2003 CHRYSLER CARAVAN light

HEADLAMP SWITCH CONTINUITY
HEADLAMP
SWITCH
POSITION13-WAY
CONNECTOR
TERMINALRESISTANCE
OFF 11 TO 6 3651 - 3729V
PARKING
LAMPS ON11 TO 6 1697 - 2517V
PARKING
LAMPS WITH
FRONT FOG
LAMPS ON11 TO 6 5765 - 5886V
HEADLAMPS
ON11 TO 6 788 - 809V
AUTO ON 11 TO 6 10056 - 10264V
HEADLAMPS
ON WITH
FRONT FOG
LAMPS11 TO 6 1171 - 1200V
AUTO ON WITH
FRONT FOG
LAMPS ON11 TO 6 24278 - 24773V
DIMMER
POSITION13-WAY
CONNECTOR
TERMINALRESISTANCE
DOME 12 TO 6 15568 - 23357V
PARADE 12 TO 6 5168 - 7757V
DIM HIGH 12 TO 6 2288 - 3437V
DIM LOW 12 TO 6 688 - 1037V
OFF 12 TO 6 240 - 365V
DIAGNOSIS AND TESTING - HEADLAMP
SWITCH - EXPORT
Using a Digital Multi-meter, refer to the HEAD-
LAMP SWITCH CONTINUITY table and (Fig. 18).
If the Headlamp Switch is not within specifica-
tions, replace as necessary.
HEADLAMP SWITCH CONTINUITY
HEADLAMP
SWITCH
POSITION13-WAY
CONNECTOR
TERMINALRESISTANCE
OFF 11 TO 6 3651 - 3729V
PARKING
LAMPS ON11 TO 6 1697 - 2517V
PARKING
LAMPS WITH
FRONT FOG
LAMPS ON11 TO 6 5765 - 5886V
HEADLAMPS
ON11 TO 6 788 - 809V
HEADLAMPS
ON WITH
FRONT FOG
LAMPS11 TO 6 1171 - 1200V
REAR FOG
LAMPS11 TO 6 271 - 277V
FRONT FOG
INDICATOR10 TO 4 LED
REAR FOG
INDICATOR5 TO 4 LED
ILLUMINATION 8 TO 4 CONTINUITY
DIMMER
POSITION13-WAY
CONNECTOR
TERMINALRESISTANCE
DOME 12 TO 6 15568 - 23357V
PARADE 12 TO 6 5168 - 7757V
DIM HIGH 12 TO 6 2288 - 3437V
DIM LOW 12 TO 6 688 - 1037V
OFF 12 TO 6 240 - 365V
Fig. 18 HEADLAMP SWITCH CONNECTOR
8L - 16 LAMPS/LIGHTING - EXTERIORRS
HEADLAMP SWITCH (Continued)
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HEADLAMP
SWITCH
POSITION13-WAY
CONNECTOR
TERMINALRESISTANCE
HEADLAMP
LEVELING
SWITCH
POSITION13-WAY
CONNECTOR
TERMINALRESISTANCE
01 TO 7 3238 - 3456V
1 TO 2 3181 - 3400V
1 1 TO 7 1195 - 1225V
2 1 TO 7 746 - 765V
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the Instrument Panel Lower Steering
Column Cover. Refer to Body, Instrument Panel,
Lower Steering Column Cover, Removal.
(3) Reach up behind the left side of the instrument
panel and depress spring clip on top or bottom of
headlamp switch. Firmly push out on the headlamp
switch assembly.
(4) Disconnect the wiring connectors.
(5) Remove switch from vehicle.
INSTALLATION
(1) Connect the wiring connectors.
(2) Place headlamp switch assembly into position
and firmly snap into place.
(3) Install the Instrument Panel Lower Steering
Column Cover. Refer to Body, Instrument Panel,
Lower Steering Column Cover, Installation.
(4) Connect the battery negative cable.
HEADLAMP UNIT
STANDARD PROCEDURE
STANDARD PROCEDURE - HEADLAMP UNIT
ALIGNMENT
HEADLAMP UNIT ALIGNMENT PREPARATION
(1) Verify headlamp dimmer switch and high beam
indicator operation.
(2) Inspect and correct damaged or defective com-
ponents that could interfere with proper headlamp
alignment.
(3) Verify proper tire inflation.
(4) Clean headlamp lenses.
(5) Verify that luggage area is loaded as the vehi-
cle is routinely used.(6) Vehicles equipped with automatic load leveling
suspension should be driven normally for approxi-
mately 5 km (3 miles) before attempting a proper
headlamp unit alignment.
