Firmly push out on the headlamp
switch assembly.
(4) Disconnect the wiring connectors.
(5) Remove switch from vehicle.
INSTALLATION
(1) Connect the wiring connectors.
(2) Place headlamp switch assembly into position
and firmly snap into place.
(3) Install the Instrument Panel Lower Steering
Column Cover. Refer to Body, Instrument Panel,
Lower Steering Column Cover, Installation.
(4) Connect the battery negative cable.
HEADLAMP UNIT
STANDARD PROCEDURE
STANDARD PROCEDURE - HEADLAMP UNIT
ALIGNMENT
HEADLAMP UNIT ALIGNMENT PREPARATION
(1) Verify headlamp dimmer switch and high beam
indicator operation.
(2) Inspect and correct damaged or defective com-
ponents that could interfere with proper headlamp
alignment.
(3) Verify proper tire inflation.
(4) Clean headlamp lenses.
(5) Verify that luggage area is loaded as the vehi-
cle is routinely used.(6) Vehicles equipped with automatic load leveling
suspension should be driven normally for approxi-
mately 5 km (3 miles) before attempting a proper
headlamp unit alignment.
(7) Fuel tank should be FULL. Add 2.94 kg (6.5
lbs.) of weight over the fuel tank for each estimated
gallon of missing fuel.
ALIGNMENT SCREEN PREPARATION
(1) Position vehicle on a level surface perpendicu-
lar to a flat wall 7.62 meters (25 ft.) away from front
of headlamp lens (Fig. 19).
(2) If necessary, tape a line on the floor 7.62
meters (25 ft.) away from and parallel to the wall.
(3) Rock vehicle side-to-side three times and allow
suspension to stabilize.
(4) Jounce front suspension three times by pushing
downward on front bumper and releasing.
(5) Measure the distance from the center of head-
lamp lens to the floor. Transfer measurement to the
alignment screen (with tape). Use this line for
up/down adjustment reference.
HEADLAMP UNIT ADJUSTMENT
The low beam headlamp will project on the screen
upper edge of the beam (cut-off) at the horizontal
lamp centerline   50 mm (2 in.). Horizontal aim is
preset and can not be adjusted. The high beam pat-
tern should be correct when the low beams are
aligned properly (Fig. 20). To adjust headlamp verti-
cal alignment, rotate adjustment screw to achieve the
specified low beam cut-off location.
STANDARD PROCEDURE - HEADLAMP UNIT
ALIGNMENT - EXPORT
HEADLAMP UNIT ALIGNMENT PREPARATION
(1) Verify that the headlamp leveling switch is in
the ª0º position.
(2) Inspect and correct damaged or defective com-
ponents that could interfere with proper headlamp
alignment.
(3) Verify proper tire inflation.
(4) Clean headlamp lenses.
(5) Verify that luggage area is loaded as the vehi-
cle is routinely used.
(6) Vehicles equipped with automatic load leveling
suspension should be driven normally for approxi-
mately 5 km (3 miles) before attempting a proper
headlamp unit alignment.
(7) Fuel tank should be FULL. Add 2.94 kg (6.5
lbs.) of weight over the fuel tank for each estimated
gallon of missing fuel.
RSLAMPS/LIGHTING - EXTERIOR8L-17
HEADLAMP SWITCH (Continued)
ProCarManuals.com

ALIGNMENT SCREEN PREPARATION
(1) Position vehicle on a level surface perpendicu-
lar to a flat wall 10 meters (32.8 ft.) away from front
of headlamp lens (Fig. 21).
(2) If necessary, tape a line on the floor 10 meters
(32.8 ft.) away from and parallel to the wall.
(3) Rock vehicle side-to-side three times and allow
suspension to stabilize.
(4) Jounce front suspension three times by pushing
downward on front bumper and releasing.
(5) Measure the distance from the center of head-
lamp lens to the floor. Transfer measurement to thealignment screen (with tape). Use this line for
up/down adjustment reference.
HEADLAMP UNIT ADJUSTMENT
The low beam headlamp will project on the screen
upper edge of the beam (cut-off) at the horizontal
lamp cut-off line   20 mm (0.75 in.). The high beam
pattern should be correct when the low beams are
aligned properly (Fig. 22). To adjust headlamp align-
ment, rotate adjustment screws to achieve the speci-
fied low beam cut-off location.
