2005 CHRYSLER CARAVAN wiring

CHANICAL/ICU (INTEGRATED CONTROL UNIT) -
DISASSEMBLY).
REMOVAL - RHD
NOTE: Before proceeding, (Refer to 5 - BRAKES -
WARNING)(Refer to 5 - BRAKES - CAUTION)
(1) Disconnect the negative (ground) cable from
the battery and isolate cable.
(2) Using a brake pedal depressor, move and lock
the brake pedal to a position past the first inch of
pedal travel.This will prevent brake fluid from
draining out of the master cylinder when the
brake tubes are removed from the HCU.
(3) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(4) Remove the routing clip attaching the ICU wir-
ing harness to the ICU mounting bracket (Fig. 17).
CAUTION: Do not apply a 12 volt power source to
any terminals of the HCU connector when discon-
nected.
(5) Remove the 24-way connector (Fig. 17) from
the CAB. The 24-way connector is removed from the
CAB using the following procedure. Grasp the lock
on the 24-way connector (Fig. 17) and pull it as far
out as possible (Fig. 18). This will raise and unlock
the 24-way connector from the socket on the CAB.
CAUTION: Before removing the brake tubes from
the HCU, the HCU must be thoroughly cleaned. Thismust be done to prevent dirt particles from falling
into the ports of HCU or entering the brake tubes.
(6) Thoroughly clean all surfaces of the HCU, and
all brake tube nuts located on the HCU. Use only a
solvent such as Mopar Brake Parts Cleaner or an
equivalent to clean the HCU.
(7) Remove the brake tubes (6) from the inlet and
outlet ports on the HCU. (Fig. 19).
Fig. 17 CAB 24-Way Connector
1 - CAB WIRING HARNESS
2 - 24±WAY CONNECTOR
3 - FLOOR PAN
4 - HCU
5 - CAB
6 - HCU MOUNTING BRACKET
7 - CONNECTOR LOCK
Fig. 18 Unlocked 24-Way CAB Connector
1 - HCU
2 - CAB
3 - 24±WAY CONNECTOR
4 - CONNECTOR LOCK (UNLOCKED)
Fig. 19 Brake Tube Connections To HCU
1 - LEFT REAR WHEEL BRAKE TUBE
2 - SECONDARY BRAKE TUBE FROM MASTER CYLINDER
3 - LEFT FRONT WHEEL BRAKE TUBE
4 - CAB
5 - RIGHT REAR WHEEL BRAKE TUBE
6 - HCU MOUNTING BRACKET
7 - BRAKE TUBE TO HCU CONNECTION LOCATION LEGEND
8 - RIGHT FRONT WHEEL BRAKE TUBE
9 - PRIMARY BRAKE TUBE FROM MASTER CYLINDER
5 - 104 BRAKES - ABSRS
ICU (INTEGRATED CONTROL UNIT) (Continued)

(8) Remove the 3 bolts (Fig. 20) attaching the ICU
mounting bracket to the front suspension crossmem-
ber.
(9) Remove ICU and the mounting bracket as a
unit from the vehicle.
(10) Remove the 3 bolts (Fig. 21) mounting the
ICU to the mounting bracket. Separate the ICU from
the mounting bracket.
(11) For the procedure on separating and attaching
the CAB to the HCU, refer to DISASSEMBLY.DISASSEMBLY - ICU
(1) Remove the ICU from the vehicle. (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ICU (INTE-
GRATED CONTROL UNIT) - REMOVAL)
(2) Disconnect the pump/motor wiring harness
from the CAB (Fig. 22).
(3) Remove the 4 bolts (Fig. 23) attaching the CAB
to the HCU.
Fig. 20 ICU To Suspension Cradle Mounting Bolts
1 - HCU MOUNTING BRACKET BOLTS
2 - HCU MOUNTING BRACKET BOLT
3 - CAB
4 - HCU MOUNTING BRACKET
5 - HCU
Fig. 21 ICU Mounting Bolts
1 - HCU
2 - HCU MOUNTING BOLTS
3 - HCU MOUNTING BRACKET
Fig. 22 INTEGRATED CONTROL UNIT (ICU)
1 - PUMP/MOTOR
2 - HCU
3 - PUMP/MOTOR CONNECTOR
4 - CAB
Fig. 23 (TYPICAL) CAB Attaching Bolts
1 - MOUNTING BOLTS
2 - CAB
3 - HCU VALVE BLOCK
RSBRAKES - ABS5 - 105
ICU (INTEGRATED CONTROL UNIT) (Continued)

(4) Remove the CAB from the HCU (Fig. 24).
