wiring CHRYSLER CARAVAN 2002 Service Manual

CONDITION POSSIBLE CAUSES CORRECTION
COWL GRILLE NOZZLE
WILL NOT FLOW.1. FROZEN NOZZLE. 1. MOVE VEHICLE INTO HEATED AREA TO
ALLOW TIME TO THAW NOZZLE. ASSURE
WASHER FLUID IS PROPERLY BLENDED
FOR AMBIENT OUTSIDE TEMPERATURES.
2. NOZZLE HOSE NOT
FLOWING.2. ASSURE NOZZLE HOSE IS NOT
PINCHED, LOOSE, BROKEN, OR
DISCONNECTED. IF NOT OK, PROPERLY
ROUTE OR REPAIR NOZZLE HOSE.
3. NOZZLE HOSE PLUGGED
BY CONTAMINATION.3. CLEAN NOZZLE HOSE OF
CONTAMINATION. DETERMINE SOURCE
OF CONTAMINATION. INSPECT
RESERVOIR FOR EXCESSIVE
CONTAMINATION. CLEAN SYSTEM AS
REQUIRED.
4. NOZZLE PLUGGED BY
CONTAMINATION.4. CLEAN NOZZLE OF CONTAMINATION
OR REPLACE NOZZLE. DETERMINE
SOURCE OF CONTAMINATION. INSPECT
RESERVOIR FOR EXCESSIVE
CONTAMINATION. CLEAN SYSTEM AS
REQUIRED.
5. DEFECTIVE WASHER HOSE
CHECK VALVE.5. REPLACE COWL GRILLE PANEL
WASHER HOSE/CHECK VALVE ASSEMBLY.
WASHER FLUID OUTPUT IS
LOW.1. PARTIALLY PINCHED HOSE. 1. ASSURE WASHER HOSE IS NOT
PARTIALLY PINCHED. IF NOT OK,
PROPERLY ROUTE HOSE.
2. REVERSE POLARITY TO
PUMP.2. CHECK FOR CROSSED CIRCUIT TO
PUMP. IF NOT OK, REPAIR CIRCUIT.
3. WORN OUT WASHER PUMP. 3. REPLACE WASHER PUMP.
COWL GRILLE NOZZLE
STREAM OVERSHOOTS
WINDSHIELD.1. NOZZLE NOT SEATED IN
COWL GRILLE.1. ASSURE NOZZLE IS SNAPPED IN
PLACE.
2. NOZZLE JET(S) OUT OF
ADJUSTMENT.2. ADJUST NOZZLE JET(S) USING A
SAFETY PIN.
WIPER WILL NOT CYCLE
WHEN WASHER SELECT
SWITCH IS DEPRESSED.1. DEFECTIVE IPM. 1. REFER TO IPM DIAGNOSTIC
PROCEDURES IN WIRING DIAGRAMS.
2. DEFECTIVE IPM/BODY
CONTROLLER.2. REFER TO IPM/BODY CONTROLLER
DIAGNOSTIC PROCEDURES IN WIRING
DIAGRAMS.
WASHER OPERATES
INTERMITTENTLY.1. INTERMITTENT MOTOR
GROUND.INTERMITTENT GROUND BETWEEN
MOTOR CONNECTOR TERMINAL 1 AND
IPM PIN 20.
2. INTERMITTENT OPEN IN
WASHER SELECT SWITCH.2. (Refer to 8 - ELECTRICAL/LAMPS/
LIGHTING - EXTERIOR/MULTI-FUNCTION
SWITCH - DIAGNOSIS AND TESTING).
3. DEFECTIVE WASHER
MOTOR.3. REPLACE WASHER MOTOR.
RSWIPERS/WASHERS8R-7
WIPERS/WASHERS (Continued)
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CONDITION POSSIBLE CAUSES CORRECTION
LOW WASHER FLUID
LEVEL INDICATOR
INOPERATIVE.1. LOOSE FLUID LEVEL
SENSOR CONNECTOR.1. PROPERLY SEAT CONNECTOR TO LOW
FLUID LEVEL SENSOR AND LOCK.
