2003 CHRYSLER CARAVAN Service Manual

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Page 585 of 2177

CHRYSLER CARAVAN 2003 Service Manual DIODE
REMOVAL
(1) Disconnect the battery.
(2) Locate the diode in the harness, and remove
the protective covering.
(3) Remove the diode from the harness, pay atten-
tion to the current flow direction

Page 586 of 2177

CHRYSLER CARAVAN 2003 Service Manual WIRE
STANDARD PROCEDURE - WIRE SPLICING
When splicing a wire, it is important that the cor-
rect gage be used as shown in the wiring diagrams.
(1) Remove one-half (1/2) inch of insulation from
each wi

Page 587 of 2177

CHRYSLER CARAVAN 2003 Service Manual ProCarManuals.com

Page 588 of 2177

CHRYSLER CARAVAN 2003 Service Manual 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-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
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Page 589 of 2177

CHRYSLER CARAVAN 2003 Service Manual Component Page
Leak Detection Pump................... 8W-30
License Lamp...................... 8W-51, 61
Lift Pump Motor....................... 8W-30
Lift Pump Relay....................... 8W-30
Liftg

Component Page
Leak Detection Pump................... 8W-30
License Lamp...................... 8W-51, 61
Lift Pump Motor....................... 8W-30
Lift Pump Relay....................... 8W-30
Liftgate Ajar Switch.................. 8W-39, 61
Liftgate Cinch/Release Motor.............. 8W-61
Liftgate Cylinder Lock Switch............. 8W-39
Liftgate Flood Lamps................... 8W-44
Liftgate Left Pinch Sensor................ 8W-61
Liftgate Right Pinch Sensor............... 8W-61
Low Beam Lamps...................... 8W-50
Manifold Absolute Pressure Sensor......... 8W-30
Mass Air Flow Sensor................... 8W-30
Memory Seat/Mirror Module............ 8W-62, 63
Memory Set Switch..................... 8W-63
Message Center........................ 8W-46
Mid Reading Lamps.................... 8W-44
Mode Door Actuator..................... 8W-42
Multi-Function Switch............. 8W-50, 52, 53
Name Brand Speaker Relay............... 8W-47
Natural Vacuum Leak Detection Assembly.... 8W-30
Output Speed Sensor.................... 8W-31
Overhead Console................... 8W-43, 49
Oxygen Sensors........................ 8W-30
Park Lamp Relay...................... 8W-10
Park Lamps.......................... 8W-50
Park/Turn Signal Lamps................. 8W-50
Parking Brake Switch................... 8W-40
Passenger Airbag...................... 8W-43
Passenger Folding Mirror Relay............ 8W-62
Power Folding Mirror Switch.............. 8W-62
Power Liftgate Module.................. 8W-61
Power Liftgate Motor.................... 8W-61
Power Mirror Switch.................... 8W-62
Power Mirrors......................... 8W-62
Power Outlet.......................... 8W-41
Power Seat Circuit Breaker............... 8W-10
Power Seat Front Riser Motors............ 8W-63
Power Seat Front Riser Position Sensors..... 8W-63
Power Seat Horizontal Motors............. 8W-63
Power Seat Horizontal Position Sensors...... 8W-63
Power Seat Rear Riser Motors............. 8W-63
Power Seat Rear Riser Position Sensors...... 8W-63
Power Seat Recliner Motors............... 8W-63
