key battery CHRYSLER CARAVAN 2002 Workshop Manual
[x] Cancel search | Manufacturer: CHRYSLER, Model Year: 2002, Model line: CARAVAN, Model: CHRYSLER CARAVAN 2002Pages: 2399, PDF Size: 57.96 MB
Page 633 of 2399
Passive disarming occurs upon normal vehicle
entry by unlocking either door with the ignition key/
remote transmitter. This disarming will also halt the
alarm once it has been activated.
A tamper alert exists to notify the driver that the
VTSS had been activated. This alert consists of 3
horn pulses when the vehicle is disarmed.
NOTE: The VTSS will not arm by pushing down the
door lock mechanism. This will manually override
the system.
For Door Cylinder Lock Switch Removal and
Installation, refer to Electrical, Power Locks, Door
Cylinder Lock Switch.
If the VTSS is triggered, the horn will pulse, head-
lamps/marker lamps will flash, and the VTSS warn-
ing lamp will flash. If BCM determines the threat to
be false and the VTSS is not triggered again, the sys-
tem will shut down and rearm itself after three min-
utes. If a trigger is still active, the alarm will
continue for an additional 15 minutes without the
horn. The VTSS monitoring portion of the system is
split into two sections. The engine compartment sec-
tion and the passenger compartment section. If a
malfunction occurs in the engine compartment sec-
tion, the passenger compartment section would still
arm and function normally.
NOTE: If hood is not secure during the arming
sequence, the lamp will stay lit and not flash. The
system will arm with hood not secured (hood ajar
switch closed) and the liftgate open (liftgate ajar
switch closed). System will not arm if passenger
compartment is not secure (all switches closed)
ARMING THE VTSS - METHOD A
(1) With the key removed from the ignition lock
and any door open (excluding liftgate), actuate one of
the following:
²Power door lock button to LOCK,
²Key fob LOCK button
²Door lock key cylinder to locked position.
(2) Close all opened doors. Liftgate can remain
open.
(3) After the last door is closed, an arming time-
out period of sixteen seconds will start, then the
VTSS will become armed.
ARMING THE VTSS - METHOD B
Actuating the key fob transmitter LOCK button,
key locking the front doors with the doors closed and
the ignition locked will begin the arming time-out
period. If method A, 16 second time-out sequence was
in process when method B was actuated, the 16 sec-ond time-out will restart from the time of the second
actuation.
If the security lamp does not illuminate at all upon
final door closure, it indicates that the system is not
arming.
The current VTSS status armed or disarmed shall
be maintained in memory to prevent battery discon-
nects from disarming the system.
TRIGGERING THE VTSS
After the VTSS is armed, the following actions will
trigger the alarm:
²Opening any door (excluding liftgate).
²Opening the hood
²Turning the ignition to the ACC, or UNLOCK
position.
NOTE: When the VTSS is ARMED, the interior
power door lock switch ªUNLOCKº will be disabled
until the vehicle is disarmed.
CAUTION: The VTSS indicator LED will trigger and
engine will continue to run if the vehicle is
equipped with SKIS and the proper key is used to
start the vehicle. This condition will occur if the
VTSS has been triggered. If valid key is used, VTSS
will disarm
SENTRY KEY IMMOBILIZER SYSTEM
The SKIS includes keys from the factory which are
pre-programmed. Each SKIM will recognize a maxi-
mum of eight Sentry Keys. If the customer would
like to own additional keys other than those provided
with the vehicle, they can be purchased from any
authorized dealer. These keys must be programmed
to the SKIM on the vehicle in order for the system to
recognize them as valid keys. This can be done by
the dealer with a DRB IIItscan tool or by a cus-
tomer if this feature is available in their market and
they have two (2) valid keys already available to
them. Refer to the Service Procedures portion of this
system for additional details. The SKIS performs a
self-test each time the ignition switch is turned to
the ON position and will store Diagnostic Trouble
Codes (DTC's) if a system malfunction is detected.
The SKIS can be diagnosed and any stored DTC's
can be retrieved using a DRB IIItscan tool as
described in the appropriate Body Diagnostic Proce-
dures manual.
8Q - 2 VEHICLE THEFT SECURITYRS
VEHICLE THEFT SECURITY (Continued)
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Page 634 of 2399
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - SENTRY KEY
IMMOBILIZER SYSTEM
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO ELECTRICAL, RESTRAINTS,
WARNINGS, BEFORE ATTEMPTING COMPONENT
DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
NOTE: The following tests may not prove conclu-
sive in the diagnosis of this system. The most reli-
able, efficient, and accurate means to diagnose the
Sentry Key Immobilizer System involves the use of
a DRB IIITscan tool. Refer to the proper Body Diag-
nostic Procedures Manual.