ASSEMBLY - ICU
(1) Install the CAB (Fig. 24) on the HCU.
(2) Install the 4 bolts mounting the CAB (Fig. 23)
to the HCU. Tighten the CAB mounting bolts to a
torque of 2 N´m (17 in. lbs.).
(3) Plug the pump/motor wiring harness into the
CAB.
(4) Install the ICU in the vehicle and bleed the
base and ABS hydraulic systems. (Refer to 5 -
BRAKES/HYDRAULIC/MECHANICAL/ICU (INTE-
GRATED CONTROL UNIT) - INSTALLATION)
INSTALLATION
INSTALLATION - LHD
(1) Place the ICU in its bracket below the master
cylinder. Start the upper mounting bolt to hold it in
place.
(2) Inside the vehicle, install the remaining 2
mounting bolts attaching the ICU to the mounting
bracket (Fig. 16). Tighten all 3 mounting bolts to a
torque of 11 N´m (97 in. lbs.).
(3) Install the dash seal and three mounting
screws (Fig. 15).
(4) If equipped, install the silencer on top of the
dash seal (Fig. 15).
(5) Connect the steering shaft coupling and install
the pinch bolt (Fig. 15). Tighten the pinch bolt to 28
N´m (250 in. lbs.).
(6) Remove the steering wheel holder.
CAUTION: Because of the flexible section in the pri-
mary and secondary brake tubes, the brake tubes
must be held in proper orientation when tightenedand torqued. These tubes must not contact each
other or other vehicle components when installed.
Also, after the brake tubes are installed on the HCU,
ensure all spacer clips are reinstalled on the brake
tubes.
(7) Install the primary and secondary brake tubes
into their correct port locations on the HCU valve
block (Fig. 14). Tighten the tube nuts to a torque of
17 N´m (145 in. lbs.).
CAUTION: When installing the chassis brake tubes
on the HCU valve block, they must be located cor-
rectly in the valve block to ensure proper ABS oper-
ation.
NOTE: The chassis brake tube attachment locations
to the HCU, are marked on the bottom of the CAB.
(8) Install the (4) chassis brake tubes into their
correct port locations on the HCU valve block as
shown (Fig. 14). Tighten the tube nuts to a torque of
17 N´m (145 in. lbs.).
NOTE: Before installing the 24±way connector in
the CAB be sure the seal is properly installed in the
connector.
(9) Install the 24±way connector on the CAB by,
first, positioning the 24±way connector in the socket
of the CAB and carefully pushing it down as far as
possible. Once connector is fully seated by hand into
the CAB socket, push down on connector lock. This
will pull the connector into the socket of the CAB
and lock it in the installed position.
(10) Install any routing clips on the brake tubes.
(11) Remove the brake pedal holder.
(12) Install the speed control servo with its mount-
ing nuts.
(13) Connect the wiring harness to the speed con-
trol servo.
(14) Install the battery tray (Refer to 8 - ELEC-
TRICAL/BATTERY SYSTEM/TRAY - INSTALLA-
TION).
(15) Install the screw securing the coolant filler
neck to the battery tray.
(16) Reconnect the vacuum hose connector at the
tank built into the battery tray.
(17) Install the battery (Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/BATTERY - INSTALLA-
TION).
(18) Install the battery shield.
(19) Remove the brake pedal holder.
(20) Connect negative cable back on negative post
of the battery.
Fig. 24 (TYPICAL) Remove/Install CAB
1 - CAB
2 - HCU VALVES
3 - HCU VALVE BLOCK
5 - 106 BRAKES - ABSRS
ICU (INTEGRATED CONTROL UNIT) (Continued)

(21) Bleed the Base and ABS brake hydraulic sys-
tems (Refer to 5 - BRAKES - STANDARD PROCE-
DURE).
(22) Road test vehicle to ensure proper operation
of the base and antilock brake systems.
INSTALLATION - RHD
(1) Install the ICU on the mounting bracket (Fig.
21). Install the 3 bolts (Fig. 21) attaching the ICU to
the mounting bracket. Tighten the 3 mounting bolts
to a torque of 11 N´m (97 in. lbs.).
CAUTION: The ICU mounting bracket to front sus-
pension cradle mounting bolts have a unique corro-
sion protection coating and a special aluminum
washer. For this reason, only the original, or origi-
nal equipment Mopar replacement bolts can be
used to mount the ICU bracket to the front suspen-
sion crossmember.