Power Seat Recliner Position Sensors........ 8W-63
Power Seat Switches.................... 8W-63
Power Window Circuit Breaker............ 8W-10
Power Window Motor................... 8W-60
Power Window Switch................... 8W-60
Powertrain Control Module............... 8W-30
PTC's............................... 8W-10
Radiator Fans......................... 8W-42
Radiator Fan Relays.................... 8W-42
Radio............................... 8W-47
Reading Lamps........................ 8W-44
Rear A/C-Heater Unit................... 8W-42
Component Page
Rear Auto Temp Control Switch............ 8W-42
Rear Blower Front Control Switch.......... 8W-42
Rear Blower Motor Power Module.......... 8W-42
Rear Blower Motor Relay................. 8W-42
Rear Blower Motor..................... 8W-42
Rear Blower Rear Control Switch........... 8W-42
Rear Dome Lamp...................... 8W-44
Rear Intrusion Sensor................... 8W-39
Rear Mode Motor...................... 8W-42
Rear Power Outlet...................... 8W-41
Rear Temperature Motor................. 8W-42
Rear Washer Pump Motor................ 8W-53
Rear Window Defogger Grid............... 8W-48
Rear Wiper Motor...................... 8W-53
Recirculation Door Actuator............... 8W-42
Remote Keyless Entry Antenna............ 8W-61
Remote Keyless Entry Module............. 8W-61
Remote Radio Switches.................. 8W-47
Repeater Lamps....................... 8W-52
Splices.............................. 8W-70
Seat Airbags.......................... 8W-43
Seat Belt Tensioner..................... 8W-43
Sentry Key Immobilizer Module............ 8W-39
Side Impact Airbag Control Modules........ 8W-43
Siren............................... 8W-39
Sliding Door Control Modules........... 8W-43, 61
Sliding Door Latch Sensing Switches........ 8W-61
Sliding Door Lock Motors................ 8W-61
Sliding Door Lock Motor/Ajar Switches...... 8W-61
Sliding Door Motors.................... 8W-61
Solenoid/Pressure Switch Assy............. 8W-31
Speakers............................. 8W-47
Speed Control Servo.................... 8W-33
Speed Control Switches.................. 8W-33
Starter Motor Relay.................... 8W-21
Starter Motor......................... 8W-21
Stop/Turn Signal Relays................. 8W-54
Sunroof Module........................ 8W-64
Sunroof Switch........................ 8W-64
Thatcham Alarm Indicator................ 8W-39
Thatcham Alarm Module................. 8W-39
Throttle Position Sensor................. 8W-30
Traction Control Switch.................. 8W-35
Trailer Tow Connector................... 8W-54
Transmission Control Module.............. 8W-31
Transmission Control Relay............... 8W-31
Transmission Range Sensor............... 8W-31
Turn Signal Lamps..................... 8W-52
Vehicle Speed Sensor.................... 8W-30
Vent Motors.......................... 8W-60
Visor/Vanity Lamps..................... 8W-44
Washer Fluid Level Switch............... 8W-53
Water In Fuel Sensor................... 8W-30
Wheel Speed Sensors.................... 8W-35
8W - 02 - 2 8W-02 COMPONENT INDEXRS
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Page 590 of 2177

