display CHRYSLER CARAVAN 2002 Service Manual

FASTENER USAGE
DESCRIPTION
DESCRIPTION - FASTENER USAGE
WARNING: USE OF AN INCORRECT FASTENER
MAY RESULT IN COMPONENT DAMAGE OR PER-
SONAL INJURY.
Fasteners and torque specifications references in
this Service Manual are identified in metric and SAE
format.
During any maintenance or repair procedures, it is
important to salvage all fasteners (nuts, bolts, etc.)
for reassembly. If the fastener is not salvageable, a
fastener of equivalent specification must be used.
DESCRIPTION - THREADED HOLE REPAIR
Most stripped threaded holes can be repaired using
a Helicoilt. Follow the vehicle or Helicoiltrecommen-
dations for application and repair procedures.
INTERNATIONAL SYMBOLS
DESCRIPTION
The graphic symbols illustrated in the following
International Control and Display Symbols Chart
(Fig. 4) are used to identify various instrument con-
trols. The symbols correspond to the controls and dis-
plays that are located on the instrument panel.
Fig. 4 INTERNATIONAL CONTROL AND DISPLAY SYMBOLS
1 High Beam 13 Rear Window Washer
2 Fog Lamps 14 Fuel
3 Headlamp, Parking Lamps, Panel Lamps 15 Engine Coolant Temperature
4 Turn Warning 16 Battery Charging Condition
5 Hazard Warning 17 Engine Oil
6 Windshield Washer 18 Seat Belt
7 Windshield Wiper 19 Brake Failure
8 Windshield Wiper and Washer 20 Parking Brake
9 Windscreen Demisting and Defrosting 21 Front Hood
10 Ventilating Fan 22 Rear hood (Decklid)
11 Rear Window Defogger 23 Horn
12 Rear Window Wiper 24 Lighter
RSINTRODUCTION5
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(5) Install wiring harness connector to brake fluid
level switch mounted in brake fluid reservoir (Fig.
57).
(6) Install battery, clamp and nut.
(7) Install battery shield.
(8) Connect positive battery terminal.
(9) Connect negative battery terminal.
(10) Fill master cylinder with clean, fresh Mopart
Brake Fluid or equivalent.
(11) Road test vehicle to ensure proper operation of
brakes.
INSTALLATION - RHD
CAUTION: Different types of master cylinders are
used on this vehicle depending on brake options. If
a new master cylinder is being installed, be sure it
is the correct master cylinder for the type of brake
system the vehicle is equipped with.
CAUTION: When replacing the master cylinder on a
vehicle, a NEW vacuum seal MUST be installed on
the master cylinder.
(1) Install a NEW vacuum seal on master cylinder
making sure seal fits squarely in groove of master
cylinder casting.
(2) Position master cylinder on studs of power
brake booster, aligning booster push rod with master
cylinder piston.
(3) Install the two master cylinder mounting nuts
(Fig. 59). Tighten both mounting nuts to a torque of
25 N´m (225 in. lbs.).
CAUTION: When tightening the primary and sec-
ondary brake tube nuts at master cylinder, be sure
brake tubes do not contact any other components
within the vehicle and that there is slack in the flex-
ible sections of the tubes. This is required due to
the movement between the ABS ICU and the master
cylinder while the vehicle is in motion.
(4) Connect primary and secondary brake tubes to
master cylinder primary and secondary ports (Fig.
59). Brake tubes must be held securely when tight-
ened to control orientation of flex section. Tighten
tube nuts to a torque of 17 N´m (145 in. lbs.).
(5) Install wiring harness connector to brake fluid
level switch mounted in brake fluid reservoir (Fig.
55).
(6) Install battery, clamp and nut.
(7) Install battery shield.
(8) Connect positive battery terminal.
(9) Connect negative battery terminal.
(10) Fill master cylinder with clean, fresh Mopart
Brake Fluid or equivalent.(11) Road test vehicle to ensure proper operation of
brakes.
PEDAL - ADJUSTABLE
DESCRIPTION
The Adjustable Pedals System (APS) is designed to
enable the fore and aft repositioning of the brake and
accelerator pedals. This results in improved ergonom-
ics in relation to the steering wheel for taller and
shorter drivers. Being able to adjust the pedal posi-
tions also allows the driver to set steering wheel tilt
and seat position to the most comfortable position.
The effort required for pedal application will not
change regardless of pedal position.