2. OPEN POWER CIRCUIT TO
FLUID LEVEL SENSOR.2. OPEN OR DEFECTIVE CIRCUIT
BETWEEN IPM CONNECTOR TERMINAL 7
AND THE LOW FLUID LEVEL SENSOR
CONNECTOR TERMINAL 2. IF NOT OK,
REPAIR CIRCUIT.
3. OPEN GROUND CIRCUIT. 3. OPEN OR DEFECTIVE CIRCUIT
BETWEEN FLUID LEVEL SENSOR
CONNECTOR TERMINAL 1 AND FLOOR
GROUND 1.
4. DEFECTIVE IPM. 4. REFER TO IPM DIAGNOSTIC
PROCEDURES IN WIRING DIAGRAMS.
5. FLUID LEVEL SENSOR
SWITCH OPEN OR
DEFECTIVE.5. APPLY OHMMETER TO THE SWITCH
TERMINALS TO CHECK FOR COMPLETE
CIRCUIT. CYCLE SWITCH FLOAT BACK
AND FORTH BY FILLING AND DEPLETING
RESERVOIR OF WASHER FLUID TO
CHECK FOR PROPER SWITCH FUNCTION.
IF NOT OK, REPLACE LOW FLUID LEVEL
SENSOR SWITCH.
LEAKING WASHER FLUID. 1. PUMP OR SENSOR
GROMMET DEFECTIVE.1. PROPERLY SEAT PUMP OR SENSOR IN
GROMMET. IF NOT OK, REPLACE PUMP
OR SENSOR GROMMET.
2. LEAKING WASHER PUMP. 2. REPLACE WASHER PUMP.
3. LEAKING FLUID LEVEL
SENSOR.3. REPLACE FLUID LEVEL SENSOR.
4. LEAKING OR DEFECTIVE
RESERVOIR BODY.4. REPLACE RESERVOIR BODY.
8R - 8 WIPERS/WASHERSRS
WIPERS/WASHERS (Continued)
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WIRING
TABLE OF CONTENTS
page page
WIRING DIAGRAM INFORMATION....... 8W-01-1
COMPONENT INDEX.................. 8W-02-1
POWER DISTRIBUTION............... 8W-10-1
GROUND DISTRIBUTION.............. 8W-15-1
BUS COMMUNICATIONS.............. 8W-18-1
CHARGING SYSTEM.................. 8W-20-1
STARTING SYSTEM.................. 8W-21-1
FUEL/IGNITION SYSTEM.............. 8W-30-1
TRANSMISSION CONTROL SYSTEM..... 8W-31-1
VEHICLE SPEED CONTROL............ 8W-33-1
ANTILOCK BRAKES................... 8W-35-1
VEHICLE THEFT SECURITY SYSTEM..... 8W-39-1
INSTRUMENT CLUSTER............... 8W-40-1
HORN/CIGAR LIGHTER/POWER OUTLET . . 8W-41-1
AIR CONDITIONING-HEATER........... 8W-42-1
AIRBAG SYSTEM.................... 8W-43-1
INTERIOR LIGHTING.................. 8W-44-1
BODY CONTROL MODULE............. 8W-45-1MESSAGE CENTER................... 8W-46-1
AUDIO SYSTEM..................... 8W-47-1
REAR WINDOW DEFOGGER............ 8W-48-1
OVERHEAD CONSOLE................. 8W-49-1
FRONT LIGHTING.................... 8W-50-1
REAR LIGHTING..................... 8W-51-1
TURN SIGNALS...................... 8W-52-1
WIPERS............................ 8W-53-1
TRAILER TOW....................... 8W-54-1
POWER WINDOWS................... 8W-60-1
POWER DOOR LOCKS................ 8W-61-1
POWER MIRRORS................... 8W-62-1
POWER SEATS...................... 8W-63-1
SPLICE INFORMATION................ 8W-70-1
CONNECTOR PIN-OUTS............... 8W-80-1
CONNECTOR/GROUND/SPLICE
LOCATION........................ 8W-91-1
POWER DISTRIBUTION SYSTEM........ 8W-97-1 RSWIRING
8W-1
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8W-01 WIRING DIAGRAM INFORMATION
TABLE OF CONTENTS
page page
WIRING DIAGRAM INFORMATION
DESCRIPTION
DESCRIPTION - HOW TO USE WIRING
DIAGRAMS...........................1
DESCRIPTION - CIRCUIT INFORMATION....5
DESCRIPTION - CIRCUIT FUNCTIONS......6
DESCRIPTION - SECTION IDENTIFICATION
AND INFORMATION....................6
DESCRIPTION - CONNECTOR, GROUND
AND SPLICE INFORMATION..............7
WARNING
