2003 CHRYSLER CARAVAN headlamp

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Input Speed Sensor GY Front of Transmission 14
Instrument Cluster BK Rear of Cluster 19, 20, 27
Instrument Panel Switch Bank BK Right Center of Instrument Panel 19, 22, 24
Instrument Panel Power Outlet NAT Center of Instrument Panel N/S
Integrated Power Module C1 LTGN Left Fender Shield 6, 7
Integrated Power Module C2 GN/BL Left Fender Shield 6, 7
Integrated Power Module C3
(Diesel)YL/RD Left Fender Shield 6, 7
Integrated Power Module C3
(Gas)NAT/RD Left Fender Shield 6, 7, 11
Integrated Power Module C4 BL Left Fender Shield 6, 7, 11
Integrated Power Module C5 BK Left Fender Shield 6, 7
Integrated Power Module C6 NAT Left Fender Shield 6, 7
Integrated Power Module C7 BK/RD Left Fender Shield 6, 7
Integrated Power Module C8 OR Left Fender Shield 6, 7
Integrated Power Module C9 BK Left Fender Shield 6, 7
Knock Sensor GY Front of Cylinder Block 11
Leak Detection Pump LTGY At Pump 10, 11 18
Left B Pillar Switch GY Left B Pillar 39
Left Cinch/Release Motor GY Left Sliding Door N/S
Left Combination Relay BK Left Rear Quarter Panel N/S
Left Cylinder Lock Switch BK At Switch 42
Left Door Speaker BK At Speaker 42
Left Fog Lamp WT At Lamp N/S
Left Front Door Ajar Switch BK At Switch 42
Left Front Door Lock Motor/Ajar
SwitchBK Left Door 42
Left Front Park/Turn Signal Lamp BK At Lamp 1, 5
Left Front Wheel Speed Sensor BK Left Fender Side Shield 5, 11
Left Full Open Switch BK Left Sliding Door N/S
Left Headlamp BK At Lamp 1, 5
Left Headlamp Leveling Motor WT At Motor N/S
Left High Beam Lamp BK At Lamp N/S
Left Instrument Panel Speaker BK At Speaker 19, 20, 26
Left Liftgate Flood Lamp GY At Lamp 48
Left Low Beam Lamp BK At Lamp N/S
Left Mid Reading Lamp GY At Lamp N/S
Left Park Lamp BK At Lamp 5
Left Power Mirror BK At Mirror 26
Left Rear Lamp Assembly BK At Lamp 46
Left Rear Pillar Speaker BK Left of Liftgate 46
Left Rear Reading Lamp GY At Lamp N/S
Left Rear Speaker BK At Speaker 46
8W - 91 - 6 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
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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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SPLICE NUMBER LOCATION FIG.
S124 (3.3L/3.8L) Near T/O for Fuel Injector No.5 and No.6 N/S
S125 (2.4L) In T/O for Manifold Absolute Pressure Sensor N/S
S126 In Right Headlamp Leveling Assembly N/S
S127 (2.5L) In T/O for Engine Starter Motor N/S
S128 (2.5L) Near T/O for Engine Starter Motor 15
S129 (2.5L) Near T/O for Battery (+) N/S
S130 (2.5L) Near T/O for Battery (+) N/S
S131 Near T/O for Transmission Control Module 11
S131 (3.3L/3.8L) Near T/O for Transmission Control Module N/S
S132 (2.5L) Near T/O for Battery (+) N/S
S133 (2.4L) Near T/O for Integrated Power Module C3 11
S134 (2.5L) IN T/O for Engine Control Module 15
S135 (2.5L) Near T/O for Glow Plug No.2 15
S136 (2.5L) In T/O for Radiator Fan Relays 2
S137 (2.5L) Near T/O for A/C Compressor Clutch 15
S138 (2.5L) Between T/O for Radiator Fan No.2 and T/O for G102 1
S139 (2.5L) Between T/O for Engine Starter Motor and T/O for
Engine Control Module C116
S141 (2.4L) Near T/O for Battery(-) 11
S141 (2.5L) Near T/O for G100 N/S
S141 (3.3L/3.8L) Near T/O for Powertrain Control Module N/S
S142 (3.3L/3.8L) Near T/O for A/C Compressor Clutch 18
S143 (2.5L) Near T/O for Engine Control Module C1 15
S143 (3.3L/3.8L) Near T/O for Integrated Power Module - C3 N/S
S144 (2.5L) Between T/O for Battery Temperature Sensor and T/O
for C10315
S148 (2.5L) Near T/O for Engine Starter Motor 15
S149 (3.3L/3.8L) Near T/O for Transmission Control Module 5
S150 (2.5L) Between T/O for Battery Temperature Sensor and T/O
for C10315
S151 (2.5L) Near T/O for Radiator Fan Relay No.1 2
S152 (2.5L) Near T/O for Radiator Fan No.1 1
S157 (2.5L) Near T/O for Glow Plug No.1 15