The Sentry Key Immobilizer System (SKIS) and
the Programmable Communication Interface (PCI)
bus network should be diagnosed using a DRB IIIt
scan tool. The DRB IIItwill allow confirmation that
the PCI bus is functional, that the Sentry Key Immo-
bilizer Module (SKIM) is placing the proper messages
on the PCI bus, and that the Powertrain Control
Module (PCM) is receiving the PCI bus messages.
Refer to the proper Body Diagnostic Procedures man-
ual, and Wiring Diagrams for complete circuit
descriptions and diagrams.
(1) Check the fuses in the Integrated Power Mod-
ule (IPM). If OK, go to Step 2. If not OK, repair the
shorted circuit or component as required and replace
the faulty fuse.
(2) Disconnect and isolate the battery negative
remote cable from the remote terminal. Unplug the
wire harness connector at the SKIM. Check for con-
tinuity between the ground circuit cavity of the
SKIM wire harness connector and a good ground.
There should be continuity. If OK, go to Step 3. If not
OK, repair the open circuit to ground as required.
(3) Connect the battery negative cable. Check for
battery voltage at the fused B(+) circuit cavity of the
SKIM wire harness connector. If OK, go to Step 4. If
not OK, repair the open circuit to the fuse in the
IPM as required.
(4) Turn the ignition switch to the ON position.
Check for battery voltage at the fused ignition switch
output (run/start) circuit cavity of the SKIM wire
harness connector. If OK, use a DRB IIItscan tool
and the proper Body Diagnostic Procedures manual
to complete the diagnosis of the SKIS. If not OK,
repair the open circuit to the fuse in the IPM as
required.
DIAGNOSIS AND TESTING - VEHICLE THEFT
SECURITY SYSTEM
Refer to the appropriate wiring information. The
wiring information includes wiring diagrams, proper
wire and connector repair procedures, further details
on wire harness routing and retention, as well as
pin-out and location views for the various wire har-
ness connectors, splices and grounds. Using a DRB
IIItscan tool. Refer to the proper Body Diagnostic
Procedures Manual for test procedures.
HOOD AJAR SWITCH
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Using a small flat blade screwdriver, pry trig-
ger switch from the bracket on the left fender well.
(3) Disconnect the hood ajar switch from the wire
connector and remove from vehicle.
INSTALLATION
(1) Connect the hood ajar switch to the wire conec-
tor.
(2) Press the hood ajar switch into position on the
bracket located on the left inner fender well.
(3) Reconnect the battery negative cable.
(4) Close the hood and check for proper operation.
TRANSPONDER KEY
DESCRIPTION
The Sentry Key Immobilizer System (SKIS) uses a
transponder chip that is integral to each ignition key
(Fig. 1) to communicate with the Sentry Key Immo-
bilizer Module (SKIM). Ignition keys are supplied
with the vehicle when it is shipped from the factory.
The transponder chip is undermolded within the
head of the key. This undermold is hidden beneath
an overmolded rubber cap.
