2003 CHRYSLER CARAVAN horn

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Page 1059 of 2177

CHRYSLER CARAVAN 2003 Service Manual 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 IGNI

Page 1073 of 2177

CHRYSLER CARAVAN 2003 Service Manual LIFTGATE CINCH/RELEASE MOTOR (POWER LIFTGATE) - BLUE 7 WAY
CAV CIRCUIT FUNCTION
1 Z78 20BK/OR GROUND
2 G78 20VT/OR LIFTGATE AJAR SWITCH SENSE
3 Q60 20OR/YL LIFTGATE PAWL SWITCH SENSE
4 Z245 18BK/GY GR

Page 1120 of 2177

CHRYSLER CARAVAN 2003 Service Manual 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) LTG

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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Page 1122 of 2177

CHRYSLER CARAVAN 2003 Service Manual CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Left Rear Vent Motor NAT At Motor 45, 46
Left Rear Wheel Speed Sensor BK Center Rear of Floor Pan 46
Left Remote Radio Switch Steering Wheel N/S
Left Repeater

Page 1127 of 2177

CHRYSLER CARAVAN 2003 Service Manual SPLICES
SPLICE NUMBER LOCATION FIG.
S101 800mm from T/O for G102 1
S102 500mm from T/O for G102 1
S103 (2.5L) Between T/O for Battery Temperature Sensor and T/O
for C10215
S104 Near T/O for G102 1
S10

SPLICES
SPLICE NUMBER LOCATION FIG.
S101 800mm from T/O for G102 1
S102 500mm from T/O for G102 1
S103 (2.5L) Between T/O for Battery Temperature Sensor and T/O
for C10215
S104 Near T/O for G102 1
S106 (2.4L) 40mm from T/O for Torque Converter Clutch Solenoid 11
S106 (2.5L) Near T/O for Battery Temperature Sensor 15
S106 (3.3L/3.8L) Near T/O for G103 18
S107 (2.4L) In T/O for EGR Solenoid 11
S107 (2.5L) Between T/O for Engine Starter Motor and T/O for
Engine Control Module C116
S107 (3.3L/3.8L Export) Near T/O for Solenoid Pressure Switch 18
S107 (3.3L/3.8L Except
Export)Near T/O for Transmission Range Sensor 11
S108 (3.3L/3.8L) Near T/O for Speed Control Servo 18
S109 (3.3L/3.8L Export) Near T/O for Transmission Control Module N/S
S109 (3.3L/3.8L Except
Export)Near T/O for Solenoid/Pressure switch Assembly 18
S110 Near T/O to G102 1
S111 (2.4L) Near T/O for C101 11
S111 (2.5L) In T/O for Battery (-) 18
S111 (3.3L/3.8L) Near T/O for Output Speed Sensor 18
S112 Near T/O for Integrated Power Module - C3 11
S113 (2.4L) Near T/O for Park/Neutral Position Switch 11
S114 (2.4L) Near T/O for Powertrain Control Module C4 11
S114 (3.3L/3.8L) In T/O to Transmission Control Module 5
S115 (2.4L) Near T/O for Powertrain Control Module C4 11
S115 (3.3L/3.8L) In T/O to Transmission Control Module 5
S116 (2.4L) 180mm from T/O for Torque Converter Clutch Solenoid 11, 13
S116 (2.5L) Near T/O for Mass Air Flow Sensor 16
S116 (3.3L/3.8L) Near T/O for G103 18
S117 (2.4L) Neat T/O for G101 and G103 11
S117 (3.3L/3.8L) Near T/O for Output Speed Sensor 18
S118 (2.4L) Near T/O for Knock Sensor 11, 13
S119 (2.5L) Near T/O for Engine Starter Motor 15
S120 (2.4L) Near T/O for Oxygen Sensors N/S
S120 (3.3L/3.8L) Near T/O for Oxygen Sensors 18
S121 (3.3L/3.8L) Near T/O for Output Speed Sensor 18
S122 (2.4L) In T/O to Engine Starter Motor 11, 13
S122 (3.3L/3.8L) In T/O to Engine Starter Motor 18
S123 In T/O to Low Note Horn 5
S124 (2.4L) Near T/O for Fuel Injector No.2 N/S
8W - 91 - 12 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
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Page 1418 of 2177