WARNINGS - GENERAL.................7
DIAGNOSIS AND TESTING - WIRING
HARNESS............................7
STANDARD PROCEDURE
STANDARD PROCEDURE -
ELECTROSTATIC DISCHARGE (ESD)
SENSITIVE DEVICES...................8
STANDARD PROCEDURE - TESTING OF
VOLTAGE POTENTIAL...................9
STANDARD PROCEDURE - TESTING FOR
CONTINUITY..........................9STANDARD PROCEDURE - TESTING FOR A
SHORT TO GROUND...................9
STANDARD PROCEDURE - TESTING FOR A
SHORT TO GROUND ON FUSES
POWERING SEVERAL LOADS...........10
STANDARD PROCEDURE - TESTING FOR A
VOLTAGE DROP......................10
SPECIAL TOOLS
WIRING/TERMINAL....................10
CONNECTOR
REMOVAL.............................11
INSTALLATION.........................11
DIODE
REMOVAL.............................14
INSTALLATION.........................14
TERMINAL
REMOVAL.............................14
INSTALLATION.........................14
WIRE
STANDARD PROCEDURE - WIRE SPLICING . . 15
WIRING DIAGRAM
INFORMATION
DESCRIPTION
DESCRIPTION - HOW TO USE WIRING
DIAGRAMS
DaimlerChrysler Corporation wiring diagrams are
designed to provide information regarding the vehi-
cles wiring content. In order to effectively use the
wiring diagrams to diagnose and repair
DaimlerChrysler Corporation vehicles, it is important
to understand all of their features and characteris-
tics.
Diagrams are arranged such that the power (B+)
side of the circuit is placed near the top of the page,
and the ground (B-) side of the circuit is placed near
the bottom of the page (Fig. 1).
All switches, components, and modules are shown
in the at rest position with the doors closed and the
key removed from the ignition (Fig. 2).Components are shown two ways. A solid line
around a component indicates that the component is
complete. A dashed line around the component indi-
cates that the component is being shown is not com-
plete. Incomplete components have a reference
number to indicate the page where the component is
shown complete.
It is important to realize that no attempt is made
on the diagrams to represent components and wiring
as they appear on the vehicle. For example, a short
piece of wire is treated the same as a long one. In
addition, switches and other components are shown
as simply as possible, with regard to function only.
SYMBOLS
International symbols are used throughout the wir-
ing diagrams. These symbols are consistent with
those being used around the world (Fig. 3).
RS8W-01 WIRING DIAGRAM INFORMATION8W-01-1
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Fig. 1 WIRING DIAGRAM EXAMPLE 1
8W - 01 - 2 8W-01 WIRING DIAGRAM INFORMATIONRS
WIRING DIAGRAM INFORMATION (Continued)
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Fig. 2 WIRING DIAGRAM EXAMPLE 2
RS8W-01 WIRING DIAGRAM INFORMATION8W-01-3
WIRING DIAGRAM INFORMATION (Continued)
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Fig. 3 WIRING DIAGRAM SYMBOLS
8W - 01 - 4 8W-01 WIRING DIAGRAM INFORMATIONRS
WIRING DIAGRAM INFORMATION (Continued)
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TERMINOLOGY
This is a list of terms and definitions used in the
wiring diagrams.
