2003 CHRYSLER CARAVAN turn signal

MULTI-FUNCTION SWITCH
DESCRIPTION - TURN SIGNAL SYSTEM.....21
OPERATION - TURN SIGNAL SYSTEM.......21
DIAGNOSIS AND TESTING - MULTI-
FUNCTION SWITCH...................21
REMOVAL.............................21
INSTALLATION.........................21
PARK/TURN SIGNAL LAMP
REMOVAL.............................21
INSTALLATION.........................21
PARK/TURN SIGNAL LAMP - EXPORT
REMOVAL.............................22
INSTALLATION.........................22
REAR FOG LAMP - EXPORT
DESCRIPTION.........................22REPEATER LAMP - EXPORT
REMOVAL.............................22
INSTALLATION.........................22
TAIL LAMP
REMOVAL.............................22
INSTALLATION.........................22
TAIL LAMP - EXPORT
REMOVAL.............................23
INSTALLATION.........................23
TAIL LAMP UNIT
REMOVAL.............................23
INSTALLATION.........................23
LAMPS/LIGHTING - EXTERIOR
DESCRIPTION
LAMP SYSTEMS
Lighting circuits are protected by fuses. Lighting
circuits require an overload protected power and high
side drivers source, ON/OFF device, lamps and body
grounds to operate properly. Plastic lamps require a
wire in the harness to supply body ground to the
lamp socket. Replace sockets and bulbs that are cor-
roded.
Some of the interior and exterior lighting functions
are governed by the Body Control Module (BCM).
The headlamp, dome, and the door ajar switches pro-
vide signals to the BCM. The BCM in turn sends a
Programmable Communication Interface (PCI) bus
message to the Front Control Module (FCM) to
enable the necessary drivers to set the required illu-
mination configuration.
Wire connectors can make intermittent contact or
become corroded. Before coupling wire connectors,
inspect the terminals inside the connector. Male ter-
minals should not be bent or disengaged from the
insulator. Female terminals should not be sprung
open or disengaged from the insulator. Bent and
sprung terminals can be repaired using needle nose
pliers and pick tool. Corroded terminals appear
chalky or green. Corroded terminals should be
replaced to avoid recurrence of the problem symp-
toms.
Begin electrical system failure diagnosis by testing
related fuses in the fuse block and intelligent power
module. Verify that bulbs are in good condition and
test continuity of the circuit ground. Refer to the
appropriate wiring information.
AUTOMATIC HEADLAMP SYSTEM
The Automatic Headlamp system turns the instru-
mentation and exterior illumination lamps ON when
the ambient light levels are Night and the engine
RPM is 450 or above, and OFF when light levels are
Day.
DAYTIME RUNNING LAMPS
Operating the high-beam headlamps at reduced
power provides daytime running lamps, which are
required on all new Canadian vehicles.
HEADLAMPS ON WITH WINDSHIELD WIPERS
For vehicles equipped with the Automatic Head-
lamp System, the instrumentation and exterior illu-
mination lamps will be turned ON when the
headlamp switch is in the AUTO position, RPM >
450 and the windshield wipers have been in the
intermittent, low or high mode of operation for more
than ten seconds. When the windshield wipers are
turned OFF the Body Control Module will determine
if the instrumentation and exterior illumination
lamps should remain ON base upon the current
ambient light level.
HEADLAMP SYSTEM
The configuration of the headlamp system of head-
lamps, park lamps and fog lamps is determined by
the BCM. The BCM determines the lighting configu-
ration as a result of the inputs from the ignition
switch, headlamp switch and multi-function switch. A
PCI bus is transmitted from the BCM to the FCM to
enable the necessary drivers to set the illumination
configuration. Four wires are connected between the
headlamp switch and the BCM. The first wire con-
tains information regarding the position of the head-
lamp switch (Off, Automatic Headlamps, Automatic
Headlamp switch fog, Park with Fog, Head, or Head
with Fog Lamps). The second wire contains informa-
tion regarding the position of the dimmer switch
8L - 2 LAMPS/LIGHTING - EXTERIORRS
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(Dome Lamp, Daytime Brightness, Dimming Level or
Off). The third wire is a dedicated signal return
(ground) wire. The fourth wire provides power to the
front fog lamp indicator.
