2003 CHRYSLER CARAVAN key

BODY CONTROL MODULE C4 - BLACK/GRAY 34 WAY
CAV CIRCUIT FUNCTION
1- -
2 E12 20OR/GY PANEL LAMPS DRIVER (HVAC)
3 E19 20OR/BR PANEL LAMPS DRIVER (HEADLAMP SWITCH)
4 D9 22WT/GY (RKE) RKE MODULE PROGRAM ENABLE
5 G150 22VT/BR INSTRUMENT CLUSTER WAKE UP SENSE
6- -
7 P162 20LG/DG (EXPORT) PASSENGER FOLDING MIRROR RELAY CONTROL
8- -
9 L161 20WT/LG LEFT TURN INDICATOR DRIVER
10 F504 20GY/PK FUSED IGNITION SWITCH OUTPUT (RUN)
11 E14 20OR/TN PANEL LAMPS DRIVER (RADIO)
12 E13 20OR/WT PANEL LAMPS DRIVER (INSTRUMENT CLUSTER)
13 X920 22GY/OR RADIO CONTROL MUX RETURN
14 G900 20VT/DB IGNITION SWITCH SENSE RETURN
15 - -
16 - -
17 L160 20WT/TN RIGHT TURN INDICATOR DRIVER
18 - -
19 - -
20 - -
21 - -
22 G902 22VT/LB MULTI-FUNCTION SWITCH MUX RETURN
23 - -
24 - -
25 - -
26 - -
27 - -
28 - -
29 - -
30 - -
31 G96 22VT/DG (RKE) REMOTE KEYLESS ENTRY INTERFACE
32 B27 20DG/WT (TRACTION CONTROL) TRACTION CONTROL SWITCH SENSE
33 P136 20TN/YL (EXPORT) FOLDING MIRROR SWITCH SENSE
34 G26 22VT/OR CHIME DRIVER
8W - 80 - 14 8W-80 CONNECTOR PIN-OUTSRS
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REMOTE KEYLESS ENTRY ANTENNA (JAPAN) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 D10 18WT REMOTE KEYLESS ENTRY ANTENNA (+)
2 D10 18WT/LB REMOTE KEYLESS ENTRY ANTENNA (-)
REMOTE KEYLESS ENTRY MODULE - BLACK 6 WAY
CAV CIRCUIT FUNCTION
1 G96 22VT/DG REMOTE KEYLESS ENTRY INTERFACE
2 D9 22WT/GY REMOTE KEYLESS ENTRY PROGRAM ENABLE
3 Z109 22BK/GY GROUND
4 D10 18WT (JAPAN) REMOTE KEYLESS ENTRY ANTENNA (+)
5 D10 18WT/LB (JAPAN) REMOTE KEYLESS ENTRY ANTENNA (-)
6 A114 18GY/RD FUSED B(+) (I.O.D.)
RIGHT B-PILLAR SWITCH (POWER SLIDING DOOR) - GRAY 3 WAY
CAV CIRCUIT FUNCTION
1 Z62 22BK/YL GROUND
2 F302 18GY/PK FUSED ACCESSORY RELAY OUTPUT
3 G42 22VT/YL RIGHT SLIDING DOOR PILLAR SWITCH MUX
RIGHT CINCH/RELEASE MOTOR (POWER SLIDING DOOR) - GRAY 4 WAY
CAV CIRCUIT FUNCTION
1 Q46 18TN/GY RIGHT CINCH/RELEASE MOTOR LATCH DRIVER
2 Z248 18BK/WT GROUND
3 Q44 18OR/GY RIGHT CINCH/RELEASE MOTOR CLUTCH DRIVER
4 Q48 18TN/WT RIGHT CINCH/RELEASE MOTOR UNLATCH DRIVER
RS8W-80 CONNECTOR PIN-OUTS8W - 80 - 119
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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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CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Recirculation Door Actuator GY Right Side of HVAC N/S
Remote Keyless Entry Antenna
(JAPAN)BK Right Upper Instrument Panel 27
Remote Keyless Entry Module BK/RD Top Left of I.P. 19, 20
Right B-Pillar Switch GY Right B Pillar 38
Right Cinch/Release Motor GY Rear of Sliding Door 44
Right Combination Relay BK Left Quarter Panel N/S
Right Cylinder Lock Switch BK Right Front Door 43
Right Door Speaker BK/RD At Speaker N/S
Right Fog Lamp WT At Lamp 3
Right Front Door Ajar Switch BK At B Pillar N/S
Right Front Door Lock Motor/Ajar
SwitchBK Right Front Door 43
Right Front Park/Turn Signal
LampBK At Lamp 1, 3
Right Front Wheel Speed Sensor GY Right Fender Side Shield 3,10, 16, 17
Right Full Open Switch BK Right Sliding Door 44
Right Headlamp BK At Lamp 1, 3
Right Headlamp Leveling Motor WT At Right Headlamp N/S
Right High Beam Lamp BK At Right Headlamp N/S
Right Instrument Panel Speaker BK At Speaker 19, 22, 23
Right Liftgate Flood Lamp BK At Lamp 48
Right Low Beam Lamp BK At Right Headlamp N/S