The adjustable pedal system allows the pedals to
adjust up to 3 inches (75 mm) at a rate of approxi-
mately 0.4 in./sec. (9 mm/sec.). An adjustment switch
is located on the left side of the steering column
lower shroud.
If the vehicle is equipped with Remote Keyless
Entry (RKE), an optional memory feature is avail-
able.
The serviceable components of the APS are:
²Adjustable pedal assembly (includes motor,
cables, pedals, gear box, sensor and module)
²Adjustable pedal module (Refer to 8 - ELECTRI-
CAL/ELECTRONIC CONTROL MODULES/
ADJUSTABLE PEDAL MODULE)
²Adjustable pedal switch
²Pedal position sensor
OPERATION
Change of pedal position is accomplished by means
of a motor driven screw. Operating the adjustable
pedal switch activates the pedal drive motor. The
pedal drive motor turns a screw that changes the
position of the accelerator pedal. The motor also
drives a cable connected to a gear box that changes
the brake pedal position the same distance as the
accelerator pedal. The pedals can be moved rearward
(closer to the driver) or forward (away from driver).
Each pedal is moved on its activating lever to a posi-
tion where the driver feels most comfortable. The
position and operation of the activating levers are not
changed.
Pedal adjustment is inhibited when the vehicle is
in reverse or when cruise control is engaged. The
Electronic Vehicle Information Center (EVIC) will
display a message when the Adjustable Pedal Module
(APM) is disabled. i.e.:9Adjustable Pedal Disabled -
Cruise Control Engaged9or9Adjustable Pedal Dis-
abled - Vehicle in Reverse9.
Foot pressure or debris can stall pedal adjustment.
In order to avoid damage to system components dur-
5 - 42 BRAKES - BASERS
MASTER CYLINDER (Continued)
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DESCRIPTION - ELECTRONIC VARIABLE
BRAKE PROPORTIONING
Vehicles equipped with ABS use electronic variable
brake proportioning (EVBP) to balance front-to-rear
braking. The EVBP is used in place of a rear propor-
tioning valve. The EVBP system uses the ABS sys-
tem to control the slip of the rear wheels in partial
braking range. The braking force of the rear wheels
is controlled electronically by using the inlet and out-
let valves located in the integrated control unit
(ICU).
DESCRIPTION - TRACTION CONTROL SYSTEM
Traction control reduces wheel slip and maintains
traction at the driving wheels at speeds below 56
km/h (35 mph) when road surfaces are slippery. The
traction control system reduces wheel slip by braking
the wheel that is losing traction.
HYDRAULIC SHUTTLE VALVES
Two pressure relief hydraulic shuttle valves are
included on vehicles with traction control. These
valves are located inside the HCU and cannot be ser-
viced separately from the HCU.
TRACTION CONTROL LAMP
The traction control function lamp is located in the
transmission range indicator display of the instru-
ment cluster, displaying TRAC, TRAC OFF or nei-
ther depending on system mode.
The TRAC OFF lamp is controlled by a Traction
Control Off switch that is a momentary contact type
switch. The Traction Control Off switch is located on
the steering column upper shroud.
OPERATION
OPERATION - ANTILOCK BRAKE SYSTEM
There are a few performance characteristics of the
Mark 20e Antilock Brake System that may at first
seem abnormal, but in fact are normal. These char-
acteristics are described below.
NORMAL BRAKING
Under normal braking conditions, the ABS func-
tions the same as a standard base brake system with
a diagonally split master cylinder and conventional
vacuum assist.
ABS BRAKING
ABS operation is available at all vehicle speeds
above 3±5 mph. If a wheel locking tendency is
detected during a brake application, the brake sys-
tem enters the ABS mode. During ABS braking,
hydraulic pressure in the four wheel circuits is mod-ulated to prevent any wheel from locking. Each
wheel circuit is designed with a set of electric sole-
noids to allow modulation, although for vehicle sta-
bility, both rear wheel solenoids receive the same
electrical signal. Wheel lockup may be perceived at
the very end of an ABS stop and is considered nor-
mal.
During an ABS stop, the brakes hydraulic system
is still diagonally split. However, the brake system
pressure is further split into three control channels.
During antilock operation of the vehicle's brake sys-
tem, the front wheels are controlled independently
and are on two separate control channels, and the
rear wheels of the vehicle are controlled together.
The system can build and release pressure at each
wheel, depending on signals generated by the wheel
speed sensors (WSS) at each wheel and received at
the controller antilock brake (CAB).
