fuse CHRYSLER CARAVAN 2002 Service Manual

RIGHT REAR LAMP ASSEMBLY - BLACK 6 WAY
CAV CIRCUIT FUNCTION
1 L62 18WT/BR (EXCEPT
BUILT-UP-EXPORT)RIGHT REAR TURN SIGNAL DRIVER
1 Z362 18BK/BR (BUILT-UP-EXPORT) GROUND
2 L62 18WT/BR (BUILT-UP-EXPORT) RIGHT REAR TURN SIGNAL DRIVER
3 L78 18WT/OR (EXCEPT
BUILT-UP-EXPORT)FUSED PARK LAMP RELAY OUTPUT (RIGHT)
3 L50 18WT/TN (BUILT-UP-EXPORT) BRAKE LAMP SWITCH OUTPUT
4 L1 18WT/LG BACK-UP LAMP DRIVER
5 Z362 18BK/BR (EXCEPT
BUILT-UP-EXPORT)GROUND
5 L38 20WT/YL (BUILT-UP-EXPORT) REAR FOG LAMP SWITCH OUTPUT
6 L50 18WT/TN (EXCEPT
BUILT-UP-EXPORT)PRIMARY BRAKE SWITCH SIGNAL
6 L78 18WT/OR (BUILT-UP-EXPORT) FUSED PARK LAMP RELAY OUTPUT (RIGHT)
RIGHT REAR PILLAR SPEAKER - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 X158 20GY/YL RIGHT REAR PILLAR SPEAKER (+)
2 X152 20GY/WT RIGHT REAR PILLAR SPEAKER (-)
RIGHT REAR READING LAMP (LUXURY) - GRAY 3 WAY
CAV CIRCUIT FUNCTION
1 M22 20YL/OR COURTESY LAMPS DRIVER
2 Z327 20BK/OR GROUND
3 M27 20YL/LB READING LAMPS DRIVER
RIGHT REAR SPEAKER - BLACK/RED 6 WAY
CAV CIRCUIT FUNCTION
1 X152 20GY/WT (HIGH LINE) RIGHT REAR PILLAR SPEAKER (-)
2 X15 16GY/DG (HIGH LINE) AMPLIFIED SPEAKER GROUND
3 X158 20GY/YL (HIGH LINE) RIGHT REAR PILLAR SPEAKER (+)
4 X52 20GY/DB RIGHT REAR SPEAKER (+)
5 X13 16DG/GY (HIGH LINE) RADIO CHOKE OUTPUT
6 X58 20GY/OR RIGHT REAR SPEAKER (-)
RIGHT REAR VENT MOTOR - NATURAL 3 WAY
CAV CIRCUIT FUNCTION
1- -
2 Q14 16OR/BR (LHD BUILT-UP-EXPORT) PASSENGER SIDE REAR WINDOW CLOSE
2 Q13 16OR/DB (RHD) DRIVER SIDE REAR WINDOW CLOSE
2 Q14 16OR/GY (LHD EXCEPT
BUILT-UP-EXPORT)PASSENGER SIDE REAR WINDOW CLOSE
3 Q23 16OR/LB (RHD) DRIVER SIDE REAR WINDOW OPEN
3 Q24 16OR/DG (LHD) PASSENGER SIDE REAR WINDOW OPEN
RS8W-80 CONNECTOR PIN-OUTS8W - 80 - 107
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RIGHT REAR WHEEL SPEED SENSOR - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 B2 18DG/LB RIGHT REAR WHEEL SPEED SENSOR 12 VOLT
SUPPLY
2 B1 18DG/OR RIGHT REAR WHEEL SPEED SENSOR SIGNAL
RIGHT REMOTE RADIO SWITCH - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 X20 20RD/BK RADIO CONTROL MUX
2 X920 20RD/DB RADIO CONTROL MUX RETURN
RIGHT REPEATER LAMP (BUILT-UP-EXPORT) - GRAY 2 WAY
CAV CIRCUIT FUNCTION
1 A701 18BR/RD FUSED B(+) (HAZARD)
2 L162 20WT/VT RIGHT SIDE REPEATER LAMP FEED
RIGHT SEAT AIRBAG - YELLOW 2 WAY
CAV CIRCUIT FUNCTION
1 R32 18LB/OR (EXCEPT
BUILT-UP-EXPORT)RIGHT SEAT SQUIB LINE 1
1 R34 18WT/BK (BUILT UP EXPORT) RIGHT SEAT SQUIB LINE 2
2 R34 18LB/WT (EXCEPT