Right Mid Reading Lamp GY At Lamp N/S
Right Park Lamp BK AT Lamp N/S
Right Power Mirror BK At Mirror 19, 23, 27
Right Rear Lamp Assembly BK At Lamp 47
Right Rear Pillar Speaker BK At Speaker 47
Right Rear Reading Lamp GY At Lamp N/S
Right Rear Speaker BK/RD At Speaker 47
Right Rear Vent Motor NAT At Motor 47
Right Rear Wheel Speed Sensor BK Center Rear of Floor Pan 47
Right Remote Radio Switch BK At Steering Wheel N/S
Right Repeater Lamp GY Right Front Fender 38
Right Seat Airbag YL At Passenger Seat N/S
Right Side Impact Airbag Control
ModuleYL/RD Right B Pillar 38
Right Sliding Door Control
Module C1BK Rear of Door 44, 45
Right Sliding Door Control
Module C2BK/RD Rear of Door 44, 45
Right Sliding Door Latch Sensing
SwitchBK At Sliding Door 44
Right Sliding Door Lock Motor BK Rear of Door 44
8W - 91 - 10 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
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CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Right Sliding Door Lock
Motor/Ajar SwitchBK At Latch N/S
Right Sliding Door Motor BK At Sliding Door 44
Right Speed Control Switch BK At Steering Wheel N/S
Right Stop/Turn Signal Relay BK LT Quarter Panel N/S
Right Turn Signal Lamp OR At Lamp N/S
Right Visor/Vanity Lamp BK At Lamp N/S
Sentry Key Immobilizer Module BK At Steering Column 19, 20, 21, 22, 30
Siren (United Kingdom) BK Left Front Body N/S
Solenoid/Pressure Switch
Assembly (EATX)BK Side of Transmission 14, 18
Speed Control Servo BK Near Controller Antilock Brake 11, 18
Sunroof Module BK At Sunroof N/S
Sunroof Switch Nat Near Overhead Console N/S
Thatcham Alarm Module C1 BK Top Right Side of Instrument Panel
Near SpeakerN/S
Thatcham Alarm Module C1 WT Top Right Side of Instrument Panel
Near SpeakerN/S
Throttle Position Sensor GY On Throttle Body 10, 11, 17
Torque Converter Clutch Solenoid BK Front of Transmission 11
Traction Control Switch BK Rear of Swtich 20, 21, 30
Trailer Tow Connector BK Left Quarter Panel N/S
Transmission Control Module BK Left Engine Compartment 5
Transmission Range Sensor GY Top of Transmission 14, 18
Turbo boost Pressure Sensor On Cylinder Block 15
Vehicle Speed Sensor BK Rear of Transmission 10, 16
Washer Fluid Level Switch BK Bottom of Reservoir 3
Water in Fuel Sensor (Diesel) Left Rear Engine Compartment N/S
Wiper Module BK Left Side Cowl 6
GROUNDS
GROUND NUMBER LOCATION FIG.
G100 Body Ground Near Powertrain Control Module N/S
G101 Above Starter 11, 13
G102 Left Headlamp Area 1
G103 Above Starter 11, 13
G200 Right Side of Instrument Panel 19, 23, 28
G201 Right Side of Instrument Panel 19, 23, 28
G202 Near Radio N/S
G300 Left B Pillar 31
G301 Right B Pillar 32, 38
G302 Left Rear Quarter 46
G400 Liftgate Ground N/S
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-11
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
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The IPM has a molded plastic cover that can be
removed to provide service access to all of the fuses
and relays in the IPM. An integral latch and hinges
are molded into the IPM cover for easy removal. A
fuse layout map is integral to the underside of the
IPM cover to ensure proper fuse and relay identifica-
tion. The IOD fuse is a 20 ampere blade-type mini
fuse and, when removed, it is stored in a fuse cavity
adjacent to the washer fuse within the IPM.