CHRYSLER CARAVAN 2003 Service Manual 8W-10 POWER DISTRIBUTION
Component Page
A/C Compressor Clutch . . . 8W-10-22, 24, 47, 48, 51
A/C Compressor Clutch
Relay............ 8W-10-22, 24, 46, 47, 48, 51
Accessory Relay............... 8W-10-1

8W-10 POWER DISTRIBUTION
Component Page
A/C Compressor Clutch . . . 8W-10-22, 24, 47, 48, 51
A/C Compressor Clutch
Relay............ 8W-10-22, 24, 46, 47, 48, 51
Accessory Relay............... 8W-10-16, 31, 68
Adjustable Pedals Relay.............. 8W-10-50
Airbag Control Module............ 8W-10-67, 72
Ambient Temperature Sensor.......... 8W-10-65
Auto Shut Down Relay......... 8W-10-21, 42, 43
Auto Temp Control.................. 8W-10-41
Back-Up Lamp Switch............... 8W-10-69
Battery............ 8W-10-13, 14, 15, 42, 43, 51
Blower Motor Resistor............ 8W-10-19, 39
Body Control Module.... 8W-10-25, 41, 47, 48, 52,
53, 55, 57, 58, 59, 60, 72
Brake Fluid Level Switch............. 8W-10-68
Brake Lamp Switch........... 8W-10-26, 55, 70
Brake Transmission Shift Interlock
Solenoid........................ 8W-10-66
Cabin Heater Assist........... 8W-10-23, 45, 63
Camshaft Position Sensor............. 8W-10-46
Center High Mounted Stop Lamp....... 8W-10-70
Clockspring........................ 8W-10-64
Clutch Pedal Interlock
Switch.............. 8W-10-18, 38, 57, 58, 64
Controller Antilock
Brake...... 8W-10-18, 25, 37, 38, 53, 59, 65, 70
Crank Case Ventilation Heater......... 8W-10-52
Data Link Connector........... 8W-10-36, 65, 72
Defogger Relay............ 8W-10-19, 20, 40, 67
Driver Door Lock Switch........ 8W-10-33, 34, 35
Driver Heated Seat Module........... 8W-10-53
Driver Power Seat Switch............ 8W-10-53
Driver Power Window Switch....... 8W-10-34, 35
DVD/DV Changer................... 8W-10-41
ECM/PCM Relay................. 8W-10-23, 45
EGR Solenoid................... 8W-10-46, 50
Engine Control
Module . . 8W-10-18, 23, 24, 38, 45, 46, 51, 65, 70
Floor Console Lamp................. 8W-10-32
Floor Console Power Outlet........ 8W-10-32, 36
Front Blower Module................ 8W-10-19
Front Blower Module................ 8W-10-39
Front Blower Motor Relay.... 8W-10-18, 19, 39, 67
Front Cigar Lighter.............. 8W-10-16, 32
Front Control Module....... 8W-10-15, 16, 17, 18,
19, 20, 22, 24, 26, 27,
28, 29, 30, 31, 36, 40,
47, 48, 50, 51, 56, 57,
58, 61, 62, 63, 64, 65,
66, 67, 68, 69, 70, 72
Front Fog Lamp Relay......... 8W-10-15, 27, 67
Front Washer Pump Motor...... 8W-10-16, 31, 72Component Page
Front Wiper High/Low Relay.... 8W-10-16, 30, 68
Front Wiper On/Off Relay....... 8W-10-16, 30, 63
Fuel Heater....................... 8W-10-52
Fuel Heater Relay............. 8W-10-24, 51, 68
Fuel Injector No. 1.................. 8W-10-44
Fuel Injector No. 2.................. 8W-10-44
Fuel Injector No. 3.................. 8W-10-44
Fuel Injector No. 4.................. 8W-10-44
Fuel Injector No. 5.................. 8W-10-44
Fuel Injector No. 6.................. 8W-10-44
Fuel Pressure Solenoid............... 8W-10-46
Fuel Pump Module............ 8W-10-22, 47, 48
Fuel Pump Relay........... 8W-10-22, 47, 48, 68
Fuse 1...................... 8W-10-15, 16, 27
Fuse 2...................... 8W-10-15, 28, 29
Fuse 3...................... 8W-10-15, 28, 29
Fuse 4................... 8W-10-15, 16, 17, 30
Fuse 5......................... 8W-10-16, 31
Fuse 6......................... 8W-10-16, 31
Fuse 8......................... 8W-10-17, 36
Fuse 9................ 8W-10-17, 18, 19, 37, 38
Fuse 10........................ 8W-10-19, 39
Fuse 11........................ 8W-10-16, 31
Fuse 12........................ 8W-10-19, 39
Fuse 13........................ 8W-10-20, 40
Fuse 14............... 8W-10-20, 21, 23, 40, 63
Fuse 15...... 8W-10-20, 21, 22, 23, 24, 42, 43, 45
Fuse 16............... 8W-10-21, 23, 42, 43, 45
Fuse 17......... 8W-10-21, 22, 23, 24, 47, 48, 51
Fuse 18............ 8W-10-22, 24, 25, 47, 48, 51
Fuse 19.................. 8W-10-22, 24, 26, 53
Fuse 20........................ 8W-10-25, 53
Fuse 21........................ 8W-10-25, 53
Fuse 22........................ 8W-10-25, 53
Fuse 23..................... 8W-10-25, 57, 58
Fuse 24........................ 8W-10-25, 55
Fuse 26..................... 8W-10-25, 26, 55
Fuse 27........................ 8W-10-26, 55
Fuse 28........................ 8W-10-16, 31
Fuse 30........................ 8W-10-26, 56
Fuse 31........................ 8W-10-26, 56
Fuse 32........................ 8W-10-26, 56
Fuse 33........................ 8W-10-16, 31
Fuselink....................... 8W-10-13, 14
G100............................. 8W-10-59
G101....................... 8W-10-42, 43, 51
G103............................. 8W-10-72
G300.......................... 8W-10-61, 62
Generator................ 8W-10-13, 14, 44, 46
Glow Plug Relay................. 8W-10-13, 46
Headlamp Switch................ 8W-10-29, 66
Headlamp Washer Pump Motor..... 8W-10-26, 56
RS8W-10 POWER DISTRIBUTION8W-10-1
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Page 591 of 2177