BUILT-UP-EXPORT)RIGHT SEAT SQUIB LINE 2
2 R32 18DG/WT (BUILT UP EXPORT) RIGHT SEAT SQUIB LINE 1
RIGHT SIDE IMPACT AIRBAG CONTROL MODULE - YELLOW/RED 7 WAY
CAV CIRCUIT FUNCTION
1 R32 18LB/OR RIGHT SEAT SQUIB LINE 1
2 R34 18LB/WT RIGHT SEAT SQUIB LINE 2
3- -
4 D25 20WT/VT PCI BUS
5 F214 18PK/LG FCM OUTPUT (SIACM RUN-START DRIVER)
6- -
7 Z104 18BK/LG GROUND
8W - 80 - 108 8W-80 CONNECTOR PIN-OUTSRS
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RIGHT SLIDING DOOR CONTROL MODULE C1 (POWER SLIDING DOOR) - BLACK 8 WAY
CAV CIRCUIT FUNCTION
1 Q44 18OR/GY RIGHT CINCH/RELEASE MOTOR CLUTCH DRIVER
2 Q68 16TN/BR RIGHT SLIDING DOOR OPEN DRIVER
3 Q70 16TN/OR RIGHT SLIDING DOOR CLOSE DRIVER
4- -
5 A113 14WT/RD FUSED B(+)
6- -
7- -
8 Z124 14BK GROUND
RIGHT SLIDING DOOR CONTROL MODULE C2 (POWER SLIDING DOOR) - BLACK/RED 20 WAY
CAV CIRCUIT FUNCTION
1 Q72 20TN/VT RIGHT DOOR MOTOR HALL EFFECT SUPPLY
2- -
3 Q34 20OR/GY RIGHT DOOR LOCK SENSE
4 Q54 20OR/BR RIGHT DOOR IN/OUT HANDLE SWITCH SENSE
5- -
6- -
7 Q64 18OR/TN RIGHT DOOR MOTOR CLUTCH DRIVER
8 Q46 18TN/GY RIGHT CINCH/RELEASE MOTOR LATCH DRIVER
9 Q48 18TN/WT RIGHT CINCH/RELEASE MOTOR UNLATCH DRIVER
10 - -
11 D25 20WT/VT PCI BUS
12 G76 20TN/OR RIGHT SLIDING DOOR AJAR SWITCH SENSE
13 Q58 20OR/YL RIGHT PAWL SWITCH SENSE
14 Q52 20OR RIGHT FULL OPEN SWITCH SENSE
15 - GROUND-DRIVER SIDE IDENTIFIER (LHD/RHD)
16 Q56 20OR/VT RIGHT DOOR CHILD LOCKOUT SWITCH SENSE
17 Q74 20TN/YL RIGHT DOOR MOTOR HALL EFFECT SIGNAL
18 - -
19 G152 20VT/GY RIGHT SLIDING DOOR WAKE UP SIGNAL
20 Z26 20BK/TN GROUND
RIGHT SLIDING DOOR LATCH SENSING SWITCH (POWER SLIDING DOOR) - BLACK 6 WAY
CAV CIRCUIT FUNCTION
1 Z76 20BK/YL GROUND
2 Q58 20OR/YL RIGHT PAWL SWITCH SENSE
3 G76 20TN/OR RIGHT SLIDING DOOR AJAR SWITCH SENSE
4 Z76 20BK/YL GROUND
5 Q54 20OR/BR RIGHT DOOR IN/OUT HANDLE SWITCH SENSE
6 Q56 20OR/VT RIGHT DOOR CHILD LOCKOUT SWITCH SENSE
RS8W-80 CONNECTOR PIN-OUTS8W - 80 - 109
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RIGHT TURN SIGNAL LAMP (BUILT-UP-EXPORT) - ORANGE 2 WAY
CAV CIRCUIT FUNCTION
1 Z344 16BR GROUND
2 L60 16YL RIGHT FRONT TURN SIGNAL DRIVER
RIGHT VISOR/VANITY LAMP (PREMIUM/LUXURY) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
A Z327 20BK/OR GROUND
B M27 20YL/LB READING LAMPS DRIVER
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 20BK/WT GROUND
6 A114 20GY/RD 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
RS8W-80 CONNECTOR PIN-OUTS8W - 80 - 111
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SPEED CONTROL SERVO (GAS) - BLACK 4 WAY