OPERATION
Each Sentry Key has a unique transponder identi-
fication code permanently programmed into it by the
manufacturer. Likewise, the SKIM has a unique
9Secret Key9code programmed into it by the manu-
facturer as well. When a Sentry Key is programmed
into the memory of the SKIM, the SKIM stores the
transponder identification code from the Sentry Key,
and the Sentry Key learns the9Secret Key9code from
the SKIM. Once the Sentry Key learns the9Secret
Key9code of the SKIM, it is also permanently pro-
grammed into the transponder's memory. Therefore,
blank keys for the SKIS must be programmed by the
RSVEHICLE THEFT SECURITY8Q-3
VEHICLE THEFT SECURITY (Continued)
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Page 746 of 2399
8W-15 GROUND DISTRIBUTION
Component PageA/C Compressor Clutch...................8W-15-7, 8
A/C- Heater Control....................8W-15-9, 11
Adjustable Pedals Module..................8W-15-17
Airbag Control Module....................8W-15-12
Auto Temp Control.......................8W-15-9
Automatic Day/Night Mirror.................8W-15-21
Autostick Switch........................8W-15-10
Back-Up Lamp Switch....................8W-15-3, 7
Battery.............................8W-15-2, 3
Body Control Module.....................8W-15-22
Brake Fluid Level Switch...................8W-15-17
Brake Lamp Switch......................8W-15-17
Cabin Heater Assist.......................8W-15-8
Center Dome Lamp......................8W-15-21
Center High Mounted Stop Lamp..............8W-15-26
Clutch Pedal Upstop Switch.................8W-15-18
Controller Antilock Brake..................8W-15-2, 3
Crank Case Ventilation Heater................8W-15-8
Crankshaft Position Sensor..................8W-15-3
Data Link Connector..................8W-15-2, 3, 17
Dosing Pump...........................8W-15-8
Driver Door Courtesy Lamp...............8W-15-15, 20
Driver Door Lock Switch.................8W-15-15, 20
Driver Heated Seat Cushion.................8W-15-11
Driver Heated Seat Module.................8W-15-11
Driver Power Seat Switch..................8W-15-11
Driver Power Window Switch..............8W-15-15, 20
Engine Control Module.....................8W-15-3
Floor Console Lamp......................8W-15-25
Floor Console Power Outlet.................8W-15-25
Front Blower Module.....................8W-15-11
Front Cigar Lighter.......................8W-15-9
Front Control Module..................8W-15-7, 8, 18
Front Reading Lamps/Switch................8W-15-21
Fuel Heater...........................8W-15-25
Fuel Heater Relay........................8W-15-3
Fuel Pump Module.......................8W-15-25
G100..............................8W-15-2, 3
G101..............................8W-15-2, 3
G102.............................8W-15-4, 5, 6
G103..............................8W-15-7, 8
G200...........................8W-15-9, 10, 11
G201...............................8W-15-12
G202...............................8W-15-13
G300........................8W-15-14, 16, 17, 18
G301........................8W-15-19, 20, 21, 22
G302...........................8W-15-23, 24, 25
G400.............................8W-15-25, 26
Glove Box Lamp........................8W-15-10
Halo Lamp............................8W-15-10
Headlamp Switch........................8W-15-9
Headlamp Washer Pump Motor................8W-15-6
High Note Horn........................8W-15-5, 6
Hood Ajar Switch........................8W-15-18
Instrument Cluster.......................8W-15-9
Instrument Panel Switch Bank...............8W-15-10
Integrated Power Module............8W-15-2, 3, 7, 8, 18
Left B-Pillar Switch......................8W-15-17
Left Cinch/Release Motor...................8W-15-14
Left Combination Relay....................8W-15-24
Left Cylinder Lock Switch................8W-15-15, 16
Left Door Speaker.......................8W-15-13
Left Fog Lamp........................8W-15-5, 6
Left Front Door Ajar Switch.................8W-15-16
Left Front Door Lock Motor/Ajar Switch.......8W-15-15, 16
Left Front Park/Turn Signal Lamp..............8W-15-5
Left Full Open Switch.....................8W-15-14
Left Headlamp.........................8W-15-18
Left Headlamp Leveling Motor................8W-15-6
Left High Beam Lamp....................8W-15-18
Left Liftgate Flood Lamp...................8W-15-26
Left Low Beam Lamp.....................8W-15-18
Left Mid Reading Lamp....................8W-15-21
Left Park Lamp.........................8W-15-18
Left Power Mirror.......................8W-15-10
Left Rear Lamp Assembly..................8W-15-24
Left Rear Reading Lamp...................8W-15-21
Left Side Impact Airbag Control Module.........8W-15-12
Left Sliding Door Control Module..............8W-15-14
Left Sliding Door Latch Sensing Switch..........8W-15-14
Left Sliding Door Lock Motor................8W-15-14Component PageLeft Sliding Door Lock Motor/Ajar Switch.........8W-15-14
Left Sliding Door Motor....................8W-15-14
Left Stop/Turn Signal Relay.................8W-15-24
Left Turn Signal Lamp....................8W-15-18
Left Visor/Vanity Lamp....................8W-15-21
License Lamp........................8W-15-23, 26
Lift Pump Motor........................8W-15-25
Liftgate Ajar Switch......................8W-15-26
Liftgate Cinch/Release Motor................8W-15-23
Liftgate Cylinder Lock Switch................8W-15-26
Liftgate Right Pinch Sensor.................8W-15-23