HEADLAMP TIME DELAY SYSTEM
The headlamp time delay system is controlled by
the Body Control Module (BCM) via a PCI bus mes-
sage transmitted by the BCM to the FCM to turn off
the headlamps.
OPERATION
AUTOMATIC HEADLAMP SYSTEM
Automatic headlamps are controlled by the Body
Control Module (BCM). With the headlamp switch in
the AUTO position, the BCM will control the head-
lamp, parking, side marker, tail and instrumentation
lamps based on ambient light levels. Ambient light
levels are monitored by the BCM using the Day/
Night signal and Electrochromatic Mirror (ECM)
present from the Compass Mini Trip (CMTC) located
on the front windshield in front of the rear view mir-
ror ECM. Ambient light readings are averaged to
limit cycling the lamps ON and OFF when passing
through areas with varying light levels. The auto-
matic headlamps will only function when the engine
is running with RPM > 450. When the headlamp
switch is in the AUTO position (Automatic mode), the
Headlamp Time Delay system will function when the
ignition switch is placed in any position other than
run/start.
DAYTIME RUNNING LAMPS
Power is reduced using pulse-width modulation to
the high beams, where by the power is switched on
and off rapidly instead of remaining on continuously.
The duration and interval of the power pulses is pro-
grammed into the FCM.
HEADLAMP SYSTEM
The headlamp system will default to headlamps
ON position when ignition switch is ON and when an
open or short circuit failure occurs on the headlamp
switch input or PCI data bus communication between
the BCM and the FCM fails. The system will return
to normal operation when the open or short is
repaired. A fault will be reported by the BCM when a
failure occurs on the dimmer or headlamp switch
input.
If the exterior lamps are ON and the headlamp
switch is in any position other than OFF or AUTO
and with the ignition switch OFF (LOCK) after 3
minutes the BCM sends a message via PCI bus tothe FCM informing the FCM to turn off the head-
lamps, park lamps and fog lamps. This feature pre-
vents the vehicle battery from being discharged when
the vehicle lights have been left ON.
HEADLAMP TIME DELAY SYSTEM
The headlamp time delay system is activated by
turning the headlamps ON (high or low beam) while
the engine is running, turning the ignition switch
OFF, and then turning the headlamp switch OFF
within 45 seconds. The system will not activate if
more than 45 seconds elapse between ignition switch
OFF and headlamp switch OFF. The BCM will allow
the headlamps to remain ON for 90 seconds (config-
urable) before they automatically turn off (If the key
is in the ignition during the headlamp time delay
mode, then both the headlamps and park lamps
(including panel dimming) will be ON). Refer to the
Owner's Manual for more information.
If the headlamp switch is in the Auto Headlamp
Position, the headlamps are ON due to the night sig-
nal from the CMTC and the ignition switch is in any
position other than run/start, the BCM shall enter a
90 second (configurable) Auto Headlamps time delay
mode. If the key is in the ignition during the head-
lamp time delay mode, then both the headlamps and
park lamps (including panel dimming) will be ON. If
the key is not in the ignition, then only the head-
lamps will be ON. The BCM will allow the head-
lamps to remain ON for 90 seconds before they
automatically turn OFF. Refer to the Owner's Man-
ual for more information.
OPTICAL HORN/HIGH BEAMS
When the multi-function switch is pulled to the
first detent (optical horn) signal, the headlamps are
ON, key-in the ignition the BCM shall send a mes-
sage via PCI bus to the FCM to turn on the head-
lamps drivers to illuminate all four filaments (Low
and High beams). When the multi-function switch is
pulled to the second detent (high beam) signal and
the headlamps are ON, the BCM shall send a mes-
sage via PCI bus to the FCM to turn on the head-
lamps drivers. The High Beams are illuminated and
the Low Beams and Fog Lamps (if ON) are extin-
guished. If the headlamps were in the high beam
configuration when power was removed from the
headlamps, the headlamps will be configured as low
beam the next time they are activated.
NOTE: For RG - Export vehicles, the low beams and
front fog lamps will remain ON when high beams
are activated.
RSLAMPS/LIGHTING - EXTERIOR8L-3
LAMPS/LIGHTING - EXTERIOR (Continued)
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WARNING
WARNING: EYE PROTECTION SHOULD BE USED
WHEN SERVICING GLASS COMPONENTS. PER-
SONAL INJURY CAN RESULT.