CHRYSLER CARAVAN 2003 Service Manual SHROUD - UPPER
REMOVAL
(1) Remove the two shroud-to-shroud mounting
screws from the lower shroud (Fig. 32).
(2) Unsnap the upper shroud from the lower on
the left side as follows:
(a) Hook a finger on

SHROUD - UPPER
REMOVAL
(1) Remove the two shroud-to-shroud mounting
screws from the lower shroud (Fig. 32).
(2) Unsnap the upper shroud from the lower on
the left side as follows:
(a) Hook a finger on the left hand around the
rear of the shrouds at the seam (Fig. 33), near the
snap points.
(b) Grasp the upper shroud at the rear using the
right hand (Fig. 33).
(c) As the left hand's hooked finger is pulled out-
ward against the seam, pull the upper shroud
upward using the right hand, disconnecting the
shroud snaps.
(3) Unsnap the upper shroud from the lower on
the right side as follows:
(a) Hook a finger on the right hand around the
rear of the shrouds at the seam (Fig. 34), near the
snap points.
(b) Grasp the upper shroud at the rear using the
left hand (Fig. 34).
(c) As the right hand's hooked finger is pulled
outward against the seam, pull the upper shroud
upward using the left hand, disconnecting the
shroud snaps.
(4) Lift the upper shroud straight up off the steer-
ing column. If vehicle is equipped with traction con-
trol, disconnect wiring connector at traction control
switch pig tail. If vehicle is equipped with power fold-
away mirrors (Export), disconnect wiring connector
at mirror switch pig tail. Remove upper shroud.
(5) If vehicle is equipped with traction control,
remove traction control switch from shroud.
(6) If vehicle is equipped with power foldaway mir-
rors (Export), remove power fold-away switch from
upper shroud.
INSTALLATION
(1) If the vehicle is equipped with power foldaway
mirrors (Export), install the power fold-away switch
in the upper shroud.
(2) If vehicle is equipped with traction control,
install the traction control switch in the upper
shroud.
(3) Place the upper shroud over the lower shroud,
aligning the snap clips and alignment tabs. If the
vehicle is equipped with traction control, connect the
wiring connector at the traction control switch pig
tail before lining the shrouds up to one another.
(4) Snap the upper shroud to the lower shroud.
Once snapped into place, verify there are no gaps
between the two mating surfaces of the shrouds.(5) Install the two shroud-to-shroud mounting
screws (Fig. 32). Tighten the screws to 2 N´m (17 in.
lbs.) torque.
(6) Ensure that the shrouds are snug and fit is
acceptable.
STEERING WHEEL
REMOVAL
NOTE: Before proceeding, (Refer to 19 - STEERING/
COLUMN - WARNING)(Refer to 8 - ELECTRICAL/RE-
STRAINTS - WARNING).
(1) Adjust the steering wheel so that the tires are
in thestraight-aheadposition.
(2) Disconnect and isolate the battery negative
cable.
(3) Remove the two bolts from the rear of the
steering wheel attaching the driver airbag. Lift the
airbag from the steering wheel.
(4) Disconnect airbag squib wiring connectors from
the airbag and the horn/speed control switch pigtail
connector from the clockspring (Fig. 35). If the steer-
ing wheel is equipped with remote radio controls, dis-
connect the connector from the clockspring (Fig. 36).
Properly store the driver airbag out of the way.
(Refer to 8 - ELECTRICAL/RESTRAINTS - WARN-
ING)
(5) Remove the steering wheel retaining nut from
the steering column shaft (Fig. 36).
(6) Remove the steering wheel damper from the
steering wheel (Fig. 36).
Fig. 35 Airbag Wiring Connections
1 - AIRBAG FEED SQUIB CONNECTORS
2 - DRIVER AIRBAG
3 - HORN/SPEED CONTROL CONNECTOR
4 - CLOCKSPRING
RSCOLUMN19-23
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Page 1420 of 2177