Low Note Horn........................8W-15-5, 6
Memory Seat/Mirror Module.................8W-15-11
Overhead Console.......................8W-15-21
Oxygen Sensor 1/2 Downstream...............8W-15-7
Park/Neutral Position Switch.................8W-15-7
Passenger Door Courtesy Lamp............8W-15-16, 20
Passenger Door Lock Switch..............8W-15-16, 20
Passenger Heated Seat Module...............8W-15-22
Passenger Power Seat Switch................8W-15-22
Passenger Power Window Switch............8W-15-16, 20
Power Folding Mirror Switch................8W-15-11
Power Liftgate Module....................8W-15-23
Power Liftgate Motor.....................8W-15-23
Power Mirror Switch......................8W-15-11
Power Outlet...........................8W-15-9
Power Window Switch.....................8W-15-15
Powertrain Control Module..................8W-15-2
Radiator Fan No. 1.......................8W-15-4
Radiator Fan No. 2.......................8W-15-4
Radiator Fan Relay.......................8W-15-4
Radiator Fan Relay No. 3...................8W-15-4
Radio...............................8W-15-13
Rear Auto Temp Control Switch...............8W-15-17
Rear Blower Front Control Switch.............8W-15-11
Rear Blower Motor Power Module...........8W-15-11, 25
Rear Blower Rear Control Switch..............8W-15-17
Rear Dome Lamp........................8W-15-21
Rear Power Outlet.......................8W-15-25
Rear Window Defogger Grid.................8W-15-26
Rear Wiper Motor.......................8W-15-26
Remote Keyless Entry Module................8W-15-10
Right B-Pillar Switch.....................8W-15-22
Right Cinch/Release Motor..................8W-15-19
Right Combination Relay...................8W-15-24
Right Cylinder Lock Switch.................8W-15-20
Right Door Speaker......................8W-15-13
Right Fog Lamp........................8W-15-5, 6
Right Front Door Ajar Switch................8W-15-20
Right Front Door Lock Motor/Ajar Switch.........8W-15-20
Right Front Park/Turn Signal Lamp.............8W-15-5
Right Full Open Switch....................8W-15-19
Right Headlamp........................8W-15-18
Right Headlamp Leveling Motor...............8W-15-6
Right High Beam Lamp....................8W-15-18
Right Liftgate Flood Lamp..................8W-15-26
Right Low Beam Lamp....................8W-15-18
Right Mid Reading Lamp...................8W-15-21
Right Park Lamp........................8W-15-18
Right Power Mirror......................8W-15-10
Right Rear Lamp Assembly.................8W-15-25
Right Rear Reading Lamp..................8W-15-21
Right Side Impact Airbag Control Module.........8W-15-12
Right Sliding Door Control Module.............8W-15-19
Right Sliding Door Latch Sensing Switch.........8W-15-19
Right Sliding Door Lock Motor...............8W-15-19
Right Sliding Door Lock Motor/Ajar Switch........8W-15-19
Right Sliding Door Motor...................8W-15-19
Right Stop/Turn Signal Relay................8W-15-24
Right Turn Signal Lamp...................8W-15-18
Right Visor/Vanity Lamp...................8W-15-21
Sentry Key Immobilizer Module...............8W-15-10
Speed Control Servo.......................8W-15-7
Traction Control Switch....................8W-15-10
Trailer Tow Connector.....................8W-15-24
Transmission Control Module.................8W-15-2
Transmission Control Relay..................8W-15-2
Transmission Range Sensor..................8W-15-7
Washer Fluid Level Switch.................8W-15-5, 6
Wiper Module..........................8W-15-17
RS8W-15 GROUND DISTRIBUTION8W-15-1
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Page 772 of 2399
8W-18 BUS COMMUNICATIONS
Component Page
A/C- Heater Control.................. 8W-18-4
Adjustable Pedals Module.............. 8W-18-5
Airbag Control Module................ 8W-18-4
Auto Temp Control................... 8W-18-4
Battery.......................... 8W-18-2, 3
Body Control Module............. 8W-18-2, 3, 4
Cabin Heater Assist.................. 8W-18-3
CD Changer........................ 8W-18-4
Controller Antilock Brake.............. 8W-18-4
Data Link Connector.............. 8W-18-2, 3, 4
Diagnostic Junction Port......... 8W-18-2, 3, 4, 5
Engine Control Module.............. 8W-18-3, 5
Front Control Module............. 8W-18-2, 3, 4
G100............................ 8W-18-2, 3
G101............................ 8W-18-2, 3
G300............................ 8W-18-2, 3
Instrument Cluster................... 8W-18-4Component Page
Integrated Power Module............ 8W-18-2, 3
Integrated Power Module.............. 8W-18-4
Left Side Impact Airbag Control Module . . . 8W-18-5
Left Sliding Door Control Module........ 8W-18-5
Memory Seat/Mirror Module............ 8W-18-5
Overhead Console.................... 8W-18-4
Power Liftgate Module................ 8W-18-5
Powertrain Control Module........... 8W-18-2, 5
PTC7 ........................... 8W-18-2, 3
Radio............................. 8W-18-4
Right Side Impact Airbag Control
Module.......................... 8W-18-5
Right Sliding Door Control Module....... 8W-18-5
Sentry Key Immobilizer Module......... 8W-18-5
Thatcham Alarm Module........... 8W-18-2, 3, 5
Transmission Control Module......... 8W-18-2, 4
RS8W-18 BUS COMMUNICATIONS8W-18-1
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Page 1200 of 2399
tion. The IOD fuse is a 15 ampere blade-type car-
tridge fuse and, when removed, it is stored in a fuse
cavity adjacent to the washer fuse within the IPM.