CHRYSLER CARAVAN 2003 Service Manual Component Page
Headlamp Washer Relay........ 8W-10-26, 56, 67
High Note Horn.................... 8W-10-36
Horn Relay.................. 8W-10-17, 36, 63
Ignition Coil....................... 8W-10-44
Ig

Component Page
Headlamp Washer Relay........ 8W-10-26, 56, 67
High Note Horn.................... 8W-10-36
Horn Relay.................. 8W-10-17, 36, 63
Ignition Coil....................... 8W-10-44
Ignition Switch . . . 8W-10-18, 25, 37, 38, 47, 48, 49,
52, 57, 58, 64
Instrument Cluster............... 8W-10-25, 55
Integrated Power
Module............. 8W-10-3, 4, 5, 13, 15, 16,
17, 18, 19, 20, 21, 22, 23, 24, 25, 26,
27, 29, 30, 31, 33, 36, 37, 38, 39, 40,
41, 42, 43, 44, 45, 46, 47, 48, 50, 51,
52, 53, 55, 56, 57, 58, 59, 60, 61, 62,
63, 64, 65, 66, 67, 68, 69, 70, 72
Leak Detection Pump................ 8W-10-50
Left B-Pillar Switch................. 8W-10-33
Left Combination Relay.............. 8W-10-71
Left Door Speaker.................. 8W-10-40
Left Fog Lamp.................. 8W-10-15, 27
Left Front Park/Turn Signal Lamp . . 8W-10-15, 28,
60, 69
Left Headlamp..................... 8W-10-61
Left Headlamp Leveling Motor . . . 8W-10-29, 66, 69
Left High Beam Lamp............... 8W-10-62
Left Low Beam Lamp................ 8W-10-62
Left Park Lamp................. 8W-10-29, 69
Left Power Mirror................... 8W-10-40
Left Rear Lamp Assembly . 8W-10-28, 29, 69, 70, 71
Left Rear Speaker.................. 8W-10-40
Left Repeater Lamp................. 8W-10-55
Left Side Impact Airbag Control Module . 8W-10-66
Left Sliding Door Control Module....... 8W-10-56
Left Stop/Turn Signal Relay........... 8W-10-71
Left Turn Signal Lamp............... 8W-10-60
License Lamp................ 8W-10-28, 29, 69
Lift Pump Motor................. 8W-10-23, 45
Lift Pump Relay................. 8W-10-23, 45
Low Note Horn..................... 8W-10-36
Mass Air Flow Sensor................ 8W-10-46
Memory Seat/Mirror Module.......... 8W-10-53
Message Center.................... 8W-10-55
Name Brand Speaker Relay..... 8W-10-20, 40, 63
Overhead Console................... 8W-10-41
Oxygen Sensor 1/1 Upstream.......... 8W-10-44
Oxygen Sensor 1/2 Downstream........ 8W-10-44
Park Lamp Relay.......... 8W-10-15, 28, 29, 63
Passenger Door Lock Switch........ 8W-10-31, 33
Passenger Folding Mirror
Relay............... 8W-10-22, 24, 47, 48, 51
Passenger Heated Seat Module........ 8W-10-54
Passenger Power Seat Switch.......... 8W-10-54
Passenger Power Window Switch....... 8W-10-31
Power Liftgate Module............... 8W-10-56