CHRYSLER CARAVAN 2003 Service Manual steering wheel onto the steering column shaft by
hand. Use care not to pinch any wiring.
NOTE: Before installing the damper on the steering
wheel, inspect the damper to ensure the rubber iso-
lator on

Page 1722 of 2177

CHRYSLER CARAVAN 2003 Service Manual CAUTION: Never attempt to train more than one
vehicle at a time. System is capable of reading tire
pressure sensor transmissions from other near-by
vehicles.
Each time a wheel rotation or tire pressur

CAUTION: Never attempt to train more than one
vehicle at a time. System is capable of reading tire
pressure sensor transmissions from other near-by
vehicles.
Each time a wheel rotation or tire pressure sensor
replacement occurs the tire pressure sensors must be
retrained. This is necessary to inform the Electronic
Vehicle Information Center (EVIC) that a sensor
change was made and where. Retraining is accom-
plished through the EVIC used in conjunction with a
Re-learn Magnet, Special Tool 8821.
NOTE: Use the following procedure to retrain all
four (4) road wheel tire pressure sensors. No
attempt should be made to retrain individual sen-
sors.
(1) Retrieve Re-learn Magnet, Special Tool 8821.
(2) Press MENU Button on EVIC until9RETRAIN
TIRE SENSORS - NO9is displayed.
(3) Press STEP button to select9YES9.
NOTE: There is a 60 second timer for training the
first sensor and a 60 second timer between training
the remaining sensors. If any of these timers expire,
the EVIC will abort the training procedure.
NOTE: If at any time the EVIC display reads(TRAIN-
ING ABORTED(, move the vehicle ahead at least
one foot and repeat the entire retraining procedure.
(4) Press MENU button to start retraining. Dis-
play will read9TRAIN LEFT FRONT TIRE9
NOTE: The order for retraining all four sensors is:
²Left Front
²Right Front
²Right Rear
²Left Rear
(5) Starting at left front tire, place Re-learn Mag-
net over valve stem (Fig. 17). Within approximately 5
seconds, vehicle horn will chirp indicating training
complete at that particular sensor. Remove the mag-
net.
(6) Repeat step (5) on remaining sensors as indi-
cated by EVIC until all four TPM sensors positions
are trained.
(7) Once EVIC displays9TRAINING COMPLETE9,
pressing either STEP, C/T, RESET or MENU button
will exit training routine.
REMOVAL
(1) Remove tire and wheel assembly from vehicle.
(Refer to 22 - TIRES/WHEELS - REMOVAL)
CAUTION: The cap used on this valve stem con-
tains an O-ring seal to prevent contamination and
moisture from entering the valve stem. Retain this
valve stem cap for reuse. Do not substitute a regu-
lar valve stem cap in its place.
CAUTION: The valve stem used on this vehicle is
made of aluminum and the core is nickel plated
brass. The original valve stem core must be rein-
stalled and not substituted with a valve stem core
made of a different material. This is required to pre-
vent corrosion in the valve stem caused by the dif-
ferent metals.
(2) Dismount tire from wheel following tire
changer manufacturers instructions while paying
special attention to the following to avoid damaging
the pressure sensor:
(a) When breaking the tire bead loose from the
wheel rim, avoid using the Bead Breaker in the
area of the sensor. That includes both front and
rear beads of the tire.
(b) When preparing to dismount the tire from
the wheel, carefully insert the mounting/dimount-
ing tool at the valve stem 10É (Fig. 18), then pro-
ceed to dismount the tire from the wheel. Use this
process on both the upper and lower tire beads.
(3) Using a thin wall socket, remove special nut
retaining sensor to wheel (Fig. 19).
(4) Remove sensor from wheel (Fig. 19).
Fig. 17 Magnet Placement Over Valve Stem
1 - RE-LEARN MAGNET
2 - VALVE STEM
RSTIRES/WHEELS22-11
SENSOR - TPM (Continued)
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