CAV CIRCUIT FUNCTION
1 V36 18VT/YL SPEED CONTROL VACUUM SOLENOID CONTROL
2 V35 18VT/OR SPEED CONTROL VENT SOLENOID CONTROL
3 V30 18VT/WT SPEED CONTROL BRAKE SWITCH OUTPUT
4 Z155 18BK/LG GROUND
THATCHAM ALARM MODULE C1 (UNITED KINGDOM) - BLACK 16 WAY
CAV CIRCUIT FUNCTION
1- -
2- -
3 G22 20YL VTSS INDICATOR SUPPLY
4 D23 20WT/BR FLASH PROGRAM ENABLE
5 D97 20WT/OR SIREN SIGNAL OUTPUT
6 D96 20WT/LB SIREN SIGNAL CONTROL
7 F20 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
8 G944 20LB/BR SIREN SIGNAL RETURN
9- -
10 - -
11 G922 20GY VTSS INDICATOR DRIVER
12 - -
13 D25 20WT/VT PCI BUS
14 - -
15 L91 20WT/DB HAZARD SWITCH SENSE
16 A600 20RD/LB SIREN SUPPLY
THATCHAM ALARM MODULE C2 (UNITED KINGDOM) - WHITE 4 WAY
CAV CIRCUIT FUNCTION
1 18BK/LB REAR INTRUSION SENSOR SIGNAL
2 18BK/LB FRONT INTRUSION SENSOR SIGNAL
3 18BK/WT SENSOR GROUND
4 18BK/WT SENSOR GROUND
THROTTLE POSITION SENSOR (GAS) - GRAY 3 WAY
CAV CIRCUIT FUNCTION
1 K900 18DB/DG SENSOR GROUND
2 K22 18BR/OR THROTTLE POSITION SENSOR SIGNAL
3 F855 18PK/YL 5 VOLT SUPPLY
8W - 80 - 112 8W-80 CONNECTOR PIN-OUTSRS
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TORQUE CONVERTER CLUTCH SOLENOID (ATX) - BLACK 3 WAY
CAV CIRCUIT FUNCTION
1- -
2 F202 18PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START)
3 K54 18DB/WT TORQUE CONVERTER CLUTCH SOLENOID CONTROL
TRACTION CONTROL SWITCH - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 B27 20DG/WT TRACTION CONTROL SWITCH SENSE
2 Z427 20BK/WT GROUND
TRAILER TOW CONNECTOR (EXCEPT BUILT-UP-EXPORT)-4WAY
CAV CIRCUIT FUNCTION
1 L74 18LG RIGHT STOP SIGNAL
2 L77 18WT/BR FUSED PARK LAMP RELAY OUTPUT (LEFT)
3 Z1 18BK/DG GROUND
4 L73 18YL LEFT STOP SIGNAL
RS8W-80 CONNECTOR PIN-OUTS8W - 80 - 113
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TRANSMISSION CONTROL MODULE (EATX) - BLACK 60 WAY
CAV CIRCUIT FUNCTION
1 T1 18DG/LB TRS T1 SENSE
2- -
3 T3 18DG/DB TRS T3 SENSE
4- -
5- -
6 K24 18BR/LB CRANKSHAFT POSITION SENSOR SIGNAL
7 D21 18WT/BR SCI TRANSMIT
8 T751 18YL FUSED IGNITION SWITCH OUTPUT (START)
9 T9 18DG/TN OVERDRIVE PRESSURE SWITCH SENSE
10 T10 18DG/LG TORQUE MANAGEMENT REQUEST SENSE
11 F1 18PK/WT FCM OUTPUT (UNLOCK-RUN-START)
12 K22 18BR/OR THROTTLE POSITION SENSOR SIGNAL
13 T13 18DG/VT SPEED SENSOR GROUND
14 T14 18DG/BR OUTPUT SPEED SENSOR SIGNAL
15 T15 18YL/BR TRANSMISSION CONTROL RELAY CONTROL
16 T16 18YL/OR TRANSMISSION CONTROL RELAY OUTPUT
17 T16 18YL/OR TRANSMISSION CONTROL RELAY OUTPUT
18 - -