(2) Install the ICU and its mounting bracket as an
assembly on the front suspension crossmember.
Install the 3 bolts attaching the ICU bracket to the
crossmember (Fig. 20). Tighten the 3 mounting bolts
to a torque of 28 N´m (250 in. lbs.).
CAUTION: Because of the flexible section in the pri-
mary and secondary brake tubes, and the brake
tubes between the HCU and the proportioning
valve, the brake tubes must be held in proper ori-
entation when tightened and torqued. These tubes
must not contact each other or other vehicle com-
ponents when installed. Also, after the brake tubes
are installed on the HCU, ensure all spacer clips are
reinstalled on the brake tubes.
CAUTION: When installing the chassis brake tubes
on the HCU valve block, they must be located cor-
rectly in the valve block to ensure proper ABS oper-
ation. Refer to (Fig. 19) for the correct chassis
brake tube locations.
NOTE: The chassis brake tube attachment locations
to the HCU, are marked on the bottom of the ICU
mounting bracket.
(3) Install the 6 chassis brake tubes into their cor-
rect port locations on the HCU valve block as shown
in (Fig. 19). Tighten the tube nuts to a torque of 17
N´m (145 in. lbs.).
NOTE: Before installing the 24-way connector in the
CAB be sure the seal is properly installed in the
connector.(4) Install the 24-way connector (Fig. 17) on the
CAB using the following procedure. Position the
24-way connector in the socket of the CAB and care-
fully push it down as far as possible. When connector
is fully seated by hand into the CAB socket, push in
the connector lock (Fig. 18). This will pull the connec-
tor into the socket of the CAB and lock it in the
installed position.
NOTE: The CAB wiring harness must be clipped to
the ICU mounting bracket. This will ensure the wir-
ing harness is properly routed and does not contact
the brake tubes or the body of the vehicle.
(5) Clip the cab wiring harness (Fig. 17) to the
ICU mounting bracket.
(6) Install the routing clips (Fig. 25) on the brake
tubes.
(7) Lower the vehicle.
(8) Connect negative cable back on negative post of
the battery.
(9) Bleed the base and ABS hydraulic systems.
(Refer to 5 - BRAKES - STANDARD PROCEDURE)
(10) Road test vehicle to ensure proper operation
of the base and antilock brake systems.
Fig. 25 Brake Tube Routing Clips
1 - ROUTING CLIP
2 - HCU
3 - BRAKE TUBES
4 - ROUTING CLIP
RSBRAKES - ABS5 - 107
ICU (INTEGRATED CONTROL UNIT) (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
COOLANT COLOR 1. Coolant color is not necessarily
an indication of adequate corrosion
or temperature protection. Do not
rely on coolant color for determining
condition of coolant.1. Check the freeze point of the
coolant. (Refer to 7 - COOLING/
ENGINE/COOLANT - DIAGNOSIS
AND TESTING) Adjust the ethylene
glycol-to-water ratio as necessary.
COOLANT LEVEL CHANGES IN
COOLANT BOTTLE.
TEMPERATURE GAUGE IS IN
NORMAL RANGE.1. Level changes are to be
expected as coolant volume
fluctuates with engine temperature.
The coolant level will also drop as
the system removes air from a
recent filling.1. A normal condition. No repair is
necessary.
Refer to (Fig. 1) when using the TEMPERATURE
GAUGE INDICATION DIAGNOSIS CHART.
TEMPERATURE GAUGE INDICATION DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
TEMPERATURE GAUGE READING
IS INCONSISTENT (FLUCTUATES,
CYCLES OR IS ERRATIC).1. Normal reaction to fan and/or
thermostat cycle (Fig. 1 ),
Examples B and C. During cold
weather operation with the heater
blower in the high position, the
gauge reading may drop slightly
(Fig. 1 ), Example D. Fluctuation is
also influenced by outside
temperature and heavy loads (Fig.
1 ), Example E.1. A normal condition. No correction
is necessary.
2. Gauge reading rises when
vehicle is brought to a stop after
heavy use (engine still running)
(Fig. 1 ), Example F.2. A normal condition. No correction
is necessary. Gauge reading should
return to normal range (Fig. 1 ),
Example A, after vehicle is driven.
3. Gauge reading high after
restarting a warmed-up (hot)
engine.3. A normal condition. No correction
is necessary. The gauge should
return to normal range (Fig. 1 ),
Example A, after a few minutes of
engine operation.