S177 In Right Headlamp Wiring Assembly N/S
S179 In Left Headlamp Wiring Assembly N/S
S187 (2.5L) In T/O for Engine Control Module C1 15
S188 (2.5L) Near T/O for Radiator Fan Relay No.1 2
S201 In T/O to Instrument Panel Speaker 19, 25
S202 Near T/O for Instrument Panel Switch Bank 19, 25
S203 Near T/O for Instrument Panel Switch Bank 19, 25
S204 Near T/O to Instrument Panel Speaker 19, 25
S205 Near T/O for C201 19
S206 Near T/O for Instrument Cluster 19
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-13
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
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Fig. 1 HEADLAMP CONNECTORS
8W - 91 - 16 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
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FRAME & BUMPERS
TABLE OF CONTENTS
page page
BUMPERS
SPECIFICATIONS - TORQUE...............1
FRONT FASCIA
REMOVAL.............................1
INSTALLATION..........................1
FRONT BUMPER REINFORCEMENT
REMOVAL.............................2
INSTALLATION..........................2
REAR FASCIA
REMOVAL.............................2
INSTALLATION..........................2
REAR BUMPER REINFORCEMENT
REMOVAL.............................3
INSTALLATION..........................3
REAR FASCIA - SCUFF PAD
REMOVAL.............................3INSTALLATION..........................4
FRAME
SPECIFICATIONS
FRAME DIMENSIONS...................4
SPECIFICATIONS - TORQUE.............4
FRONT CRADLE CROSSMEMBER
DESCRIPTION
DESCRIPTION - FRONT CRADLE
CROSSMEMBER.......................9
DESCRIPTION - FRONT CRADLE
CROSSMEMBER THREAD REPAIR.........9
REMOVAL.............................9
INSTALLATION.........................11
FRONT CROSSMEMBER MOUNT BUSHINGS
REMOVAL.............................12
INSTALLATION.........................12
BUMPERS
SPECIFICATIONS - TORQUE
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Front bumper reinforcement attaching nut 54 40 Ð
Rear bumper reinforcement attaching nut 27 20 Ð
FRONT FASCIA
REMOVAL
(1) Release hood latch and open hood.
(2) Remove the headlamp assemblies (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
HEADLAMP - REMOVAL).
(3) Hoist vehicle and support with safety stands.
(4) Remove the five bolts attaching bottom of fas-
cia/air dam to radiator closure panel.
(5) Remove front wheels.
(6) Remove front wheelhouse splash shields fasten-
ers as necessary to gain access to bolts attaching
front fascia to fender. (Refer to 23 - BODY/EXTERI-
OR/ WHEELHOUSE SPLASH SHIELD - REMOV-
AL).
(7) Remove the two bolts and two nuts attaching
fascia to the front fenders (Fig. 1).
(8) Disconnect fog lamp wire connectors, if neces-
sary.
(9) Lower vehicle.(10) Remove two bolts attaching the upper grille
support to the headlamp mounting panel at each side
of the grille.
(11) Remove bumper fascia from vehicle.
INSTALLATION
(1) Position front bumper fascia on vehicle.
(2) Install the two bolts attaching fascia to head-
lamp mounting panel at each side of grille.
(3) Hoist vehicle and support with safety stands.
(4) Install the two bolts and two nuts attaching
fascia to the front fenders (Fig. 1). The fascia should
be flush to fender.
(5) Install front wheelhouse splash shields fasten-
ers. (Refer to 23 - BODY/EXTERIOR/ WHEEL-
HOUSE SPLASH SHIELD - INSTALLATION).
(6) Install front wheels.
(7) Connect fog lamp wire connectors, if necessary.
(8) Install the five bolts attaching bottom of fascia
to radiator closure panel.
(9) Lower the vehicle.
RSFRAME & BUMPERS13-1
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(10) Install the headlamp assemblies. (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
HEADLAMP - INSTALLATION).
FRONT BUMPER
REINFORCEMENT
REMOVAL
(1) Remove front bumper fascia. (Refer to 13 -
FRAMES & BUMPERS/BUMPERS/FRONT FASCIA
- REMOVAL)
(2) Support front bumper reinforcement on a suit-
able lifting device.