CAUTION: Do not touch the glass of halogen bulbs
with fingers or other possibly oily surface, reduced
bulb life will result. Do not use bulbs other than
those indicated in the Bulb Application table. Dam-
age to lamp and/or Daytime Running Lamp Module
can result. Do not use fuses, circuit breakers or
relays having greater amperage value than indi-
cated on the fuse panel or in the Owners Manual.
CAUTION: Do not use bulbs other than those listed
in the Bulb Application Table. Damage to lamp can
result. Do not touch halogen bulbs with fingers or
other oily surfaces. Bulb life will be reduced.
SPECIFICATIONS
EXTERIOR LAMPS
BULB APPLICATION TABLE
LAMP BULB
BACK-UP 3057
CHMSL 921
FRONT SIDE MARKER/PARK/
TURN3157A
FRONT FOG 9040
HEADLAMP 9007
LICENSE 168
TAIL, STOP 3057
TURN SIGNAL 3057
BULB APPLICATION TABLE - EXPORT
LAMP BULB
HEADLAMP LOW/HIGH BEAM H7
FRONT FOG H3
FRONT POSITION W5W
FRONT TURN SIGNAL PY21W
SIDE REPEATER T4W
LICENSE PLATE W5W/168
REAR TAIL AND STOP P21/5W
REAR TURN SIGNAL PY21W
BACK-UP P21W
REAR FOG P21W
CHMSL W16W/921
BRAKE LAMP SWITCH
DESCRIPTION
The brake lamp switch is located under the instru-
ment panel, at the brake pedal arm (Fig. 3). It has
three internal switches controlling various functions
of the vehicle. It's main function is to control opera-
tion of the vehicle's brake lamps. Other functions
include speed control deactivation, brake sense for
the antilock brake system and brake sense for the
brake transmission shift interlock.
CAUTION: 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.
OPERATION
When the brake pedal is pressed, the plunger on
the outside of the brake lamp switch extends out-
ward. This action opens or closes the contacts of the
three switches inside the brake lamp switch.
With the brake pedal pressed down (plunger
extended), the switch for terminals 1 and 2 is closed
completing the circuit. The switch for terminals 3
and 4 is open and so is the switch for terminals 5
and 6.
When the brake pedal is released (plunger pushed
in), the three switches assume the opposite positions.
The switch for terminals 1 and 2 is now open while
the other two switches are now closed, completing
their circuits.
A lever on the back of the switch is used to set the
switch into the ªadjustedº position. A non-adjusted
switch will have the lever set to the diagonal position
in relation to the switch housing. The plunger can be
moved in and out, but the states of the internal
switches will not change.
CAUTION: Never move the adjustment lever of the
new brake lamp switch without it being properly
installed in the vehicle first. Such action will render
the switch unusable and the switch must be dis-
carded.
Once installed in the vehicle as described in the
brake lamp switch installation procedure (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
BRAKE LAMP SWITCH - INSTALLATION), the new
switch's adjustment lever is rotated to the adjusted
position as indicated (Fig. 4). This action locks the
plunger to the internal switches.Once in this posi-
tion the switch is permanently adjusted (or
8L - 4 LAMPS/LIGHTING - EXTERIORRS
LAMPS/LIGHTING - EXTERIOR (Continued)
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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)
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(2) Remove the three retaining screws (Fig. 23).
(3) Disconnect the wiring harness from the bulbs
(Fig. 24).
(4) Remove wire harness retainer from back of
headlamp unit.
(5) Remove the headlamp unit.
INSTALLATION
(1) Reconnect wire harness to the bulbs.
(2) Install wire harness retainer to headlamp unit.
(3) Install the three retaining screws.
(4) Reconnect the battery negative cable.
HEADLAMP UNIT - EXPORT
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the three retaining screws.
(3) Disconnect the central wiring harness connec-
tor from the headlamp unit.
(4) Remove the headlamp unit from vehicle.
INSTALLATION
(1) Connect the wiring harness to the headlamp
unit's central connector.
(2) Place headlamp unit into headlamp unit pocket
in front end.
(3) Install the three retaining screws.
(4) Connect the battery negative cable.
(5) Verify vehicle and system operation.
LICENSE LAMP
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove two screws (Fig. 25).
(3) Twist bulb socket and remove (Fig. 26).
(4) Pull bulb from socket.
INSTALLATION
(1) Push bulb into socket.
(2) Install socket into lamp.
(3) Install two screws.