4. Temperature gauge or engine
coolant temperature sensor
defective or shorted. Also, corroded
or loose wiring in the electrical
circuit.4. Check operation of gauge or
engine coolant temperature sensor
and repair, if necessary.
RSENGINE7-17
ENGINE (Continued)

DIAGNOSIS AND TESTING - RADIATOR FAN MOTOR
RADIATOR FAN DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
NOISY RADIATOR FAN 1. Fan blade loose. 1. Replace fan assembly. (Refer to
7 - COOLING/ENGINE/RADIATOR
FAN - REMOVAL)
2. Fan blade striking a surrounding
object.2. Locate point of fan blade contact
and repair as necessary.
3. Air obstructions at radiator or A/C
condenser.3. Remove obstructions and/or
clean debris.
4. Electric fan motor defective. 4. Replace fan assembly. (Refer to
7 - COOLING/ENGINE/RADIATOR
FAN - REMOVAL)
ELECTRIC FAN MOTOR DOES
NOT OPERATE1. Fan relay, powertrain control
module (PCM), coolant temperature
sensor, or wiring defective.1. (Refer to Appropriate Diagnostic
Information) Repair as necessary.
2. Defective A/C pressure
transducer.2. (Refer to Appropriate Diagnostic
Information) Repair as necessary.
ELECTRIC RADIATOR FAN
OPERATES ALL THE TIME1. Fan relay, powertrain control
module (PCM), coolant temperature
sensor or wiring defective.1. (Refer to Appropriate Diagnostic
Information) Repair as necessary.
2. Check for low coolant level. 2. Add coolant as necessary.
3. Defective A/C pressure
transducer.3. (Refer to Appropriate Diagnostic
Information) Repair as necessary.
REMOVAL
There are no repairs to be made to the fan or
shroud assembly. If the fan is warped, cracked, or
otherwise damaged, it must be replaced as an assem-
bly (Fig. 20).
(1) Remove the radiator upper crossmember. (Refer
to 23 - BODY/EXTERIOR/GRILLE OPENING REIN-
FORCEMENT - REMOVAL)
(2) Disconnect the radiator fan electrical connec-
tors.
(3) Remove radiator fan(s) retaining screw (Fig.
20).
(4) Remove the radiator fan(s) by lifting upward to
release from mounts.
INSTALLATION
(1) Install the radiator fan(s) into mounts and
attaching clips on the radiator.
(2) Install radiator fan(s) attaching screws (Fig.
20). Tighten to 5 N´m (45 in. lbs.).
(3) Connect the radiator fan(s) electrical connec-
tors.(4) Install the radiator upper support crossmem-
ber. (Refer to 23 - BODY/EXTERIOR/GRILLE OPEN-
ING REINFORCEMENT - INSTALLATION)
Fig. 20 Radiator Fans
1 - SCREWS - RADIATOR FAN ATTACHING
2 - RADIATOR FAN - RIGHT
3 - MOUNT - RIGHT RADIATOR FAN
4 - CLIPS - RADIATOR FAN LOWER
5 - MOUNT - LEFT RADIATOR FAN
6 - RADIATOR FAN - LEFT
7 - 30 ENGINERS
RADIATOR FAN (Continued)

(5) Install the upper radiator mounts to the cross-
member bolts, if removed. Tighten to 8 N´m (70 in.
lbs.).
(6) Install the radiator upper hose to the support
clip (2.4L engine).
RADIATOR FAN RELAY
DESCRIPTION
The radiator fan relay is a solid state type and is
located on the front bumper reinforcment (Fig. 21).
Refer to WIRING DIAGRAMS for a circuit sche-
matic.
OPERATION
The solid state radiator fan relay is controlled by
the Powertrain Control Module (PCM) by way of a
Pulse Width Modulated (PWM) signal. The relay con-
trol circuit supplies a 12 volt signal to the PCM. The
PCM then pulses the ground circuit to achieve fan on
time. The relay provides a voltage to the fan motors
which is proportional to the pulse width it receives
from the PCM. The duty cycle ranges from 30% for
low speed operation, then ramps-up to 100% for high
speed operation. This fan control system provides
infinitely variable fan speeds, allowing for improved
fan noise, A/C performance, better engine cooling,
and additional vehicle power.