OPERATION
The term ignition-off draw identifies a normal con-
dition where power is being drained from the battery
with the ignition switch in the Off position. The IOD
fuse feeds the memory and sleep mode functions for
some of the electronic modules in the vehicle as well
as various other accessories that require battery cur-
rent when the ignition switch is in the Off position,
including the clock. The only reason the IOD fuse is
removed is to reduce the normal IOD of the vehicle
electrical system during new vehicle transportation
and pre-delivery storage to reduce battery depletion,
while still allowing vehicle operation so that the
vehicle can be loaded, unloaded and moved as needed
by both vehicle transportation company and dealer
personnel.
The IOD fuse is removed from the IPM fuse cavity
when the vehicle is shipped from the assembly plant.
Dealer personnel must install the IOD fuse when the
vehicle is being prepared for delivery in order to
restore full electrical system operation. Once the
vehicle is prepared for delivery, the IOD function of
this fuse becomes transparent and the fuse that has
been assigned the IOD designation becomes only
another Fused B(+) circuit fuse. The IOD fuse serves
no useful purpose to the dealer technician in the ser-
vice or diagnosis of any vehicle system or condition,
other than the same purpose as that of any other
standard circuit protection device.
The IOD fuse can be used by the vehicle owner as
a convenient means of reducing battery depletion
when a vehicle is to be stored for periods not to
exceed about thirty days. However, it must be
remembered that removing the IOD fuse will not
eliminate IOD, but only reduce this normal condition.
If a vehicle will be stored for more than about thirty
days, the battery negative cable should be discon-
nected to eliminate normal IOD; and, the battery
should be tested and recharged at regular intervals
during the vehicle storage period to prevent the bat-
tery from becoming discharged or damaged. Refer to
Battery Systemfor additional service information.
REMOVAL
(1) Turn the ignition switch to the Off position.
(2) Unlatch and open the cover of the intelligent
power module.
(3) Remove the IOD fuse from fuse location
markedIODof the Integrated Power Module (IPM).
(4) Store the removed IOD fuse by installing it in
the unused fuse storage markedSPAREof the IPM.
(5) Close and latch the IPM.
INSTALLATION
(1) Be certain the ignition switch is in the Off posi-
tion.
(2) Unlatch and open the cover of the Integrated
Power Module (IPM).
(3) Remove the stored 15 amp IOD fuse from fuse
storage markedSPAREof the IPM.
(4) Use a thumb to press the IOD fuse firmly down
into IPM fuse cavity markedIOD.
(5) Close and latch the IPM cover.
POWER OUTLET
DESCRIPTION
Accessory power outlets are standard equipment on
this model. Two power outlets are installed in the
instrument panel center lower bezel, which is located
near the bottom of the instrument panel center stack
area. Two additional power outlets are also incorpo-
rated into the vehicle, one on the left rear C-pillar
trim and the other in the center console, if equipped.
The power outlets bases are secured by a snap fit in
the appropriate bezels. A hinged plug flips closed to
conceal and protect the power outlet base when the
power outlet is not being used.
The power outlet receptacle unit and the power
outlet plugs are each available for service replace-
ment.
OPERATION
The power outlet base or receptacle shell is con-
nected to ground, and an insulated contact in the
bottom of the shell is connected to battery current.
The power outlet on the instrument panel marked
with a battery receives battery voltage from a fuse in
the Integrated Power Module (IPM) at all times. The
other power outlet on the instrument panel marked
with a key receives battery voltage only when the
key is in the on position.
The power outlet located in the center console
receives battery voltage all the time when positioned
between thefront seatsand key-on voltage when
positioned between therear seats. The power outlet
located on the C-pillar receives battery voltage only
when the key is in the on position.