(4) Reconnect the battery negative cable.
Fig. 23 HEADLAMP UNIT FASTENERS
1 - HEADLAMP UNIT RETAINING SCREW
2 - HEADLAMP UNIT
Fig. 24 HEADLAMP UNIT
1 - HEADLAMP UNIT
2 - HEADLAMP
3 - PARK/TURN SIGNAL LAMP
4 - WIRE HARNESS RETAINER
Fig. 25 LICENSE PLATE LAMP UNITS
1 - SCREW
2 - LICENSE PLATE LAMP
8L - 20 LAMPS/LIGHTING - EXTERIORRS
HEADLAMP UNIT (Continued)
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MULTI-FUNCTION SWITCH
DESCRIPTION - TURN SIGNAL SYSTEM
The turn signals are actuated with a lever on
Multi-Function Switch, located on the left side of the
steering wheel. The signals are automatically turned
off by a canceling cam (two lobes molded to the clock
spring mechanism). The cam comes in contact with
the cancel actuator on the turn signal (multi-func-
tion) switch assembly. Either cam lobe, pushing on
the cancel actuator, returns the switch to the OFF
position. The multi-function switch is a resistive
MUX switch that feeds inputs to the BCM.
OPERATION - TURN SIGNAL SYSTEM
Lane change signaling is actuated by applying par-
tial turn signal stalk movement toward the direction
desired until the indicator lamps flashes in the
instrument cluster. When the switch stalk is released
the stalk will spring back into the neutral position
turning OFF the turn signal.
With the ignition switch ON and the turn signal
switch stalk actuated left or right, current flows
through the:
²Multi-function switch
²Body Control Module
²Integrated Power Module (IPM)
²Turn indicator lamp
²Front and rear turn signal bulbs.
A chime will sound after the vehicle has traveled a
distance of approximately 1.0 mile and a speed of 15
mph, with the turn signal ON.
DIAGNOSIS AND TESTING - MULTI-FUNCTION
SWITCH
To test turn signal, headlamp beam select and opti-
cal horn portion of the multi-function switch:(1) Remove the multi-function switch, refer to
Electrical, Lamps/Lighting - Exterior, Multi-Function
Switch, Removal, and Installation.
(2) Using an ohmmeter check the resistance read-
ings between multi-function switch pins. Refer to
Wiring Diagrams for proper pin numbers and the
MULTI-FUNCTION SWITCH RESISTANCE table.
MULTI-FUNCTION SWITCH RESISTANCE
SWITCH
POSITIONPIN NUMBER RESISTANCE
LEFT 2 AND 3 2.7V 5%
RIGHT 2 AND 3 1KV 5%
OPTICAL
HORN2 AND 4 1.7KV 5%
HI BEAM 2 AND 4 2.32KV 5%
REMOVAL
(1) Disconnect and isolate battery negative cable.
(2) Remove upper and lower steering column
shrouds. Refer to Steering, Column, Shroud,
Removal.
(3) Disconnect wire connector from back of multi-
function switch.
(4) Remove screws holding multi-function switch to
steering column adapter collar.
(5) Remove the multi-function switch.
INSTALLATION
(1) Position the switch on to the steering column.
(2) Install the two retaining screws.
(3) Connect the wire harness connector.
(4) Install the upper and lower steering column
shrouds. Refer to Steering, Column, Shroud, Installa-
tion.
(5) Connect the battery negative cable.
PARK/TURN SIGNAL LAMP
REMOVAL
(1) Disconnect and isolate battery negative cable.
(2) Remove headlamp retaining screws.
(3) Twist socket counter - clockwise and remove
(Fig. 27).
(4) Pull bulb from socket.
INSTALLATION
(1) Push bulb into socket.
(2) Twist socket into headlamp.
(3) Install headlamp retaining screws.
(4) Reconnect battery negative cable.
Fig. 26 LICENSE PLATE LAMP - REMOVE/INSTALL
1 - LICENSE PLATE LAMP UNIT
2 - BULB
RSLAMPS/LIGHTING - EXTERIOR8L-21
LICENSE LAMP (Continued)
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PARK/TURN SIGNAL LAMP -
EXPORT
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the headlamp unit (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING - EXTERIOR/HEAD-
LAMP UNIT - EXPORT - REMOVAL).
(3) Remove the rubber boot cover.