NOISE AND BRAKE PEDAL FEEL
During ABS braking, some brake pedal movement
may be felt. In addition, ABS braking will create
ticking, popping, or groaning noises heard by the
driver. This is normal and is due to pressurized fluid
being transferred between the master cylinder and
the brakes. If ABS operation occurs during hard
braking, some pulsation may be felt in the vehicle
body due to fore and aft movement of the suspension
as brake pressures are modulated.
At the end of an ABS stop, ABS is turned off when
the vehicle is slowed to a speed of 3±4 mph. There
may be a slight brake pedal drop anytime that the
ABS is deactivated, such as at the end of the stop
when the vehicle speed is less than 3 mph or during
an ABS stop where ABS is no longer required. These
conditions exist when a vehicle is being stopped on a
road surface with patches of ice, loose gravel, or sand
on it. Also, stopping a vehicle on a bumpy road sur-
face activates ABS because of the wheel hop caused
by the bumps.
TIRE NOISE AND MARKS
Although the ABS system prevents complete wheel
lockup, some wheel slip is desired in order to achieve
optimum braking performance. Wheel slip is defined
as follows: 0 percent slip means the wheel is rolling
freely and 100 percent slip means the wheel is fully
locked. During brake pressure modulation, wheel slip
is allowed to reach up to 25±30 percent. This means
that the wheel rolling velocity is 25±30 percent less
than that of a free rolling wheel at a given vehicle
speed. This slip may result in some tire chirping,
depending on the road surface. This sound should not
be interpreted as total wheel lockup.
Complete wheel lockup normally leaves black tire
marks on dry pavement. The ABS will not leave dark
5 - 86 BRAKES - ABSRS
BRAKES - ABS (Continued)
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black tire marks since the wheel never reaches a
fully locked condition. However, tire marks may be
noticeable as light patched marks.
START-UP CYCLE
When the ignition is turned on, a popping sound
and a slight brake pedal movement may be noticed.
The ABS warning lamp will also be on for up to 5
seconds after the ignition is turned on. When the
vehicle is first driven off, a humming may be heard
or felt by the driver at approximately 20±40 kph
(12±25 mph). All of these conditions are a normal
function of ABS as the system is performing a diag-
nosis check.
PREMATURE ABS CYCLING
Symptoms of premature ABS cycling include: click-
ing sounds from the solenoid valves; pump/motor
running; and pulsations in the brake pedal. Prema-
ture ABS cycling can occur at any braking rate of the
vehicle and on any type of road surface. Neither the
red BRAKE warning lamp, nor the amber ABS warn-
ing lamp, illuminate and no fault codes are stored in
the CAB.
Premature ABS cycling is a condition that needs to
be correctly assessed when diagnosing problems with
the antilock brake system. It may be necessary to use
a DRB scan tool to detect and verify premature ABS
cycling.
Check the following common causes when diagnos-
ing premature ABS cycling: damaged tone wheels;
incorrect tone wheels; damaged steering knuckle
wheel speed sensor mounting bosses; loose wheel
speed sensor mounting bolts; excessive tone wheel
runout; or an excessively large tone wheel-to-wheel
speed sensor air gap. Give special attention to these
components when diagnosing a vehicle exhibiting
premature ABS cycling.
After diagnosing the defective component, repair or
replace it as required. When the component repair or
replacement is completed, test drive the vehicle to
verify that premature ABS cycling has been cor-
rected.
OPERATION - ELECTRONIC VARIABLE BRAKE
PROPORTIONING
Upon entry into EVBP the inlet valve for the rear
brake circuit is switched on so that the fluid supply
from the master cylinder is shut off. In order to
decrease the rear brake pressure, the outlet valve for
the rear brake circuit is pulsed. This allows fluid to
enter the low pressure accumulator (LPA) in the
hydraulic control unit (HCU) resulting in a drop in
fluid pressure to the rear brakes. In order to increase
the rear brake pressure, the outlet valve is switched
off and the inlet valve is pulsed. This increases thepressure to the rear brakes. This back-and-forth pro-
cess will continue until the required slip difference is
obtained. At the end of EVBP braking (brakes
released) the fluid in the LPA drains back to the
master cylinder by switching on the outlet valve and
draining through the inlet valve check valve. At the
same time the inlet valve is switched on in case of
another brake application.
The EVBP will remain functional during many
ABS fault modes. If both the red BRAKE and amber
ABS warning indicators are illuminated, the EVBP
may not be functioning.
