hood release CHRYSLER CARAVAN 2003 User Guide
[x] Cancel search | Manufacturer: CHRYSLER, Model Year: 2003, Model line: CARAVAN, Model: CHRYSLER CARAVAN 2003Pages: 2177, PDF Size: 59.81 MB
Page 545 of 2177
SWITCH
DESCRIPTION
There are two separate switch pods that operate
the speed control system and are located on the
steering wheel.
OPERATION
The speed control system has five separate resis-
tive switches that provide a single multiplexed
(MUX) voltage inputs to the PCM.The switch names
are: ON, OFF, SET, COAST, RESUME, ACCEL, TAP-
UP, COAST, and CANCEL. Based on conditions when
the buttons are pushed (and released), the five volt-
ages ranges provided to the PCM result in the follow-
ing functions: ON, OFF, SET, COAST, RESUME,
ACCEL, TAP-UP, TAP-DOWN, COAST, and CAN-
CEL. Refer to the Speed Control Section for more
information
Also the PCM receives an input from the brake
switch to sense whether the brake pedal has been
depressed. When the PCM receives the brake
depressed input, it turns off power to the speed con-
trol servo and disengages speed control. Also the
power to the servo is supplied through the brake
switch, which opens the circuit when the brake pedal
is depressed.
The individual switches cannot be repaired. If one
switch fails, the entire switch module must be
replaced.
REMOVAL
The speed control switches are mounted in the
steering wheel and wired through the clock spring
device under the airbag module.
WARNING: IF REMOVAL OF AIRBAG MODULE IS
NECESSARY, REFER TO THE RESTRAINT SYS-
TEMS SECTION FOR MORE INFORMATION.
(1) Remove the negative battery cable.
(2) Turn off ignition.
(3) Remove the air bag, refer to the restraint sec-
tion for more information.
(4) Remove the screw from bottom of the switch.
(5) Remove switch from steering wheel.
(6) Disconnect two-way electrical connector.
(7) Repeat for the other switch.
INSTALLATION
The speed control switches are mounted in the
steering wheel and wired through the clock spring
device under the airbag module.WARNING: IF REMOVAL OF AIRBAG MODULE IS
NECESSARY, REFER TO THE RESTRAINT SYS-
TEMS SECTION FOR MORE INFORMATION.
(1) Connect two-way electrical connector.
(2) Install switch.
(3) Install screw for the switch.
(4) Repeat for the other switch.
(5) Install the air bag, refer to the restraint section
for more information.
(6) Install the negative battery cable.
VACUUM RESERVOIR
DESCRIPTION
The vacuum reservoir is located in the engine com-
partment. It is made of plastic.
OPERATION
The reservoir stores engine vacuum. Manifold vac-
uum is supplied from the brake booster check valve.
The speed control vacuum supply hose has a check
valve at the source (brake booster) to maintain the
highest available vacuum level in the servo, reservoir
and vacuum hoses. When engine vacuum drops, as in
climbing a grade while driving, the reservoir supplies
the vacuum needed to maintain proper speed control
operation. The vacuum reservoir cannot be repaired
and must be replaced if faulty.
REMOVAL
(1) Release hood latch and open hood.
(2) Disconnect the negative battery cable.
(3) Disconnect the vacuum line to the battery tray/
vacuum reservoir.
(4) Remove battery tray/vacuum reservoir, refer to
the Battery section for more information.
INSTALLATION
(1) Install battery tray/vacuum reservoir, refer to
the Battery section for more information.
(2) Connect vacuum line that leads to the battery
tray/vacuum reservoir.
(3) Connect the negative battery cable.
8P - 6 SPEED CONTROLRS
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Page 569 of 2177
INSTALLATION
(1) Connect the wire harness connector.
(2) Install the linkage on the wiper unit.
(3) Install the nut holding the linkage to the wiper
unit.
(4)
Install the cowl cover brackets to the wiper nut.
(5) Install the front wiper unit (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
INSTALLATION).
(6) Install the cowl cover.
(7) Install the wiper arms and blades.
WIPER MODULE
REMOVAL
(1) Release the hood latch and open hood.
(2) Disconnect and isolate the battery negative
cable.
(3) Remove the wiper arms.
(4) Remove the cowl cover (Refer to 23 - BODY/
EXTERIOR/COWL GRILLE - REMOVAL).
(5) Disconnect the positive lock on the wiper mod-
ule wire connector (Fig. 8).