LHD .................Left Hand Drive Vehicles
RHD................Right Hand Drive Vehicles
ATX . . Automatic Transmissions-Front Wheel Drive
MTX....Manual Transmissions-Front Wheel Drive
AT ....Automatic Transmissions-Rear Wheel Drive
MT .....Manual Transmissions-Rear Wheel Drive
SOHC...........Single Over Head Cam Engine
DOHC..........Double Over Head Cam Engine
Built-Up-Export........ Vehicles Built For Sale In
Markets Other Than North America
Except Built-Up-Export . . Vehicles Built For Sale In
North America
DESCRIPTION - CIRCUIT INFORMATION
Each wire shown in the diagrams contains a code
which identifies the main circuit, part of the main
circuit, gage of wire, and color (Fig. 4).
WIRE COLOR CODE CHART
COLOR CODE COLOR
BL BLUE
BK BLACK
BR BROWN
DB DARK BLUE
DG DARK GREEN
GY GRAY
LB LIGHT BLUE
LG LIGHT GREEN
OR ORANGE
PK PINK
RD RED
TN TAN
VT VIOLET
WT WHITE
YL YELLOW
* WITH TRACER
Fig. 4 WIRE CODE IDENTIFICATION
1 - COLOR OF WIRE (LIGHT BLUE WITH YELLOW TRACER
2 - GAGE OF WIRE (18 GAGE)
3 - PART OF MAIN CIRCUIT (VARIES DEPENDING ON
EQUIPMENT)
4 - MAIN CIRCUIT IDENTIFICATION
RS8W-01 WIRING DIAGRAM INFORMATION8W-01-5
WIRING DIAGRAM INFORMATION (Continued)
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DESCRIPTION - CIRCUIT FUNCTIONS
All circuits in the diagrams use an alpha/numeric
code to identify the wire and it's function. To identify
which circuit code applies to a system, refer to the
Circuit Identification Code Chart. This chart shows
the main circuits only and does not show the second-
ary codes that may apply to some models.
CIRCUIT IDENTIFICATION CODE CHART
CIRCUIT FUNCTION
A BATTERY FEED
B BRAKE CONTROLS
C CLIMATE CONTROLS
D DIAGNOSTIC CIRCUITS
E DIMMING ILLUMINATION
CIRCUITS
F FUSED CIRCUITS
G MONITORING CIRCUITS
(GAUGES)
H OPEN
I NOT USED
J OPEN
K POWERTRAIN CONTROL
MODULE
L EXTERIOR LIGHTING
M INTERIOR LIGHTING
N NOT USED
O NOT USED
P POWER OPTION (BATTERY
FEED)
Q POWER OPTIONS (IGNITION
FEED)
R PASSIVE RESTRAINT
S SUSPENSION/STEERING
T TRANSMISSION/TRANSAXLE/
TRANSFER CASE
U OPEN
V SPEED CONTROL, WIPER/
WASHER
W OPEN
X AUDIO SYSTEMS
Y OPEN
Z GROUNDS
DESCRIPTION - SECTION IDENTIFICATION AND
INFORMATION
The wiring diagrams are grouped into individual
sections. If a component is most likely found in a par-
ticular group, it will be shown complete (all wires,
connectors, and pins) within that group. For exam-
ple, the Auto Shutdown Relay is most likely to be
found in Group 30, so it is shown there complete. It
can, however, be shown partially in another group if
it contains some associated wiring.
Splice diagrams in Section 8W-70 show the entire
splice and provide references to other sections the
splices serves. Section 8W-70 only contains splice dia-
grams that are not shown in their entirety some-
where else in the wiring diagrams.
Section 8W-80 shows each connector and the cir-
cuits involved with that connector. The connectors
are identified using the name/number on the dia-
gram pages.