OPERATION - TRACTION CONTROL SYSTEM
The traction control module monitors wheel speed.
During acceleration, if the module detects front
(drive) wheel slip and the brakes are not applied, the
module enters traction control mode. Traction control
operation proceeds in the following order:
(1) Close the normally open isolation valves.
(2) Start the pump/motor and supply volume and
pressure to the front (drive) hydraulic circuit. (The
pump/motor runs continuously during traction con-
trol operation.)
(3) Open and close the build and decay valves to
maintain minimum wheel slip and maximum trac-
tion.
The cycling of the build and decay valves during
traction control is similar to that during antilock
braking, except the valves work to control wheel spin
by applying the brakes, whereas the ABS function is
to control wheel skid by releasing the brakes.
If the brakes are applied at anytime during a trac-
tion control cycle, the brake lamp switch triggers the
controller to switch off traction control.
HYDRAULIC SHUTTLE VALVES
Two pressure relief hydraulic shuttle valves allow
pressure and volume to return to the master cylinder
reservoir when not consumed by the build and decay
valves. These valves are necessary because the
pump/motor supplies more volume than the system
requires.
TRACTION CONTROL LAMP
The traction control system is enabled at each igni-
tion cycle. It may be turned off by depressing the
Traction Control Off switch button when the ignition
is in the ON position. The traction control function
lamp (TRAC OFF) illuminates immediately upon
depressing the button.
The traction control function lamp illuminates dur-
ing a traction control cycle, displaying TRAC.
If the CAB calculates that the brake temperatures
are high, the traction control system becomes inoper-
ative until a time-out period has elapsed. During this
RSBRAKES - ABS5-87
BRAKES - ABS (Continued)
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The ABS portion of the brake system must be bled
separately. Use the following procedure to properly
bleed the brake hydraulic system including the ABS.
BLEEDING
When bleeding the ABS system, the following
bleeding sequence must be followed to insure com-
plete and adequate bleeding.
(1) Make sure all hydraulic fluid lines are installed
and properly torqued.
(2) Connect the DRBIIItscan tool to the diagnos-
tics connector. The diagnostic connector is located
under the lower steering column cover to the left of
the steering column.
(3) Using the DRB, check to make sure the CAB
does not have any fault codes stored. If it does, clear
them using the DRB.
WARNING: WHEN BLEEDING THE BRAKE SYSTEM
WEAR SAFETY GLASSES. A CLEAR BLEED TUBE
MUST BE ATTACHED TO THE BLEEDER SCREWS
AND SUBMERGED IN A CLEAR CONTAINER FILLED
PART WAY WITH CLEAN BRAKE FLUID. DIRECT
THE FLOW OF BRAKE FLUID AWAY FROM YOUR-
SELF AND THE PAINTED SURFACES OF THE VEHI-
CLE. BRAKE FLUID AT HIGH PRESSURE MAY
COME OUT OF THE BLEEDER SCREWS WHEN
OPENED.
(4) Bleed the base brake system using the stan-
dard pressure or manual bleeding procedure. (Refer
to 5 - BRAKES - BASE - STANDARD PROCEDURE)
(5) Using the DRB, select ANTILOCK BRAKES,
followed by MISCELLANEOUS, then BLEED
BRAKES. Follow the instructions displayed. When
the scan tool displays TEST COMPLETED, discon-
nect the scan tool and proceed.
(6) Bleed the base brake system a second time.
Check brake fluid level in the reservoir periodically
to prevent emptying, causing air to enter the hydrau-
lic system.
(7) Fill the master cylinder reservoir to the full
level.
(8) Test drive the vehicle to be sure the brakes are
operating correctly and that the brake pedal does not
feel spongy.
SPECIFICATIONS
ABS FASTENER TORQUE
(Refer to 5 - BRAKES - BASE - SPECIFICA-
TIONS)
TONE WHEEL RUNOUT
DESCRIPTION SPECIFICATION
Front Tone Wheel
Maximum Runout0.15 mm (0.006 in.)
Rear Tone Wheel
Maximum Runout0.15 mm (0.006 in.)
WHEEL SPEED SENSOR AIR GAP
DESCRIPTION SPECIFICATION
Front Sensor0.35 ± 1.20 mm
0.014 ± 0.047 in.
Rear Sensor0.40 ± 1.20 mm
0.016 ± 0.047 in.
FRONT WHEEL SPEED
SENSOR
REMOVAL
(1) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(2) Remove the tire and wheel assembly.