Power Mirror Switch........ 8W-10-22, 24, 50, 51
Power Outlet...................... 8W-10-36Component Page
Power Seat Circuit Breaker........ 8W-10-25, 53
Power Window Circuit Breaker...... 8W-10-16, 31
Power Window Switch............... 8W-10-34
Powertrain Control
Module.......... 8W-10-18, 21, 22, 37, 42, 43,
44, 47, 48, 50, 59, 65, 66, 72
PTC4 ......................... 8W-10-20, 40
PTC7 ................... 8W-10-16, 17, 18, 36
Radiator Fan Relay............ 8W-10-26, 55, 59
Radiator Fan Relay No. 1.......... 8W-10-13, 46
Radiator Fan Relay No. 2....... 8W-10-26, 46, 55
Radiator Fan Relay No. 3............. 8W-10-46
Radio......................... 8W-10-32, 41
Rear A/C-Heater Unit............. 8W-10-19, 39
Rear Blower Motor Relay.... 8W-10-19, 20, 39, 67
Rear Power Outlet............ 8W-10-16, 31, 32
Rear Washer Pump Motor....... 8W-10-16, 31, 72
Rear Window Defogger Grid........ 8W-10-20, 40
Rear Wiper Motor................... 8W-10-33
Remote Keyless Entry Module......... 8W-10-41
Right B-Pillar Switch................ 8W-10-33
Right Combination Relay............. 8W-10-71
Right Door Speaker................. 8W-10-40
Right Fog Lamp................. 8W-10-15, 27
Right Front Park/Turn Signal
Lamp.................. 8W-10-15, 28, 60, 64
Right Headlamp.................... 8W-10-61
Right Headlamp Leveling Motor . . 8W-10-29, 64, 66
Right High Beam Lamp.............. 8W-10-62
Right Low Beam Lamp............... 8W-10-62
Right Park Lamp................ 8W-10-29, 64
Right Power Mirror................. 8W-10-40
Right Rear Lamp Assembly . . . 8W-10-15, 28, 29, 70
Right Rear Speaker................. 8W-10-40
Right Repeater Lamp................ 8W-10-55
Right Side Impact Airbag Control
Module......................... 8W-10-66
Right Sliding Door Control Module..... 8W-10-56
Right Stop/Turn Signal Relay.......... 8W-10-71
Right Turn Signal Lamp.............. 8W-10-60
Sentry Key Immobilizer
Module.............. 8W-10-41, 49, 52, 57, 58
Solenoid/Pressure Switch Assy...... 8W-10-42, 43
Starter Motor.......... 8W-10-13, 14, 18, 37, 38
Starter Motor Relay...... 8W-10-18, 37, 38, 57, 58
Sunroof Module.................... 8W-10-56
Thatcham Alarm Module....... 8W-10-49, 52, 58
Trailer Tow Connector............ 8W-10-28, 69
Transmission Control
Module........... 8W-10-21, 37, 43, 65, 66, 72
Transmission Control Relay..... 8W-10-21, 42, 43
Vehicle Speed Sensor................ 8W-10-45
Washer Fluid Level Switch............ 8W-10-64
Wiper Module................ 8W-10-16, 30, 63
8W - 10 - 2 8W-10 POWER DISTRIBUTIONRS
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