DIAGNOSIS AND TESTING
DIAGNOSIS & TESTING - POWER OUTLET
For complete circuit diagrams, refer toCigar
Lighter/Power Outletin Wiring Diagrams.
RS8W-97 POWER DISTRIBUTION SYSTEM8W-97-5
IOD FUSE (Continued)
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Page 1201 of 2399
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO RESTRAINTS BEFORE ATTEMPT-
ING ANY STEERING WHEEL, STEERING COLUMN,
SEAT OR INSTRUMENT PANEL COMPONENT DIAG-
NOSIS OR SERVICE. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
(1) Check the fused B(+) fuse in the Integrated
Power Module (IPM). If OK, go to Step 2. If not OK,
repair the shorted circuit or component as required
and replace the faulty fuse.
(2) Check for battery voltage at the fused B(+) fuse
in the IPM. If OK, go to Step 3. If not OK, repair the
open fused B(+) circuit to the IPM fuse as required.
(3)
Open the power outlet door. Check for continuity
between the inside circumference of the power outlet
receptacle and a good ground. There should be continu-
ity. If OK, go to Step 4. If not OK, go to Step 5.
(4) Check for battery voltage at the insulated con-
tact located at the back of the power outlet recepta-
cle. If not OK, go to Step 5.
(5) Disconnect and isolate the battery negative
cable. Remove the appropriate bezel. Check for conti-
nuity between the ground circuit cavity of the power
outlet wire harness connector and a good ground.
There should be continuity. If OK, go to Step 6. If not
OK, repair the open ground circuit to ground as
required.
(6) Connect the battery negative cable. Check for
battery voltage at the fused B(+) circuit cavity of the
power outlet wire harness connector. If OK, replace
the faulty power outlet receptacle. If not OK, repair
the open fused B(+) circuit to the IPM fuse as
required.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Look inside and note position of the retaining
bosses (Fig. 5).
(3) Using external snap ring pliers with 90 degree
tips. Insert pliers with tips against bosses and
squeeze forcing bosses out of base.
(4) Pull out the base through mounting ring by
gently rocking pliers. A tool can be made to do the
same. Refer to (Fig. 6).
(5) Disconnect the base wires.
(6) Set base aside. Remove light ring and discon-
nect wire.
INSTALLATION
(1) Position the mounting ring on the instrument
panel and feed the wires through the ring. Index the
cap and the mounting ring with the index tab at the9 o'clock position to the key in the instrument panel.
Install the ring.
(2) Connect the wires to the base. Orientate the
base alignment rib at the 11 o'clock position to mate
the groove in the mounting ring to the base.
(3) Push the base into the bezel until it locks in
place.
(4) Check operation of outlet or element and
install the 12 volt outlet cap.
Fig. 5 Outlet Base Removal
1 - RETAINING BOSSES-ENGAGE PLIERS HERE
2 - PARTIALLY REMOVED
3 - EXTERNAL SNAP-RING PLIERS
4 - PULL BASE OUT-THROUGH MOUNTING RING
Fig. 6 Tool For Outlet Removal
1 - 2.5MM (3/32 INS.)
2 - WELD
3 - 100MM (4 INS.)
4 - 22.25 TO 22.45MM (7/8 TO 57/64 INS.)
8W - 97 - 6 8W-97 POWER DISTRIBUTION SYSTEMRS
POWER OUTLET (Continued)
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Page 1256 of 2399
INSTALLATION
(1) Clean and check filter mounting surface. The
surface must be smooth, flat and free of debris or
pieces of gasket.
(2) Lubricate new oil filter gasket with clean
engine oil.
(3) Screw oil filter (Fig. 88) on until the gasket
contacts base. Tighten to 12 N´m (105 in. lbs.).
OIL PAN
REMOVAL
(1) Raise vehicle on hoist and drain engine oil.
(2) Remove structural collar. (Refer to 9 -
ENGINE/ENGINE BLOCK/STRUCTURAL COVER -
REMOVAL)
(3) Remove air conditioning compressor bracket to
oil pan bolt.
(4) Remove bolts attaching oil pan.
(5) Remove oil pan.
(6) Clean oil pan and all gasket surfaces.
INSTALLATION
(1) Apply MopartEngine RTV GEN II at the oil
pump to engine block parting line (Fig. 89).
(2) Install the oil pan gasket to the block.
(3) Install pan and tighten the screws to 12 N´m
(105 in. lbs.).
(4) Install air conditioning compressor bracket to
oil pan bolt.