(6) Disconnect the wiper module wire connector
from the engine compartment wire harness.
(7) Disconnect the windshield washer hose from
coupling outside the module.
(8) Disconnect the drain tubes from nipples on bot-
tom of the wiper module.
(9) Remove nuts holding wiper module to lower
windshield fence.
(10) Remove bolts holding the wiper module to the
dash panel (Fig. 9).(11) Lift wiper module from weld-studs on lower
windshield fence.
CAUTION: Do not allow wiper module to rest on
brake master cylinder reservoir, damage to brake
system can result.
(12) Remove wiper module.
INSTALLATION
(1) Position the wiper module into the cowl.
(2) Install the bolts that secure the wiper module
to the dash (Fig. 9).
(3) Install the nuts that retain the wiper module.
(4) Connect the drain tubes to the nipples on the
wiper module.
(5) Connect the windshield washer tube.
(6) Connect the wire harness connector to the
wiper module (Fig. 9).
(7) Connect the positive lock on the wiper module
wire connector (Fig. 8).
CAUTION: Do not allow wiper module to rest on
brake master cylinder reservoir, damage to brake
system can result.
(8) Install the cowl cover (Refer to 23 - BODY/EX-
TERIOR/COWL GRILLE - INSTALLATION).
(9) Install the wiper arms and blades.
(10) Connect the battery negative cable.
(11) Close the hood.
Fig. 8 WIPER MODULE WIRE CONNECTOR
1 - WIPER SYSTEM WIRE CONNECTOR
2 - LOCK TAB
3 - POSITIVE LOCK
4 - WIPER MODULE
Fig. 9 WIPER MODULE
1 - BOLT
2 - NUTS
3 - BOLT
4 - WIPER MODULE
5 - WINDSHIELD
8R - 18 WIPERS/WASHERSRS
WIPER LINKAGE (Continued)
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Page 588 of 2177
8W-02 COMPONENT INDEX
Component Page
A/C Compressor Clutch Relay............. 8W-42
A/C Compressor Clutch.................. 8W-42
A/C-Heater Control..................... 8W-42
A/C Pressure Sensor.................... 8W-42
Accelerator Pedal Position Sensor.......... 8W-30
Accessory Relay........................ 8W-10
Adjustable Pedals Module................ 8W-30
Adjustable Pedals Relay................. 8W-30
Adjustable Pedals Switch................. 8W-30
Airbag Control Module.................. 8W-43
Ambient Temperature Sensor.............. 8W-49
Antenna............................. 8W-47
ATC Remote Sensor..................... 8W-42
Auto Shut Down Relay.................. 8W-30
Auto Temp Control..................... 8W-42
Automatic Day/Night Mirror.............. 8W-49
Back-Up Lamp Switch................... 8W-51
Battery Temperature Sensor.............. 8W-20
Battery.............................. 8W-20
Blend Door Actuators................... 8W-42
Blower Motor Resistor................... 8W-42
Body Control Module.................... 8W-45
Boost Pressure Sensor................... 8W-30
B-Pillar Switches....................... 8W-61
Brake Fluid Level Switch................ 8W-40
Brake Lamp Switch.................. 8W-30, 51
Brake Transmission Shift Interlock Solenoid . . 8W-31
Cabin Heater Assist..................... 8W-30
Camshaft Position Sensor................ 8W-30
CD Changer.......................... 8W-47
Center Dome Lamp..................... 8W-44
Center High Mounted Stop Lamp........... 8W-51
Cinch/Release Motors................... 8W-61
Clockspring................ 8W-30, 33, 41, 43, 47
Clutch Pedal Interlock Switch.......... 8W-10, 30
Clutch Pedal Upstop Switch............... 8W-30
Combination Relays..................... 8W-54
Controller Antilock Brake................ 8W-35
Crank Case Ventilation Heater............ 8W-30
Crankshaft Position Sensor............... 8W-30
Cylinder Lock Switches.................. 8W-39
Data Link Connector.................... 8W-18
Defogger Relay........................ 8W-48
Door Ajar Switches..................... 8W-39
Door Lock Motor/Ajar Switches............ 8W-61
Door Courtesy Lamps................... 8W-44
Door Lock Switches..................... 8W-61
Dosing Pump......................... 8W-30
Driver Airbag Squibs.................... 8W-43
Driver Seat Belt Switch.................. 8W-43
DVD Screen.......................... 8W-47
DVD/CD Changer...................... 8W-47
ECM/PCM Relay....................... 8W-30
EGR Solenoid......................... 8W-30
Electronic Control Unit.................. 8W-64
Engine Control Module.................. 8W-30