(4) Twist bulb socket and remove from headlamp
unit (Fig. 28).
(5) Depress, then rotate the bulb and remove from
bulb socket.
INSTALLATION
(1) Install bulb into bulb socket.
(2) Install bulb socket to headlamp unit.
(3) Install rubber boot cover.
(4) Install headlamp unit (Refer to 8 - ELECTRI-
CAL/LAMPS/LIGHTING - EXTERIOR/HEADLAMP
UNIT - EXPORT - INSTALLATION).
(5) Connect battery negative cable.
REAR FOG LAMP - EXPORT
DESCRIPTION
The rear fog lamps are incorporated into the tail
lamp unit. (Refer to 8 - ELECTRICAL/LAMPS/
LIGHTING - EXTERIOR/TAIL LAMP - REMOVAL)
for service procedures.
REPEATER LAMP - EXPORT
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Push the side repeater lamp to the right and
release retaining tab on the left.
(3) Pull side repeater lamp out and disengage bulb
socket from lamp.
(4) Depress, then rotate and pull bulb from socket.
INSTALLATION
(1) Install bulb to socket.
(2) Push lamp socket into the side repeater lamp.
(3) Position metal spring clip in fender hole notch.
(4) Position side repeater lamp to hole in fender.
(5) Push side repeater lamp to compress metal
spring clip and seat retaining tab into fender.
(6) Connect battery negative cable.
TAIL LAMP
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the tail lamp unit. (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING - EXTERIOR/TAIL
LAMP UNIT - REMOVAL).
(3) Squeeze the tabs on the bulb socket and
remove from tail lamp unit (Fig. 29).
(4) Pull bulb from lamp socket.
INSTALLATION
(1) Push bulb into the lamp socket.
Fig. 27 PARK/TURN SIGNAL LAMP
1 - PARK/TURN SIGNAL LAMP
2 - LAMP SOCKET
Fig. 28 PARK/TURN SIGNAL LAMP
1 - LOW BEAM HEADLAMP
2 - PARK/TURN SIGNAL LAMP
8L - 22 LAMPS/LIGHTING - EXTERIORRS
PARK/TURN SIGNAL LAMP (Continued)
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(2) Install bulb socket into the tail lamp unit.
Ensure that both retaining tabs engage with an audi-
ble click.
(3) Install the tail lamp unit. (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING - EXTERIOR/TAIL
LAMP UNIT - INSTALLATION).
(4) Reconnect the battery negative cable.
TAIL LAMP - EXPORT
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the tail lamp unit (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING - EXTERIOR/TAIL
LAMP UNIT - REMOVAL).
(3) Squeeze the tabs on the back plate retaining
the bulbs and remove from the tail lamp unit (Fig.
30).
(4) Remove bulbs by depressing, then turning
counter-clockwise.
INSTALLATION
(1) Install bulbs by turning clockwise.
(2) Install back plate to tail lamp unit making
sure that both tabs are engaged to the housing.
(3) Install the tail lamp unit (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING - EXTERIOR/TAIL
LAMP UNIT - INSTALLATION).
(4) Connect the battery negative cable.
TAIL LAMP UNIT
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Raise the liftgate.(3) Remove the two retaining fasteners by prying
under the head of the fastener with a flat bladed tool
(Fig. 31).
(4) Rotate the lamp away from the vehicle body to
disengage hook from the rubber grommet in the
quarter panel opening.
(5) Disconnect wire harness connector from tail
lamp unit by sliding the red lock, then pressing
release tab (Fig. 32).
INSTALLATION
(1) Reconnect wire harness connector to the tail
lamp. Slide red connector lock into position.
(2) Engage hook into rubber grommet in quarter
panel opening.
(3) Place lamp into position on quarter panel.
Fig. 29 TAIL LAMP SOCKET
1 - LAMP SOCKET
2 - TAIL LAMP UNIT
Fig. 30 TAIL LAMP BULBS - EXPORT
1 - TAIL LAMP UNIT
2 - TAIL LAMP
3 - TURN SIGNAL LAMP
4 - BACK UP LAMP
5 - REAR FOG LAMP
Fig. 31 TAIL LAMP UNIT FASTENERS
1 - TAIL LAMP UNIT FASTENER
2 - TAIL LAMP UNIT
RSLAMPS/LIGHTING - EXTERIOR8L-23
TAIL LAMP (Continued)
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