(3) Remove the sensor cable routing clamp screws.
CAUTION: When disconnecting the wheel speed
sensor from vehicle wiring harness, be careful not
to damage pins on connector
(4) Remove speed sensor cable grommets from
intermediate bracket on strut.
(5) Disconnect speed sensor cable from vehicle wir-
ing harness behind fender well shield.
(6) Remove the wheel speed sensor head mounting
bolt (Fig. 1).
(7) Remove sensor head from steering knuckle. If
sensor has seized due to corrosion,DO NOT USE
PLIERS ON SENSOR HEAD.Use a hammer and a
punch and tap edge of sensor ear, rocking the sensor
side-to-side until free.
(8) Remove front wheel speed sensor from vehicle.
INSTALLATION
CAUTION: Proper installation of wheel speed sen-
sor cables is critical to continued system operation.
Be sure that cables are installed in retainers. Fail-
ure to install cables in retainers as shown in this
section may result in contact with moving parts and
over extension of cables, resulting in an open cir-
cuit.
RSBRAKES - ABS5-89
BRAKES - ABS (Continued)
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CONDITION POSSIBLE CAUSES CORRECTIONS
BELT ROLLED OVER IN GROOVE
OR BELT JUMPS OFF1. Broken cord in belt 1. Replace belt
2. Belt too loose, or too tight 2. (a) Replace belt (auto-tensioned
belts.)
(b) Adjust power steering belt
tension (4 cyl. engine)
3. Misaligned pulleys 3. Align accessories
4. Non-uniform groove or eccentric
pulley4. Replace pulley
DRIVE BELTS - 2.4L
STANDARD PROCEDURE - CHECKING POWER
STEERING BELT TENSION
WARNING: DO NOT CHECK BELT TENSION WITH
ENGINE RUNNING.
Accessory drive belt tension can be measured with
Special Tool 8371 ± Belt Tension Gauge Adapter, and
the DRBIIItusing the following procedures:
(1) Connect 8371 to the DRBIIItfollowing the
instructions provided with tool.
(2) Place end of microphone probe approximately
2.54 cm (1 in.) from belt at belt center span location
shown in (Fig. 3).
(3) Pluck the belt a minimum of 3 times. (Use your
finger or other suitable tool) The frequency of the
belt in hertz (Hz) will display on DRBIIItscreen.
(4) Adjust belt to obtain proper frequency (ten-
sion). Refer to ACCESSORY DRIVE BELT TENSION
CHART for belt tension specifications.
ACCESSORY DRIVE BELT TENSION CHART -
2.4L
Accessory Drive Belt Belt Tension
Air Conditioning
Compressor/GeneratorDynamic Tensioner
Power Steering PumpNew183 - 218
Hz
Used* 150 - 183
Hz
*A belt is considered used after 15 minutes of run-in
time.
REMOVAL
GENERATOR AND AIR CONDITIONING BELT
(1) Raise vehicle on hoist.
(2) Remove the drive belt shield (Fig. 8).WARNING: DO NOT ALLOW DRIVE BELT TEN-
SIONER TO SNAP BACK, AS DAMAGE TO TEN-
SIONER AND/OR PERSONAL INJURY COULD
RESULT.
(3) Position a wrench on the belt tensioner lug
(Fig. 4).
(4) Release belt tension by rotating the tensioner
clockwise (Fig. 4).
(5) Remove belt.
(1) Carefully return tensioner to its relaxed posi-
tion.
POWER STEERING PUMP
(1) From top of the vehicle, loosen locking nuts (D)
and (F) (Fig. 5).
Fig. 3 Power Steering Belt - Center Span Location
1 - POWER STEERING BELT CENTER SPAN LOCATION
7 - 10 ACCESSORY DRIVERS
DRIVE BELTS (Continued)
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information and location views for the various wire
harness connectors, splices and grounds.
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 FAULTY. 1. CHECK RADIO FUSES IN FUSE BLOCK MODULE.
REPLACE FUSES, IF REQUIRED.
2. RADIO CONNECTOR
FAULTY.2. CHECK FOR LOOSE OR CORRODED RADIO CONNECTOR.
REPAIR, IF REQUIRED.
3. WIRING FAULTY. 3. CHECK FOR BATTERY VOLTAGE AT RADIO CONNECTOR.
REPAIR WIRING, IF REQUIRED.
4. GROUND FAULTY. 4. CHECK FOR CONTINUITY BETWEEN RADIO CHASSIS AND
A KNOWN GOOD GROUND. THERE SHOULD BE
CONTINUITY. REPAIR GROUND, IF REQUIRED.