Component Page
Engine Coolant Temp Sensor.............. 8W-30
Engine Oil Pressure Sensor............... 8W-30
Engine Oil Pressure Switch............... 8W-30
EVAP/Purge Solenoid.................... 8W-30
Evaporator Temperature Sensor............ 8W-42
Floor Console Lamp..................... 8W-44
Floor Console Power Outlet............... 8W-41
Fog Lamps........................... 8W-50
Front Blower Module.................... 8W-42
Front Blower Motor Relay................ 8W-42
Front Blower Motor..................... 8W-42
Front Cigar Lighter..................... 8W-41
Front Control Module................... 8W-10
Front Fog Lamp Relay................... 8W-50
Front Intrusion Sensor.................. 8W-39
Front Reading Lamps/Switch.............. 8W-44
Front Washer Pump Motor............... 8W-53
Front Wiper High/Low Relay.............. 8W-53
Front Wiper On/Off Relay................ 8W-53
Fuel Heater Relay...................... 8W-30
Fuel Heater.......................... 8W-30
Fuel Injectors......................... 8W-30
Fuel Pressure Sensor.................... 8W-30
Fuel Pressure Solenoid.................. 8W-30
Fuel Pump Module..................... 8W-30
Fuel Pump Relay....................... 8W-30
Full Open Switches..................... 8W-61
Fuses............................... 8W-10
Fuselink............................. 8W-10
Grounds............................. 8W-15
Generator............................ 8W-20
Glow Plugs........................... 8W-30
Glow Plug Relay....................... 8W-30
Headlamp Leveling Motors............... 8W-50
Headlamp Switch...................... 8W-50
Headlamp Washer Pump Motor............ 8W-53
Headlamp Washer Relay................. 8W-53
Headlamps........................... 8W-50
Heated Seat Backs..................... 8W-63
Heated Seat Cushions................... 8W-63
Heated Seat Modules.................... 8W-63
High Beam Lamps...................... 8W-50
Hood Ajar Switch...................... 8W-39
Horn Relay........................... 8W-41
Horn Switch.......................... 8W-41
Horns............................... 8W-41
Idle Air Control Motor................... 8W-30
Ignition Coil.......................... 8W-30
Ignition Switch........................ 8W-10
Inlet Air Temperature Sensor.............. 8W-30
Input Speed Sensor..................... 8W-31
Instrument Cluster..................... 8W-40
Instrument Panel Switch Bank.... 8W-44, 52, 53, 63
Integrated Power Module................. 8W-10
Knock Sensor......................... 8W-30
Lamp Assemblies...................... 8W-51
RS8W-02 COMPONENT INDEX8W-02-1
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Page 662 of 2177
8W-15 GROUND DISTRIBUTION
Component PageA/C Compressor Clutch......................8W-15-8, 9
A/C-Heater Control......................8W-15-10, 12
Adjustable Pedals Module.....................8W-15-11
Airbag Control Module.......................8W-15-13
Auto Temp Control.........................8W-15-10
Automatic Day/Night Mirror...................8W-15-23
Back-Up Lamp Switch......................8W-15-4, 8
Battery.............................8W-15-2, 3, 4
Body Control Module.......................8W-15-24
Brake Fluid Level Switch.....................8W-15-19
Brake Lamp Switch........................8W-15-19
Cabin Heater Assist.........................8W-15-9
Center Dome Lamp........................8W-15-23
Center High Mounted Stop Lamp.................8W-15-28
Clutch Pedal Interlock Switch...................8W-15-19
Clutch Pedal Upstop Switch....................8W-15-20
Controller Antilock Brake...................8W-15-2, 3, 4
Crank Case Ventilation Heater...................8W-15-9
Crankshaft Position Sensor.....................8W-15-4
Data Link Connector...................8W-15-2, 3, 4, 19
Dosing Pump............................8W-15-9
Driver Door Courtesy Lamp..................8W-15-16, 22
Driver Door Lock Switch....................8W-15-16, 22
Driver Heated Seat Cushion....................8W-15-18
Driver Heated Seat Module....................8W-15-18
Driver Power Seat Switch.....................8W-15-18
Driver Power Window Switch...................8W-15-16
Driver Power Window Switch...................8W-15-22
DVD/CD Changer.........................8W-15-11