(5) Install structural collar. (Refer to 9 - ENGINE/
ENGINE BLOCK/STRUCTURAL COVER - INSTAL-
LATION)
(6) Lower vehicle and fill engine crankcase with
proper oil to correct level.
OIL PRESSURE SWITCH
REMOVAL
(1) Raise vehicle.
(2) Position oil collecting container under pressure
switch location.
(3) Disconnect oil pressure switch electrical con-
nector and remove switch (Fig. 90).
INSTALLATION
(1) Install oil pressure switch. Torque switch to 21
N´m (190 in. lbs.) (Fig. 90).
(2) Connect electrical connector
(3) Lower vehicle.
(4) Start engine and allow to run a minimum of 2
minutes.
(5) Shut engine off and check engine oil level.
Adjust level as necessary.
OIL PUMP
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
REMOVAL).
(3) Remove timing belt rear cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT COVER(S)
- REMOVAL).
(4) Remove oil pan (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - REMOVAL).
(5) Remove crankshaft sprocket using Special
Tools 6793 and C-4685-C2 (Fig. 91).
(6) Remove crankshaft key (Fig. 92).
(7) Remove oil pick-up tube.
(8) Remove oil pump (Fig. 93) and front crankshaft
seal.
Fig. 89 Oil Pan Sealing - Typical
1 - SEALER LOCATIONS
Fig. 90 Engine Oil Pressure Switch
RSENGINE 2.4L9-55
OIL FILTER (Continued)
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Page 1453 of 2399
FUEL DELIVERY
DESCRIPTION
DESCRIPTION
The front wheel drive car uses a plastic fuel tank
located rear center of the vehicle.
The Fuel Delivery System consists of: the following
items:
²Electric fuel pump module
²Fuel filter
²Tubes/lines/hoses
²Fuel injectors
The in-tank fuel pump module contains the fuel
pump. The pump is serviced as part of the fuel pump
module. Refer to Fuel Pump Module.
The fuel filter is replaceable, it is mounted on the
outside, on top of, the fuel tank. Refer to the Main-
tenance Schedules in the Introduction section of this
manual for recommended fuel filter replacement
intervals.
DESCRIPTION - FFV REPLACEMENT PARTS
Many components in a Flexible Fuel Vehicle (FFV)
are designed to be compatible with ethanol. Always
be sure that the vehicle is serviced with correct etha-
nol compatible parts.
CAUTION: Replacing fuel system components with
non-ethanol compatible components can damage
your vehicle and may void the warranty.
OPERATION
The fuel system provides fuel pressure by an
in-tank pump module. The PCM controls the opera-
tion of the fuel system by providing battery voltage
to the fuel pump through the fuel pump relay. The
PCM requires only three inputs and a good ground to
operate the fuel pump relay. The three inputs are:²Ignition voltage
²Crankshaft Position (CKP) sensor
²Camshaft Position (CMP) sensor
DIAGNOSIS AND TESTING - FUEL DELIVERY
SYSTEM
(Refer to Appropriate Diagnostic Information)
STANDARD PROCEDURE
STANDARD PROCEDURE - FUEL SYSTEM
PRESSURE RELEASE PROCEDURE
(1) Remove Fuel Pump relay from Power Distribu-
tion Center (PDC). For location of relay, refer to label
on underside of PDC cover.
(2) Start and run engine until it stalls.
(3) Attempt restarting engine until it will no
longer run.
(4) Turn ignition key to OFF position.
(5) Return fuel pump relay to PDC.
(6) One or more Diagnostic Trouble Codes (DTC's)
may have been stored in PCM memory due to fuel
pump relay removal. The DRB IIItscan tool must be
used to erase a DTC.
STANDARD PROCEDURE - DRAINING FUEL
TANK
(1) Release fuel system pressure, refer to the Fuel
System Release Procedure in this section.
(2) Insert a 1/4 inch siphon (max. O. D. 5/16) hose
from a portable fuel siphoning tank through the fuel
filler neck opening into the fuel tank. Hose most
have a 30 degree angle cut on the end to bypass the
check valve in the end of the filler neck. Refer to the
siphoning tank's Manufacturing Instructions.
(3) Drain fuel from fuel tank into siphoning tank.
14 - 2 FUEL DELIVERYRS
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Page 1480 of 2399
age will be higher at colder temperatures and is
gradually reduced at warmer temperatures.
The battery temperature information is also used
for OBD II diagnostics. Certain faults and OBD II
monitors are either enabled or disabled depending
upon the battery temperature sensor input (example:
disable purge, enable LDP). Most OBD II monitors
are disabled below 20ÉF.