(7) Fuel tank should be FULL. Add 2.94 kg (6.5
lbs.) of weight over the fuel tank for each estimated
gallon of missing fuel.
ALIGNMENT SCREEN PREPARATION
(1) Position vehicle on a level surface perpendicu-
lar to a flat wall 7.62 meters (25 ft.) away from front
of headlamp lens (Fig. 19).
(2) If necessary, tape a line on the floor 7.62
meters (25 ft.) away from and parallel to the wall.
(3) Rock vehicle side-to-side three times and allow
suspension to stabilize.
(4) Jounce front suspension three times by pushing
downward on front bumper and releasing.
(5) Measure the distance from the center of head-
lamp lens to the floor. Transfer measurement to the
alignment screen (with tape). Use this line for
up/down adjustment reference.
HEADLAMP UNIT ADJUSTMENT
The low beam headlamp will project on the screen
upper edge of the beam (cut-off) at the horizontal
lamp centerline   50 mm (2 in.). Horizontal aim is
preset and can not be adjusted. The high beam pat-
tern should be correct when the low beams are
aligned properly (Fig. 20). To adjust headlamp verti-
cal alignment, rotate adjustment screw to achieve the
specified low beam cut-off location.
STANDARD PROCEDURE - HEADLAMP UNIT
ALIGNMENT - EXPORT
HEADLAMP UNIT ALIGNMENT PREPARATION
(1) Verify that the headlamp leveling switch is in
the ª0º position.
(2) Inspect and correct damaged or defective com-
ponents that could interfere with proper headlamp
alignment.
(3) Verify proper tire inflation.
(4) Clean headlamp lenses.
(5) Verify that luggage area is loaded as the vehi-
cle is routinely used.
(6) Vehicles equipped with automatic load leveling
suspension should be driven normally for approxi-
mately 5 km (3 miles) before attempting a proper
headlamp unit alignment.
(7) Fuel tank should be FULL. Add 2.94 kg (6.5
lbs.) of weight over the fuel tank for each estimated
gallon of missing fuel.
RSLAMPS/LIGHTING - EXTERIOR8L-17
HEADLAMP SWITCH (Continued)
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ALIGNMENT SCREEN PREPARATION
(1) Position vehicle on a level surface perpendicu-
lar to a flat wall 10 meters (32.8 ft.) away from front
of headlamp lens (Fig. 21).
(2) If necessary, tape a line on the floor 10 meters
(32.8 ft.) away from and parallel to the wall.
(3) Rock vehicle side-to-side three times and allow
suspension to stabilize.
(4) Jounce front suspension three times by pushing
downward on front bumper and releasing.
(5) Measure the distance from the center of head-
lamp lens to the floor. Transfer measurement to thealignment screen (with tape). Use this line for
up/down adjustment reference.
HEADLAMP UNIT ADJUSTMENT
The low beam headlamp will project on the screen
upper edge of the beam (cut-off) at the horizontal
lamp cut-off line   20 mm (0.75 in.). The high beam
pattern should be correct when the low beams are
aligned properly (Fig. 22). To adjust headlamp align-
ment, rotate adjustment screws to achieve the speci-
fied low beam cut-off location.
Fig. 19 HEADLAMP ALIGNMENT SCREEN
1 - CENTER OF HEADLAMPS 3 - FRONT OF HEADLAMP
2 - HEADLAMP BEAM 4 - 7.62 METERS (25 FT.)
8L - 18 LAMPS/LIGHTING - EXTERIORRS
HEADLAMP UNIT (Continued)
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REMOVAL
(1) Disconnect and isolate the battery negative
cable.
Fig. 20 HEADLAMP UNIT ADJUSTMENT
1 - ADJUSTMENT LOCATION
2 - HEADLAMP UNIT
Fig. 21 HEADLAMP UNIT ALIGNMENT SCREEN - EXPORT
1 - CENTER OF VEHICLE 5 - 10 METERS (32.8 FT.)
2 - CENTER OF HEADLAMPS 6 - HORIZONTAL CUT-OFF LINE
3 - 15É CUT-OFF LINE 7 - 110 mm (4.3 in.)
4 - FRONT OF HEADLAMP
Fig. 22 HEADLAMP UNIT ADJUSTMENT - EXPORT
1 - HEADLAMP ADJUSTMENT - HORIZONTAL
2 - HEADLAMP ADJUSTMENT - VERTICAL
RSLAMPS/LIGHTING - EXTERIOR8L-19
HEADLAMP UNIT (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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