WIRING SECTION CHART
GROUP TOPIC
8W-01 thru
8W-09General information and Diagram
Overview
8W-10 thru
8W-19Main Sources of Power and
Vehicle Grounding
8W-20 thru
8W-29Starting and Charging
8W-30 thru
8W-39Powertrain/Drivetrain Systems
8W-40 thru
8W-49Body Electrical items and A/C
8W-50 thru
8W-59Exterior Lighting, Wipers and
Trailer Tow
8W-60 thru
8W-69Power Accessories
8W-70 Splice Information
8W-80 Connector Pin Outs
8W-91 Connector, Ground and Splice
Locations
8W - 01 - 6 8W-01 WIRING DIAGRAM INFORMATIONRS
WIRING DIAGRAM INFORMATION (Continued)
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DESCRIPTION - CONNECTOR, GROUND AND
SPLICE INFORMATION
CAUTION: Not all connectors are serviced. Some
connectors are serviced only with a harness. A typ-
ical example might be the Supplemental Restraint
System connectors. Always check parts availability
before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as
follows:
²In-line connectors located in the engine compart-
ment are C100 series numbers
²In-line connectors located in the Instrument
Panel area are C200 series numbers.
²In-line connectors located in the body are C300
series numbers.
²Jumper harness connectors are C400 series
numbers.
²Grounds and ground connectors are identified
with a ªGº and follow the same series numbering as
the in-line connectors.
²Splices are identified with an ªSº and follow the
same series numbering as the in-line connectors.
²Component connectors are identified by the com-
ponent name instead of a number. Multiple connec-
tors on a component use a C1, C2, etc. identifier.
LOCATIONS
Section 8W-91 contains connector/ground/splice
location illustrations. The illustrations contain the
connector name (or number)/ground number/splice
number and component identification. Connector/
ground/splice location charts in section 8W-91 refer-
ence the figure numbers of the illustrations.
The abbreviation T/O is used in the component
location section to indicate a point in which the wir-
ing harness branches out to a component. The abbre-
viation N/S means Not Shown in the illustrations
WARNING
WARNINGS - GENERAL
WARNINGSprovide information to prevent per-
sonal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a
vehicle is being serviced.
WARNING: ALWAYS WEAR SAFETY GLASSES FOR
EYE PROTECTION.
WARNING: USE SAFETY STANDS ANYTIME A PRO-
CEDURE REQUIRES BEING UNDER A VEHICLE.WARNING: BE SURE THAT THE IGNITION SWITCH
ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
WARNING: SET THE PARKING BRAKE WHEN
WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL
TRANSMISSION SHOULD BE IN NEUTRAL.
WARNING: OPERATE THE ENGINE ONLY IN A
WELL-VENTILATED AREA.
WARNING: KEEP AWAY FROM MOVING PARTS
WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
WARNING: TO PREVENT SERIOUS BURNS, AVOID
CONTACT WITH HOT PARTS SUCH AS THE RADIA-
TOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATA-
LYTIC CONVERTER AND MUFFLER.
WARNING: DO NOT ALLOW FLAME OR SPARKS
NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
WARNING: ALWAYS REMOVE RINGS, WATCHES,
LOOSE HANGING JEWELRY AND AVOID LOOSE
CLOTHING.
DIAGNOSIS AND TESTING - WIRING HARNESS
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit
there are several common tools necessary. These tools
are listed and explained below.
²Jumper Wire - This is a test wire used to con-
nect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS
A LOAD, SUCH AS A MOTOR, CONNECTED
BETWEEN A BATTERY FEED AND GROUND.
²Voltmeter - Used to check for voltage on a cir-
cuit. Always connect the black lead to a known good
ground and the red lead to the positive side of the
circuit.
CAUTION: Most of the electrical components used
in today's vehicles are Solid State. When checking
voltages in these circuits, use a meter with a 10 -
megohm or greater impedance rating.
RS8W-01 WIRING DIAGRAM INFORMATION8W-01-7
WIRING DIAGRAM INFORMATION (Continued)
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