(3) Remove the four nuts attaching front bumper
reinforcement to frame rail (Fig. 2).
(4) Remove front bumper reinforcement from vehi-
cle.
INSTALLATION
NOTE: Check position of the arrows molded into
the foam for correct orientation.
(1) Support front bumper reinforcement using a
suitable lifting device and lift into position.
(2) Install the four nuts attaching reinforcement to
frame rails. Tighten nuts to 54 N´m (40 ft. lbs.)
torque.(3) Install front fascia. (Refer to 13 - FRAMES &
BUMPERS/BUMPERS/FRONT FASCIA - INSTAL-
LATION).
REAR FASCIA
REMOVAL
(1) Open liftgate.
(2) Remove the two screws attaching the upper
fascia to the fascia support.
(3) Hoist and support vehicle with safety stands.
(4) Remove the six screws attaching rear fascia to
rear fascia brackets (Fig. 3).
(5) Remove the four plastic push pin attaching bot-
tom of rear fascia to fascia support.
(6) Remove rear fascia from vehicle by lifting sides
of fascia up and outboard to release from rear fascia
brackets.
INSTALLATION
(1) Hoist and support vehicle with safety stands.
(2) Position rear fascia on vehicle.
(3) Engage front edge of fascia under the fascia
support flange.
(4) Engage sides of fascia to top and front edge of
the rear fascia brackets.
NOTE: Verify fascia is still engaged under the lift-
gate. Ensure acceptable and consistent gap
between liftgate and fascia.
Fig. 1 FRONT BUMPER FASCIA
1 - FRONT BUMPER FASCIA
2 - FRONT BUMPER REINFORCEMENT
3 - RADIATOR ENCLOSURE
Fig. 2 FRONT BUMPER REINFORCEMENT
1 - FRONT BUMPER REINFORCEMENT
2 - FRAME RAILS
13 - 2 FRAME & BUMPERSRS
FRONT FASCIA (Continued)
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FRONT FENDER
REMOVAL
(1) Remove headlamp housing. (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING - EXTERIOR/HEAD-
LAMP UNIT - REMOVAL)
(2) Remove mud guard.
(3) Remove inner splash shield.
(4) Remove fender to fascia nuts.
(5) Remove outboard cowl grille/fender bracket
screw.
(6) Remove fender bolt to lower rocker panel.
(7) Remove fender bolt to lower cowl.
(8) Pull fascia away from fender.
(9) Remove bolts attaching fender to upper rail.
(10) Remove fender from vehicle (Fig. 8).
INSTALLATION
(1) Place fender in position on vehicle.
(2) From inside engine compartment, start the
center upper rail bolt. install all the bolts attaching
fender to upper rail and tighten.
(3) Install fender to lower cowl panel bolt.
(4) Install fender to rocker panel bolt.
(5) Place fascia into position.
(6) Install outboard cowl grille/fender bracket
screw.
(7) Install fender to fascia nuts.
(8) Install inner splash shield.
(9) Install mud guard.(10) Install headlamp assembly. (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
HEADLAMP UNIT - INSTALLATION)
(11) Check fender for flush and gap.
FUEL FILL DOOR
REMOVAL
(1) Remove left quarter trim panel.
(2) Remove water shield patch covering access hole
in C-pillar.
(3) Disengage latch release link from clip on fuel
fill blocker latch arm (Fig. 12).
(4) Open fuel fill door.
(5) Remove screws holding fuel fill neck to fuel
filler housing.
(6) Position fuel fill neck out of the way.
(7) Reaching inside fuel filler housing, release clips
holding housing to quarter panel (Fig. 9).
(8) Remove fuel fill door from vehicle.
(9) Disengage clip holding link to fuel fill door
(Fig. 13).
(10) Remove link from fuel fill door.
INSTALLATION
(1) Install spring to housing and door
(2) Snap door into housing.
(3) Insert lockout link into clip on fuel fill door.
(4) Engage clip to hold link to fuel fill door.
(5) Insert lockout link through grommet in panel
between inner and outer quarter panel.
(6) Close fuel fill door.
(7) Install fuel filler housing to outer quarter
panel.
Fig. 8 FENDER
1 - FASTENERS
2 - FENDER
3 - FASTENERS
Fig. 9 FUEL FILLER HOUSING AND DOOR
1 - FUEL FILLER HOUSING W/LATCH
2 - CLIP
3 - FUEL FILLER HOUSING DOOR
4 - CLIPS
5 - FIX CLIP
RSEXTERIOR23-51
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