OPERATION
The term ignition-off draw identifies a normal con-
dition where power is being drained from the battery
with the ignition switch in the Off position. The IOD
fuse feeds the memory and sleep mode functions for
some of the electronic modules in the vehicle as well
as various other accessories that require battery cur-
rent when the ignition switch is in the Off position,
including the clock. The only reason the IOD fuse is
removed is to reduce the normal IOD of the vehicle
electrical system during new vehicle transportation
and pre-delivery storage to reduce battery depletion,
while still allowing vehicle operation so that the
vehicle can be loaded, unloaded and moved as needed
by both vehicle transportation company and dealer
personnel.
The IOD fuse is removed from the IPM fuse cavity
when the vehicle is shipped from the assembly plant.
Dealer personnel must install the IOD fuse when the
vehicle is being prepared for delivery in order to
restore full electrical system operation. Once the
vehicle is prepared for delivery, the IOD function of
this fuse becomes transparent and the fuse that has
been assigned the IOD designation becomes only
another Fused B(+) circuit fuse. The IOD fuse serves
no useful purpose to the dealer technician in the ser-
vice or diagnosis of any vehicle system or condition,
other than the same purpose as that of any other
standard circuit protection device.
The IOD fuse can be used by the vehicle owner as
a convenient means of reducing battery depletion
when a vehicle is to be stored for periods not to
exceed about thirty days. However, it must be
remembered that removing the IOD fuse will not
eliminate IOD, but only reduce this normal condition.
If a vehicle will be stored for more than about thirty
days, the battery negative cable should be discon-
nected to eliminate normal IOD; and, the battery
should be tested and recharged at regular intervals
during the vehicle storage period to prevent the bat-
tery from becoming discharged or damaged. Refer to
Battery Systemfor additional service information.
REMOVAL
(1) Turn the ignition switch to the Off position.(2) Unlatch and open the cover of the intelligent
power module.
(3) Remove the IOD fuse from fuse location
markedIODof the Integrated Power Module (IPM).
(4) Store the removed IOD fuse by installing it in
the unused fuse storage markedSPAREof the IPM.
(5) Close and latch the IPM.
INSTALLATION
(1) Be certain the ignition switch is in the Off posi-
tion.
(2) Unlatch and open the cover of the Integrated
Power Module (IPM).
(3) Use a thumb to press the IOD fuse firmly down
into IPM fuse cavity markedIOD.
(4) Close and latch the IPM cover.
POWER OUTLET
DESCRIPTION
Accessory power outlets are standard equipment on
this model. Two power outlets are installed in the
instrument panel center lower bezel, which is located
near the bottom of the instrument panel center stack
area. Two additional power outlets are also incorpo-
rated into the vehicle, one on the left rear C-pillar
trim and the other in the center console, if equipped.
The power outlets bases are secured by a snap fit in
the appropriate bezels. A hinged plug flips closed to
conceal and protect the power outlet base when the
power outlet is not being used.
The power outlet receptacle unit and the power
outlet plugs are each available for service replace-
ment.
OPERATION
The power outlet base or receptacle shell is con-
nected to ground, and an insulated contact in the
bottom of the shell is connected to battery current.
The power outlet on the instrument panel marked
with a battery receives battery voltage from a fuse in
the Integrated Power Module (IPM) at all times. The
other power outlet on the instrument panel marked
with a key receives battery voltage only when the
key is in the on position.
The power outlet located in the center console
receives battery voltage all the time when positioned
between thefront seatsand key-on voltage when
positioned between therear seats. The power outlet
located on the C-pillar receives battery voltage only
when the key is in the on position.