19 T19 18YL/DB 2-4 SOLENOID CONTROL
20 T20 18DG/WT LOW/REVERSE SOLENOID CONTROL
21 - -
22 - -
23 - -
24 - -
25 - -
26 - -
27 - -
28 - -
29 - -
30 - -
31 - -
32 - -
33 - -
34 - -
35 - -
36 - -
37 - -
38 - -
39 - -
40 - -
41 T41 18DG/GY (3.3L/3.8L) TRS T41 SENSE
41 T41 18YL/DB (2.4L) TRS T41 SENSE
42 T42 18DG/YL TRS T42 SENSE
43 D25 18WT/VT PCI BUS
44 - -
45 - -
46 D16 18WT/OR SCI RECEIVE
47 T47 18YL/DG 2-4 PRESSURE SWITCH SENSE
48 - -
49 - -
50 T50 18YL/TN LOW/REVERSE PRESSURE SWITCH SENSE
51 K900 18DB/DG SENSOR GROUND
52 T52 18DG/WT INPUT SPEED SENSOR SIGNAL
53 Z132 16BK/YL GROUND
54 T54 18DG/OR TRANSMISSION TEMPERATURE SENSOR SIGNAL
8W - 80 - 114 8W-80 CONNECTOR PIN-OUTSRS
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TRANSMISSION CONTROL MODULE (EATX) - BLACK 60 WAY
CAV CIRCUIT FUNCTION
55 T55 18YL/VT (AUTOSTICK) AUTOSTICK/OVERDRIVE OFF MUX INPUT
56 A104 18YL/RD FUSED B(+)
57 Z133 16BK/LG GROUND
58 N7 18DB/OR VEHICLE SPEED SENSOR SIGNAL
59 T59 18YL/LB UNDERDRIVE SOLENOID CONTROL
60 T60 18YL/GY OVERDRIVE SOLENOID CONTROL
TRANSMISSION RANGE SENSOR (EATX) - DK. GRAY 10 WAY
CAV CIRCUIT FUNCTION
1 T2 18DG/WT TRS REVERSE SENSE
2- -
3 T13 18DG/VT SPEED SENSOR GROUND
4 T54 18DG/OR TRANSMISSION TEMPERATURE SENSOR SIGNAL
5 T41 18YL/DB (2.4L) TRS T41 SENSE
5 T41 18DG/GY (3.3L/3.8L) TRS T41 SENSE
6 Z252 18BK/WT GROUND
7 T1 18DG/LB TRS T1 SENSE
8 T3 18DG/DB TRS T3 SENSE
9 T42 18DG/YL TRS T42 SENSE
10 T41 18YL/DB PARK/NEUTRAL POSITION SWITCH SENSE (TRS T41)
TXV SOLENOID (ATC)-2WAY
CAV CIRCUIT FUNCTION
1 C200 18LB/DG TXV SOLENOID FEED
2 C51 18DB/BR FUSED REAR BLOWER MOTOR RELAY OUTPUT
VEHICLE SPEED SENSOR (MTX/ATX) - BLACK 3 WAY
CAV CIRCUIT FUNCTION
1 F202 18PK/GY (DIESEL) FUSED IGNITION SWITCH OUTPUT (RUN-START)
1 F888 18BR/PK (2.4L) 8 VOLT SUPPLY
2 K900 20DB/DG (DIESEL) SENSOR GROUND
2 K900 18DB/DG (2.4L) SENSOR GROUND
3 N7 20DB/OR (DIESEL) VEHICLE SPEED SENSOR SIGNAL
3 N7 18DB/OR (2.4L) VEHICLE SPEED SENSOR SIGNAL
WASHER FLUID LEVEL SWITCH - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 Z401 18BK/TN (EXCEPT
BUILT-UP-EXPORT)GROUND
1 Z401 20BK/TN (BUILT UP EXPORT) GROUND
2 W1 18BR/TN WASHER FLUID LEVEL SWITCH SENSE
RS8W-80 CONNECTOR PIN-OUTS8W - 80 - 115
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8W-97 POWER DISTRIBUTION SYSTEM
TABLE OF CONTENTS
page page
POWER DISTRIBUTION SYSTEM
DESCRIPTION..........................1
OPERATION............................1
SPECIAL TOOLS
POWER DISTRIBUTION SYSTEMS.........2
ACCESSORY RELAY