5. RADIO FAULTY. 5. EXCHANGE OR REPLACE RADIO, IF REQUIRED.
6. SPEAKERS FAULTY. 6. SEE SPEAKER DIAGNOSIS, IN THIS GROUP.
NO DISPLAY. 1. FUSE FAULTY. 1. CHECK RADIO FUSES IN FUSE BLOCK MODULE.
REPLACE FUSES, IF REQUIRED.
2. RADIO CONNECTOR
FAULTY.2. CHECK FOR LOOSE OR CORRODED RADIO CONNECTOR.
REPAIR, IF REQUIRED.
3. WIRING FAULTY. 3. CHECK FOR BATTERY VOLTAGE AT RADIO CONNECTOR.
REPAIR WIRING, IF REQUIRED.
4. GROUND FAULTY. 4. CHECK FOR CONTINUITY BETWEEN RADIO CHASSIS AND
A KNOWN GOOD GROUND. THERE SHOULD BE
CONTINUITY. REPAIR GROUND, IF REQUIRED.
5. RADIO FAULTY. 5. EXCHANGE OR REPLACE RADIO, IF REQUIRED.
NO MEMORY. 1. FUSE FAULTY. 1. CHECK IGNITION-OFF DRAW FUSE. REPLACE FUSE, IF
REQUIRED.
2. RADIO CONNECTOR
FAULTY.2. CHECK FOR LOOSE OR CORRODED RADIO CONNECTOR.
REPAIR, IF REQUIRED.
3. WIRING FAULTY. 3. CHECK FOR BATTERY VOLTAGE AT RADIO CONNECTOR.
REPAIR WIRING, IF REQUIRED.
4. GROUND FAULTY. 4. CHECK FOR CONTINUITY BETWEEN RADIO CHASSIS AND
A KNOWN GOOD GROUND. THERE SHOULD BE
CONTINUITY. REPAIR GROUND, IF REQUIRED.
5. RADIO FAULTY. 5. EXCHANGE OR REPLACE RADIO, IF REQUIRED.
POOR RADIO
RECEPTION.1. ANTENNA FAULTY. 1. SEE ANTENNA DIAGNOSIS, IN THIS GROUP. REPAIR OR
REPLACE ANTENNA, IF REQUIRED.
8A - 2 AUDIORS
AUDIO (Continued)
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REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Lower headliner as necessary to access
antenna module (Fig. 5).
(3) Disconnect antenna coax cable lead and electri-
cal harness connector from antenna module.
(4) Disconnect the antenna module connector from
the quarter glass.
(5) Remove the mounting screw and the antenna
module.
INSTALLATION
(1) Install the antenna module and the mounting
fastener.
(2) Connect the antenna connector to the quarter
glass.
(3) Connect the antenna lead and electrical con-
nector to the antenna module.
(4) Raise and install headliner.
(5) Connect the battery negative cable.
CD CHANGER
DESCRIPTION
The 4 Disc In-Dash CD Changer (if equipped) is
located in the instrument panel below the radio. The
remote changer does not use a cartridge or magazine
for the CD's. Up to 4 CD's can be directly loaded into
this unit.
OPERATION
Due to its compact design, the CD changer can
carry out only one operation at a time. For example,you can not load a new disc while playing another at
the same time. Each operation happens sequentially.
The radio unit provides control over all features of
the CD changer with the exception of the CD load
and eject functions, which are controlled by buttons
located on the front of the CD changer. All features
you would expect, such as Disc Up/Down, Track
Up/Down, Random and Scan are controlled by the
radio, which also displays all relevant CD changer
information on the radio display.
The CD changer contains a Load/Eject button and
an indicator LED for each of the four disc positions
as well as an illuminated disc opening. The individ-
ual LED indicates whether a CD is currently loaded
in that particular chamber of the CD changer. Press-
ing the individual Load/Eject button for a particular
chamber will eject a disc currently present in that
chamber. If the chamber is currently empty, actuat-
ing the Load/Eject button will position that chamber
to receive and load a new disc in that chamber.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove screws holding CD changer.
(3) Disconnect the wire connector from the back of
the CD changer.
(4) Remove the CD changer from the vehicle (Fig.
6).
INSTALLATION
(1) Reconnect the wire connector to the CD
changer.
(2) Insert the CD changer into the instrument
panel.