RS8W-97 POWER DISTRIBUTION SYSTEM8W-97-5
IOD FUSE (Continued)
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DIAGNOSIS AND TESTING
DIAGNOSIS & TESTING - POWER OUTLET
For complete circuit diagrams, refer toCigar
Lighter/Power Outletin Wiring Diagrams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO RESTRAINTS BEFORE ATTEMPT-
ING ANY STEERING WHEEL, STEERING COLUMN,
SEAT OR INSTRUMENT PANEL COMPONENT DIAG-
NOSIS OR SERVICE. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
(1) Check the fused B(+) fuse in the Integrated
Power Module (IPM). If OK, go to Step 2. If not OK,
repair the shorted circuit or component as required
and replace the faulty fuse.
(2) Check for battery voltage at the fused B(+) fuse
in the IPM. If OK, go to Step 3. If not OK, repair the
open fused B(+) circuit to the IPM fuse as required.
(3)
Open the power outlet door. Check for continuity
between the inside circumference of the power outlet
receptacle and a good ground. There should be continu-
ity. If OK, go to Step 4. If not OK, go to Step 5.
(4) Check for battery voltage at the insulated con-
tact located at the back of the power outlet recepta-
cle. If not OK, go to Step 5.
(5) Disconnect and isolate the battery negative
cable. Remove the appropriate bezel. Check for conti-
nuity between the ground circuit cavity of the power
outlet wire harness connector and a good ground.
There should be continuity. If OK, go to Step 6. If not
OK, repair the open ground circuit to ground as
required.
(6) Connect the battery negative cable. Check for
battery voltage at the fused B(+) circuit cavity of the
power outlet wire harness connector. If OK, replace
the faulty power outlet receptacle. If not OK, repair
the open fused B(+) circuit to the IPM fuse as
required.
REMOVAL
(1)Disconnect and isolate the battery negative cable.
(2) Look inside and note position of the retaining
bosses (Fig. 5).
(3) Using external snap ring pliers with 90 degree
tips. Insert pliers with tips against bosses and
squeeze forcing bosses out of base.
(4) Pull out the base through mounting ring by
gently rocking pliers. A tool can be made to do the
same. Refer to (Fig. 6).
(5) Disconnect the base wires.
(6) Set base aside. Remove light ring and discon-
nect wire.
INSTALLATION
(1) Position the mounting ring on the instrument
panel and feed the wires through the ring. Index the
cap and the mounting ring with the index tab at the
9 o'clock position to the key in the instrument panel.
Install the ring.
(2) Connect the wires to the base. Orientate the
base alignment rib at the 11 o'clock position to mate
the groove in the mounting ring to the base.
(3)
Push the base into the bezel until it locks in place.
(4) Check operation of outlet or element and
install the 12 volt outlet cap.
Fig. 5 Outlet Base Removal
1 - RETAINING BOSSES-ENGAGE PLIERS HERE
2 - PARTIALLY REMOVED
3 - EXTERNAL SNAP-RING PLIERS
4 - PULL BASE OUT-THROUGH MOUNTING RING
Fig. 6 Tool For Outlet Removal
1 - 2.5MM (3/32 INS.)
2 - WELD
3 - 100MM (4 INS.)
4 - 22.25 TO 22.45MM (7/8 TO 57/64 INS.)
8W - 97 - 6 8W-97 POWER DISTRIBUTION SYSTEMRS
POWER OUTLET (Continued)
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OIL PUMP
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
REMOVAL).
(3) Remove timing belt rear cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT COVER(S)
- REMOVAL).
(4) Remove oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - REMOVAL).
(5) Remove crankshaft sprocket using Special
Tools 6793 and C-4685-C2 (Fig. 90).
(6) Remove crankshaft key (Fig. 91).
(7) Remove oil pick-up tube.(8) Remove oil pump (Fig. 92) and front crankshaft
seal.
DISASSEMBLY
(1) To remove the relief valve, proceed as follows:
(a) Remove the threaded plug and gasket from
the oil pump (Fig. 93) .
(b) Remove spring and relief valve (Fig. 93) .
Fig. 90 Crankshaft Sprocket - Removal
1 - SPECIAL TOOL 6793
2 - SPECIAL TOOL C-4685±C2
3 - CRANKSHAFT SPROCKET
Fig. 91 Crankshaft Key
1 - CRANKSHAFT KEY
Fig. 92 Oil Pump
1 - BOLTS
2 - BOLTS
3 - OIL PUMP
Fig. 93 Oil Pressure Relief Valve
1 - PLUG
2 - OIL PUMP BODY
3 - RELIEF VALVE
4 - SPRING
5 - SEAL
RSENGINE 2.4L9-55
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