DESCRIPTION..........................2
OPERATION............................2
DIAGNOSIS AND TESTING
DIAGNOSIS & TESTING - ACCESSORY
RELAY...............................2
REMOVAL.............................3
INSTALLATION..........................3
INTEGRATED POWER MODULE
DESCRIPTION..........................3OPERATION............................3
REMOVAL.............................4
INSTALLATION..........................4
IOD FUSE
DESCRIPTION..........................4
OPERATION............................5
REMOVAL.............................5
INSTALLATION..........................5
POWER OUTLET
DESCRIPTION..........................5
OPERATION............................5
DIAGNOSIS AND TESTING
DIAGNOSIS & TESTING - POWER OUTLET . . 5
REMOVAL.............................6
INSTALLATION..........................6
POWER DISTRIBUTION
SYSTEM
DESCRIPTION
This group covers the various standard and
optional power distribution components used on this
model. The power distribution system for this vehicle
consists of the following components:
²Integrated Power Module (IPM)
²Front Control Module (FCM)
²Power Outlets
Refer to Wiring Diagrams for complete circuit sche-
matics.
The power distribution system also incorporates
various types of circuit control and protection fea-
tures, including:
²Automatic resetting circuit breakers
²Blade-type fuses
²Bus bars
²Cartridge fuses
²Circuit splice blocks
²Flashers
²Fusible links
²Relays
Following are general descriptions of the major
components in the power distribution system. See the
owner's manual in the vehicle glove box for more
information on the features and use of all of the
power distribution system components.
OPERATION
The power distribution system for this vehicle is
designed to provide safe, reliable, and centralized dis-
tribution points for the electrical current required to
operate all of the many standard and optional facto-
ry-installed electrical and electronic powertrain,
chassis, safety, security, comfort and convenience sys-
tems. At the same time, the power distribution sys-
tem was designed to provide ready access to these
electrical distribution points for the vehicle techni-
cian to use when conducting diagnosis and repair of
faulty circuits. The power distribution system can
also prove useful for the sourcing of additional elec-
trical circuits that may be required to provide the
electrical current needed to operate many accessories
that the vehicle owner may choose to have installed
in the aftermarket.