MAP SENSOR
DESCRIPTION
The MAP sensor (Fig. 18) or (Fig. 19) mounts to
the intake manifold. The sensor is connects electri-
cally to the PCM.
OPERATION
The MAP serves as a PCM input, using a silicon
based sensing unit, to provide data on the manifold
vacuum that draws the air/fuel mixture into the com-
bustion chamber. The PCM requires this information
to determine injector pulse width and spark advance.
When MAP equals Barometric pressure, the pulse
width will be at maximum.
Also like the cam and crank sensors, a 5 volt ref-
erence is supplied from the PCM and returns a volt-
age signal to the PCM that reflects manifold
pressure. The zero pressure reading is 0.5V and full
scale is 4.5V. For a pressure swing of0Ð15psithe
voltage changes 4.0V. The sensor is supplied a regu-
lated 4.8 to 5.1 volts to operate the sensor. Like the
cam and crank sensors ground is provided through
the sensor return circuit.
The MAP sensor input is the number one contrib-
utor to pulse width. The most important function of
the MAP sensor is to determine barometric pressure.
The PCM needs to know if the vehicle is at sea level
or is it in Denver at 5000 feet above sea level,
because the air density changes with altitude. It will
also help to correct for varying weather conditions. If
a hurricane was coming through the pressure would
be very, very low or there could be a real fair
weather, high pressure area. This is important
because as air pressure changes the barometric pres-
sure changes. Barometric pressure and altitude have
a direct inverse correlation, as altitude goes up baro-
metric goes down. The first thing that happens as
the key is rolled on, before reaching the crank posi-
tion, the PCM powers up, comes around and looks at
the MAP voltage, and based upon the voltage it sees,
it knows the current barometric pressure relative to
altitude. Once the engine starts, the PCM looks at
the voltage again, continuously every 12 milliseconds,
and compares the current voltage to what it was at
key on. The difference between current and what it
was at key on is manifold vacuum.
During key On (engine not running) the sensor
reads (updates) barometric pressure. A normal range
can be obtained by monitoring known good sensor in
you work area.
As the altitude increases the air becomes thinner
(less oxygen). If a vehicle is started and driven to a
very different altitude than where it was at key On
the barometric pressure needs to be updated. Any
time the PCM sees Wide Open throttle, based upon
TPS angle and RPM it will update barometric pres-
sure in the MAP memory cell. With periodic updates,
the PCM can make its calculations more effectively.
The PCM uses the MAP sensor to aid in calculat-
ing the following:
²Barometric pressure
²Engine load
Fig. 18 MAP SENSOR - 2.4L
Fig. 19 MAP SENSOR - 3.3/3.8L
RSFUEL INJECTION14-29
INLET AIR TEMPERATURE SENSOR (Continued)
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Page 1497 of 2399
(6) Using special tool VM.1055 (Fig. 7), torque
injection pump sprocket retaining nut to 88.3N´m.
(7) Connect fuel pressure solenoid electrical con-
nector (Fig. 11).
(8) Connect fuel supply and return lines at injec-
tion pump (Fig. 11).
(9) Install generator (Fig. 11)(Refer to 8 - ELEC-
TRICAL/CHARGING/GENERATOR - INSTALLA-
TION).(10) Install outer timing belt cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(11) Install right engine mount assembly.
(12) Install accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(13) Install power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(14) Install air cleaner housing assembly.
(15) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
(16) Connect negative battery cable.
WATER IN FUEL SENSOR
DESCRIPTION
The WIF sensor is located in the bowl assembly of
the fuel filter/water separator.
OPERATION
The sensor sends an input to the Engine Control
Module (ECM) when it senses water in the fuel filter/
water separator. As the water level in the filter/sep-
arator increases, the resistance across the WIF
sensor decreases. This decrease in resistance is sent
as a signal to the ECM and compared to a high
water standard value. Once the value reaches 30 to
40 kilohms, the ECM will activate the water-in-fuel
warning lamp through CCD bus circuits. This all
takes place when the ignition key is initially put in
the ON position. The ECM continues to monitor the
input at the end of the intake manifold air heater
post-heat cycle.
Fig. 11 FUEL INJECTION PUMP LOCATION
1 - CYLINDER HEAD COVER/INTAKE MANIFOLD
2 - INJECTION PUMP
3 - FUEL PRESSURE SOLENOID
4 - ACCESSORY MOUNTING BRACKET
5 - GENERATOR
14a - 10 FUEL DELIVERYRG
FUEL INJECTION PUMP (Continued)
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