Fig. 5 ANTENNA MODULE
1 - ANTENNA MODULE
2 - ANTENNA MODULE CONNECTOR
Fig. 6 CD - CHANGER
1 - CD-CHANGER
2 - POWER OUTLET
RSAUDIO8A-7
ANTENNA MODULE - EXPORT (Continued)
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ignition switch. This chime will operate for all igni-
tion positions except ON and START.
With the ignition switch in the OFF position
O N LY:
²Driver's door is open/ajar (door ajar switch is
closed to ground)
²Key is in the ignition switch (ignition is in the
LOCK position)
The chime will sound until one of the above condi-
tions is removed or until battery protection time out
(15 min.) has expired. Chime rate: 168 to 192 chimes
per minute.
To test the key-in ignition function, insert key into
the ignition and open drivers door. Do not turn igni-
tion ON. Chime should sound until key is removed
from ignition or drivers door is closed.
For diagnosis and testing of the Key-In chime for
other ignition positions, use the same testing proce-
dure as above but with the key in the accessory or
unlock position.
DIAGNOSIS AND TESTING - LOW OIL
PRESSURE CHIME
The low oil pressure chime will warn the driver
that the engine oil pressure is low. The oil pressure
switch will close to ground during a low oil pressure
condition. The oil pressure lamp will illuminate in
the message center. The PCM will monitor the oil
pressure switch and signal a low oil pressure condi-
tion. A continuous four minute warning chime will
sound and the oil pressure lamp will come ON when
the following conditions are met:
²Ignition on and engine not cranking
²Engine running at 420 to 480 rpm for 10 sec-
onds
²Oil pressure switch closed to ground for (1 sec-
ond minimum, 2 seconds maximum)
Chime rate: 168 to 192 chimes per minute.
DIAGNOSIS AND TESTING - SEAT BELT CHIME
The seat belt chime will sound for 4 to 8 seconds,
when the ignition is turned on and the driver's seat
belt is not buckled (seat belt switch is closed to
ground). This is a reminder to the driver to buckle
the seat belt. The seat belt lamp is controlled by the
ORC. The cluster will also bulb check the seat belt
warning lamp for 6 seconds. Buckling the driver's
seat belt before the time out has expired will cause
the chime to stop immediately. Chime rate: 38 to 62
chimes per minute but the lamp will remain on until
6 seconds have expired.
To test the seat belt warning system, the ignition
switch must be in the OFF position for 1 minute
before starting the test. Turn the ignition switch to
the on position with the driver's seat belt not buck-led. The seat belt warning lamp should light and the
chime should sound 4 to 8 seconds.
DIAGNOSIS AND TESTING - SEAT BELT LAMP
The seat belt lamp in the instrument cluster sig-
nals the vehicle passengers to fasten their seat belts.
The seat belt lamp is illuminated directly by the
instrument cluster for 6 seconds after the instrument
cluster receives the message from the ORC. The seat
belt lamp is therefore illuminated for 6 seconds
whenever the ignition switch is moved to run/start
position.
(1) While ignition is off, the seat belt lamp will not
be illuminated.
(2) The ignition power feed status will be updated
every 250 milliseconds or on change.
(3) This lamp will be checked by the instrument
cluster for 6 seconds with every run/start cycle of the
ignition switch.
DIAGNOSIS AND TESTING - TIRE PRESSURE
MONITOR
The Tire Pressure Warning chime, as well as the
information being displayed in the EVIC, will act as
a warning to the driver that a tire has either Low or
High pressure, or if there is a need to service the
Tire Pressure Monitor System. With the ignition
switch in the ON position and the ªLow Pressure/
High Pressureº or ªService the TPM Systemº dis-
played on the EVIC display, a single chime will
sound.
DIAGNOSIS AND TESTING - TURN SIGNAL ON
CHIME
The turn signal on chime will warn the driver that
the turn signals have been left on. When the body
control module receives a turn signal input for 1.0
mile, vehicle speed is greater than 24 km/h (15 mph),
the chime will sound continuously until the turn sig-
nal is turned OFF. If vehicle speed drops below 24
km/h (15 mph) prior to the warning being activated,
the accumulated distance traveled will be reset. The
turn signal chime is not activated when the emer-
gency flashers are turned on. Chime rate: 50   12
chimes per minute.
For the turn signal warning system to operate:
²Must have input from either the right or left
turn signal lamps. Creates a voltage change between
0 and battery voltage.