Fig. 19 HEADLAMP ALIGNMENT SCREEN
1 - CENTER OF HEADLAMPS 3 - FRONT OF HEADLAMP
2 - HEADLAMP BEAM 4 - 7.62 METERS (25 FT.)
8L - 18 LAMPS/LIGHTING - EXTERIORRS
HEADLAMP UNIT (Continued)
ProCarManuals.com

LAMPS/LIGHTING - INTERIOR
TABLE OF CONTENTS
page page
LAMPS/LIGHTING - INTERIOR
SPECIFICATIONS
INTERIOR LAMPS.....................25
CENTER CONSOLE LAMP SWITCH
REMOVAL.............................26
INSTALLATION.........................26
CLUSTER ILLUMINATION LAMPS
REMOVAL.............................26
INSTALLATION.........................26
COURTESY LAMP
REMOVAL.............................26
INSTALLATION.........................26
DOME/CARGO LAMP
REMOVAL.............................26INSTALLATION.........................26
GLOVE BOX LAMP SWITCH
REMOVAL.............................26
INSTALLATION.........................26
LIFTGATE LAMP
REMOVAL.............................27
INSTALLATION.........................27
READING LAMP
REMOVAL.............................27
INSTALLATION.........................28
VANITY LAMP
REMOVAL.............................28
INSTALLATION.........................28
LAMPS/LIGHTING - INTERIOR
SPECIFICATIONS
INTERIOR LAMPS
BULB APPLICATION TABLE
LAMP BULB
ABS LED
AIRBAG LED
ALARM SET PC74
AUTOSTICK VFD*
BRAKE SYSTEM
WARNINGLED
CONSOLE 194
CRUISE INDICATOR VFD*
DOME/RAIL LAMPS 578
DOOR AJAR INDICATOR LED
DOOR COURTESY
LAMP578
FRONT DOOR
COURTESY567
GLOVE BOX 194
HIGH BEAM INDICATOR
(BASE CLUSTER)LED
HIGH BEAM INDICATOR PC74
LAMP BULB
CLUSTER
ILLUMINATIONPC74
LIFTGATE 578
LIFTGATE AJAR LED
LOW FUEL INDICATOR LED
LOW WASHER FLUID
INDICATORLED
MIL (BASE CLUSTER) LED
MIL PC74
OIL INDICATOR (BASE
CLUSTER)LED
OIL INDICATOR PC74
OVERHEAD CONSOLE
READINGPC579
OVERDRIVE OFF
INDICATORVFD*
READING 578
SEAT BELT INDICATOR LED
TEMPERATURE
INDICATORLED
TRAC OFF INDICATOR VFD*
TURN SIGNAL
INDICATOR (BASE
CLUSTER)LED
TURN SIGNAL
INDICATORPC74
VISOR VANITY 6501966
RSLAMPS/LIGHTING - INTERIOR8L-25
ProCarManuals.com

8W-02 COMPONENT INDEX
Component Page
A/C Compressor Clutch Relay............. 8W-42
A/C Compressor Clutch.................. 8W-42
A/C-Heater Control..................... 8W-42
A/C Pressure Sensor.................... 8W-42
Accelerator Pedal Position Sensor.......... 8W-30
Accessory Relay........................ 8W-10
Adjustable Pedals Module................ 8W-30
Adjustable Pedals Relay................. 8W-30
Adjustable Pedals Switch................. 8W-30
Airbag Control Module.................. 8W-43
Ambient Temperature Sensor.............. 8W-49
Antenna............................. 8W-47
ATC Remote Sensor..................... 8W-42
Auto Shut Down Relay.................. 8W-30
Auto Temp Control..................... 8W-42
Automatic Day/Night Mirror.............. 8W-49
Back-Up Lamp Switch................... 8W-51
Battery Temperature Sensor.............. 8W-20
Battery.............................. 8W-20
Blend Door Actuators................... 8W-42
Blower Motor Resistor................... 8W-42
Body Control Module.................... 8W-45
Boost Pressure Sensor................... 8W-30
B-Pillar Switches....................... 8W-61
Brake Fluid Level Switch................ 8W-40
Brake Lamp Switch.................. 8W-30, 51
Brake Transmission Shift Interlock Solenoid . . 8W-31
Cabin Heater Assist..................... 8W-30
Camshaft Position Sensor................ 8W-30
CD Changer.......................... 8W-47
Center Dome Lamp..................... 8W-44
Center High Mounted Stop Lamp........... 8W-51
Cinch/Release Motors................... 8W-61
Clockspring................ 8W-30, 33, 41, 43, 47
Clutch Pedal Interlock Switch.......... 8W-10, 30