RS8W-97 POWER DISTRIBUTION SYSTEM8W-97-1
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SPECIAL TOOLS
POWER DISTRIBUTION SYSTEMS
ACCESSORY RELAY
DESCRIPTION
The accessory relay is an electromechanical device
that switches fused battery current to the accessory
powered vehicle circuits when the ignition switch is
turned to the Accessory or On positions. The delay
feature will maintain power to the accessories for 45
seconds after the ignition is shut off or until a door is
opened. This allows sufficient time to close windows
and park the windshield wipers. The accessory relay
is located in the Integrated Power Module (IPM) in
the engine compartment.
The accessory relay is a International Standards
Organization (ISO) relay. Relays conforming to the
ISO specifications have common physical dimensions,
current capacities, terminal patterns, and terminal
functions.
The accessory relay cannot be repaired or adjusted
and, if faulty or damaged, it must be replaced.
OPERATION
The ISO relay consists of an electromagnetic coil, a
resistor or diode, and three (two fixed and one movable)
electrical contacts. The movable (common feed) relay
contact is held against one of the fixed contacts (normal-
ly closed) by spring pressure. When the electromagnetic
coil is energized, it draws the movable contact away
from the normally closed fixed contact, and holds it
against the other (normally open) fixed contact.
When the electromagnetic coil is de-energized,
spring pressure returns the movable contact to the
normally closed position. The resistor or diode is con-
nected in parallel with the electromagnetic coil in the
relay, and helps to dissipate voltage spikes that are
produced when the coil is de-energized.
DIAGNOSIS AND TESTING
DIAGNOSIS & TESTING - ACCESSORY RELAY
The accessory relay (Fig. 1) is located in the Inte-
grated Power Module (IPM), in the engine compart-
ment. For complete circuit diagrams, refer toWiring
Diagrams.
(1) Remove the accessory relay from the IPM.
Refer toAccessory Relayin the Removal and
Installation section of this group for the procedure.
(2) A relay in the de-energized position should
have continuity between terminals 87A and 30, and
no continuity between terminals 87 and 30. If OK, go
to Step 3. If not OK, replace the faulty relay.
(3) Resistance between terminals 85 and 86 (elec-
tromagnet) should be 75   5 ohms. If OK, go to Step
4. If not OK, replace the faulty relay.
(4) Connect a battery to terminals 85 and 86.
There should now be continuity between terminals
30 and 87, and no continuity between terminals 87A
and 30. If OK, perform the Relay Circuit Test that
follows. If not OK, replace the faulty relay.
DIAGNOSIS & TESTING - RELAY CIRCUIT TEST
(1) The relay common feed terminal cavity (30) of
the IPM is connected to battery voltage and should
be hot at all times. Check for battery voltage at the
fused B(+) circuit cavity in the IPM receptacle for the
accessory relay. If OK, go to Step 2. If not OK, repair
the fused B(+) circuit to the IPM fuse as required.
(2) The relay normally closed terminal (87A) is
connected to terminal 30 in the de-energized position,
but is not used for this application. Go to Step 3.
(3) The relay normally open terminal (87) is con-
nected to the common feed terminal (30) in the ener-
gized position. This terminal supplies battery voltage
to the fused B(+) fuse in the IPM that feeds the
accessories when the relay is energized by the igni-
tion switch. There should be continuity between the
IPM cavity for relay terminal 87 and the fused B(+)
fuse in the IPM at all times. If OK, go to Step 4. If
not OK, repair the open fused B(+) circuit to the IPM
fuse as required.
Terminal Pick Kit 6680
Fig. 1 Accessory Relay
8W - 97 - 2 8W-97 POWER DISTRIBUTION SYSTEMRS
POWER DISTRIBUTION SYSTEM (Continued)
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