²The vehicle speed sensor sends a message to the
Powertrain Control Module that vehicle has exceeded
24 km/h (15 mph) for 1.0 mile).
²When the above two conditions are met, the
chime will sound. The chime will stop when no fur-
ther voltage change is detected.
RSCHIME/BUZZER8B-3
CHIME/BUZZER (Continued)
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ELECTRONIC CONTROL
MODULES
STANDARD PROCEDURE - PCM/SKIM
PROGRAMMING
NOTE: Before replacing the PCM for a failed driver,
control circuit or ground circuit, be sure to check
the related component/circuit integrity for failures
not detected due to a double fault in the circuit.
Most PCM driver/control circuit failures are caused
by internal component failures (i.e. relay and sole-
noids) and shorted circuits (i.e. pull-ups, drivers
and switched circuits). These failures are difficult to
detect when a double fault has occurred and only
one DTC has set.
When a PCM (SBEC) and the SKIM are replaced
at the same time perform the following steps in
order:
(1) Program the new PCM (SBEC)
(2) Program the new SKIM
(3) Replace all ignition keys and program them to
the new SKIM.
PROGRAMMING THE PCM (SBEC)
The SKIS Secret Key is an ID code that is unique
to each SKIM. This code is programmed and stored
in the SKIM, PCM and transponder chip (ignition
keys). When replacing the PCM it is necessary to
program the secret key into the new PCM using the
DRB III. Perform the following steps to program the
secret key into the PCM.
(1) Turn the ignition switch on (transmission in
park/neutral).
(2) Use the DRB III and select THEFT ALARM,
SKIM then MISCELLANEOUS.
(3) Select PCM REPLACED (GAS ENGINE).
(4) Enter secured access mode by entering the
vehicle four-digit PIN.
(5) Select ENTER to update PCM VIN.
NOTE: If three attempts are made to enter secure
access mode using an incorrect PIN, secured
access mode will be locked out for one hour. To
exit this lockout mode, turn the ignition to the RUN
position for one hour then enter the correct PIN.
(Ensure all accessories are turned off. Also monitor
the battery state and connect a battery charger if
necessary).
(6) Press ENTER to transfer the secret key (the
SKIM will send the secret key to the PCM).
(7) Press Page Back to get to the Select System
menu and select ENGINE, MISCELLANEOUS, and
SRI MEMORY CHECK.(8) The DRB III will ask, Is odometer reading
between XX and XX? Select the YES or NO button on
the DRB III. If NO is selected, the DRB III will read,
Enter odometer Reading. Enter
the odometer reading from the Instrument Panel and
press ENTER.
PROGRAMMING THE SKIM
(1) Turn the ignition switch on (transmission in
park/neutral).
(2) Use the DRB III and select THEFT ALARM,
SKIM then MISCELLANEOUS.
(3) Select PCM REPLACED (GAS ENGINE).
(4) Program the vehicle four-digit PIN into SKIM.
(5) Select COUNTRY CODE and enter the correct
country.
NOTE: Be sure to enter the correct country code. If
the incorrect country code is programmed into
SKIM, the SKIM must be replaced.
(6) Select YES to update VIN (the SKIM will learn
the VIN from the PCM).
(7) Press ENTER to transfer the secret key (the
PCM will send the secret key to the SKIM).
(8) Program ignition keys to SKIM.
NOTE: If the PCM and the SKIM are replaced at the
same time, all vehicle keys will need to be replaced
and programmed to the new SKIM.
PROGRAMMING IGNITION KEYS TO THE SKIM
(1) Turn the ignition switch on (transmission in
park/neutral).
(2) Use the DRB III and select THEFT ALARM,
SKIM then MISCELLANEOUS.
(3) Select PROGRAM IGNITION KEY'S.
(4) Enter secured access mode by entering the
vehicle four-digit PIN.
NOTE: A maximum of eight keys can be learned to
each SKIM. Once a key is learned to a SKIM it (the
key) cannot be transferred to another vehicle.
If ignition key programming is unsuccessful, the
DRB III will display one of the following messages:
Programming Not Attempted - The DRB III
attempts to read the programmed key status and
there are no keys programmed into SKIM memory.
Programming Key Failed (Possible Used Key From
Wrong Vehicle) - SKIM is unable to program key due
to one of the following:
²faulty ignition key transponder
²ignition key is programmed to another vehicle.
8 Keys Already Learned, Programming Not Done -
SKIM transponder ID memory is full.
8E - 2 ELECTRONIC CONTROL MODULESRS
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