Clutch Pedal Upstop Switch............... 8W-30
Combination Relays..................... 8W-54
Controller Antilock Brake................ 8W-35
Crank Case Ventilation Heater............ 8W-30
Crankshaft Position Sensor............... 8W-30
Cylinder Lock Switches.................. 8W-39
Data Link Connector.................... 8W-18
Defogger Relay........................ 8W-48
Door Ajar Switches..................... 8W-39
Door Lock Motor/Ajar Switches............ 8W-61
Door Courtesy Lamps................... 8W-44
Door Lock Switches..................... 8W-61
Dosing Pump......................... 8W-30
Driver Airbag Squibs.................... 8W-43
Driver Seat Belt Switch.................. 8W-43
DVD Screen.......................... 8W-47
DVD/CD Changer...................... 8W-47
ECM/PCM Relay....................... 8W-30
EGR Solenoid......................... 8W-30
Electronic Control Unit.................. 8W-64
Engine Control Module.................. 8W-30
Component Page
Engine Coolant Temp Sensor.............. 8W-30
Engine Oil Pressure Sensor............... 8W-30
Engine Oil Pressure Switch............... 8W-30
EVAP/Purge Solenoid.................... 8W-30
Evaporator Temperature Sensor............ 8W-42
Floor Console Lamp..................... 8W-44
Floor Console Power Outlet............... 8W-41
Fog Lamps........................... 8W-50
Front Blower Module.................... 8W-42
Front Blower Motor Relay................ 8W-42
Front Blower Motor..................... 8W-42
Front Cigar Lighter..................... 8W-41
Front Control Module................... 8W-10
Front Fog Lamp Relay................... 8W-50
Front Intrusion Sensor.................. 8W-39
Front Reading Lamps/Switch.............. 8W-44
Front Washer Pump Motor............... 8W-53
Front Wiper High/Low Relay.............. 8W-53
Front Wiper On/Off Relay................ 8W-53
Fuel Heater Relay...................... 8W-30
Fuel Heater.......................... 8W-30
Fuel Injectors......................... 8W-30
Fuel Pressure Sensor.................... 8W-30
Fuel Pressure Solenoid.................. 8W-30
Fuel Pump Module..................... 8W-30
Fuel Pump Relay....................... 8W-30
Full Open Switches..................... 8W-61
Fuses............................... 8W-10
Fuselink............................. 8W-10
Grounds............................. 8W-15
Generator............................ 8W-20
Glow Plugs........................... 8W-30
Glow Plug Relay....................... 8W-30
Headlamp Leveling Motors............... 8W-50
Headlamp Switch...................... 8W-50
Headlamp Washer Pump Motor............ 8W-53
Headlamp Washer Relay................. 8W-53
Headlamps........................... 8W-50
Heated Seat Backs..................... 8W-63
Heated Seat Cushions................... 8W-63
Heated Seat Modules.................... 8W-63
High Beam Lamps...................... 8W-50
Hood Ajar Switch...................... 8W-39
Horn Relay........................... 8W-41
Horn Switch.......................... 8W-41
Horns............................... 8W-41
Idle Air Control Motor................... 8W-30
Ignition Coil.......................... 8W-30
Ignition Switch........................ 8W-10
Inlet Air Temperature Sensor.............. 8W-30
Input Speed Sensor..................... 8W-31
Instrument Cluster..................... 8W-40
Instrument Panel Switch Bank.... 8W-44, 52, 53, 63
Integrated Power Module................. 8W-10
Knock Sensor......................... 8W-30
Lamp Assemblies...................... 8W-51
RS8W-02 COMPONENT INDEX8W-02-1
ProCarManuals.com