To control operation of the relay, the PCM looks at
inputs from:
²Engine coolant temperature
²A/C pressure transducer
²Ambient temperature from the body controller
²Vehicle speed
²Transmission oil temperature
The PCM uses these inputs to determine when the
fan should operate and at what speed. For further
information on fan operation, (Refer to 7 - COOL-
ING/ENGINE/RADIATOR FAN - OPERATION).
REMOVAL
(1) Open hood.
(2) Disconnect and isolate the battery negative
cable.
(3) Remove the radiator crossmember to front fas-
cia closure panel.
(4) Disconnect the relay electrical connector (Fig.
21).
(5) Remove the rivet attaching the relay to the
front bumper beam (Fig. 21).
(6) Remove the relay.
INSTALLATION
CAUTION: The relay mounting location is designed
to dissipate heat. Ensure the relay is securely
attached to prevent relay ªthermalº shutdown and
relay damage, resulting in possible engine over-
heating.
(1) Position relay and install a new rivet (Fig. 21).
(2) Connect electrical connector to relay.
(3) Install closure panel and attaching screws.
(4) Connect negative cable to battery.
Fig. 21 Radiator Fan Relay
1 - FRONT FASCIA
2 - FAN RELAY
3 - RIVET
4 - A/C CONDENSER (FRONT SIDE)
RSENGINE7-31
RADIATOR FAN (Continued)

mation. For diagnosis of these electronic modules or
of the data bus network, the use of a DRB IIItscan
tool and the proper Diagnostic Procedures informa-
tion is recommended.
DIAGNOSIS AND TESTING
AUDIO/VIDEO
Any diagnosis of the Audio system should
begin with the use of the DRB IIItdiagnostic
tool. For information on the use of the DRBIIIt, refer to the appropriate Diagnostic Service
information.
Refer to the appropriate wiring information.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO ELECTRICAL, RESTRAINTS
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
AUDIO SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSE CORRECTION
NO AUDIO. 1. FUSE INOPERATIVE. 1. CHECK RADIO FUSES IN FUSE BLOCK MODULE.
REPLACE FUSES, IF REQUIRED.
2. RADIO CONNECTOR
DAMAGED.2. CHECK FOR LOOSE OR CORRODED RADIO CONNECTOR.
REPAIR, IF REQUIRED.
3. WIRING DAMAGED. 3. CHECK FOR BATTERY VOLTAGE AT RADIO CONNECTOR.
REPAIR WIRING, IF REQUIRED.
4. GROUND DAMAGED. 4. CHECK FOR CONTINUITY BETWEEN RADIO CHASSIS AND
A KNOWN GOOD GROUND. THERE SHOULD BE
CONTINUITY. REPAIR GROUND, IF REQUIRED.
5. RADIO
INOPERATIVE.5. USING A SCAN TOOL, CHECK FOR TROUBLE CODES IN
THE AUDIO SYSTEM.
6. SPEAKERS
INOPERATIVE6. REFER TO SPEAKER DIAGNOSIS.
NO DISPLAY. 1. FUSE INOPERATIVE. 1. CHECK RADIO FUSES IN FUSE BLOCK MODULE.
REPLACE FUSES, IF REQUIRED.
2. RADIO CONNECTOR
DAMAGED.2. CHECK FOR LOOSE OR CORRODED RADIO CONNECTOR.
REPAIR, IF REQUIRED.
3. WIRING DAMAGED. 3. CHECK FOR BATTERY VOLTAGE AT RADIO CONNECTOR.
REPAIR WIRING, IF REQUIRED.
4. GROUND DAMAGED. 4. CHECK FOR CONTINUITY BETWEEN RADIO CHASSIS AND
A KNOWN GOOD GROUND. THERE SHOULD BE
CONTINUITY. REPAIR GROUND, IF REQUIRED.
5. RADIO
INOPERATIVE.5. USING A SCAN TOOL, CHECK FOR TROUBLE CODES IN
THE AUDIO SYSTEM.
NO MEMORY. 1. FUSE INOPERATIVE. 1. CHECK IGNITION-OFF DRAW FUSE. REPLACE FUSE, IF
REQUIRED.
2. RADIO CONNECTOR
DAMAGED.2. CHECK FOR LOOSE OR CORRODED RADIO CONNECTOR.
REPAIR, IF REQUIRED.
3. WIRING DAMAGED. 3. CHECK FOR BATTERY VOLTAGE AT RADIO CONNECTOR.
REPAIR WIRING, IF REQUIRED.
8A - 2 AUDIO/VIDEORS
AUDIO/VIDEO (Continued)