Engine Control Module.......................8W-15-4
Floor Console Lamp........................8W-15-27
Floor Console Power Outlet....................8W-15-27
Front Blower Module.......................8W-15-12
Front Cigar Lighter........................8W-15-10
Front Control Module....................8W-15-8, 9, 20
Front Reading Lamps/Switch...................8W-15-23
Fuel Heater............................8W-15-27
Fuel Heater Relay..........................8W-15-4
Fuel Pump Module.........................8W-15-27
G100..............................8W-15-2, 3, 4
G101..............................8W-15-2, 3, 4
G102..............................8W-15-5, 6, 7
G103...............................8W-15-8, 9
G200............................8W-15-10, 11, 12
G201................................8W-15-13
G202................................8W-15-14
G300........................8W-15-15, 17, 18, 19, 20
G301..........................8W-15-21, 22, 23, 24
G302............................8W-15-25, 26, 27
G303..............................8W-15-27, 28
Generator..............................8W-15-8
Headlamp Switch.........................8W-15-10
Headlamp Washer Pump Motor..................8W-15-7
High Note Horn..........................8W-15-6 7
Hood Ajar Switch.........................8W-15-20
Instrument Cluster........................8W-15-10
Instrument Panel Switch Bank..................8W-15-11
Integrated Power Module..............8W-15-2, 3, 4, 8, 9, 20
Left B-Pillar Switch........................8W-15-19
Left Cinch/Release Motor.....................8W-15-15
Left Combination Relay......................8W-15-26
Left Cylinder Lock Switch...................8W-15-16 17
Left Door Speaker.........................8W-15-14
Left Fog Lamp..........................8W-15-6, 7
Left Front Door Ajar Switch....................8W-15-17
Left Front Door Lock Motor/Ajar Switch...........8W-15-16, 17
Left Front Park/Turn Signal Lamp.................8W-15-6
Left Full Open Switch.......................8W-15-15
Left Headlamp...........................8W-15-20
Left Headlamp Leveling Motor...................8W-15-7
Left High Beam Lamp.......................8W-15-20
Left Liftgate Flood Lamp.....................8W-15-28
Left Low Beam Lamp.......................8W-15-20
Left Mid Reading Lamp......................8W-15-23
Left Park Lamp..........................8W-15-20
Left Power Mirror.........................8W-15-11
Left Rear Lamp Assembly.....................8W-15-26
Left Rear Reading Lamp......................8W-15-23
Left Rear Speaker.........................8W-15-14
Left Side Impact Airbag Control Module.............8W-15-13
Left Sliding Door Control Module.................8W-15-15
Left Sliding Door Latch Sensing Switch.............8W-15-15
Left Sliding Door Lock Motor...................8W-15-15
Left Sliding Door Lock Motor/Ajar Switch............8W-15-15Component PageLeft Sliding Door Motor......................8W-15-15
Left Stop/Turn Signal Relay....................8W-15-26
Left Turn Signal Lamp......................8W-15-20
Left Visor/Vanity Lamp......................8W-15-23
License Lamp.........................8W-15-25, 28
Lift Pump Motor..........................8W-15-27
Liftgate Ajar Switch........................8W-15-28
Liftgate Cinch/Release Motor...................8W-15-25
Liftgate Cylinder Lock Switch...................8W-15-28
Liftgate Right Pinch Sensor....................8W-15-25
Low Note Horn..........................8W-15-6, 7
Memory Seat/Mirror Module...................8W-15-18
Natural Vacuum Leak Detection Assembly.............8W-15-8
Overhead Console.........................8W-15-23
Oxygen Sensor 1/1 Upstream....................8W-15-2
Oxygen Sensor 1/2 Downstream.................8W-15-2, 8
Passenger Door Courtesy Lamp................8W-15-17, 22
Passenger Door Lock Switch.................8W-15-17, 22
Passenger Heated Seat Cushion..................8W-15-24
Passenger Heated Seat Module..................8W-15-24
Passenger Power Seat Switch...................8W-15-24
Passenger Power Window Switch...............8W-15-17, 22
Power Folding Mirror Switch...................8W-15-12
Power Liftgate Module.......................8W-15-25
Power Liftgate Motor.......................8W-15-25
Power Mirror Switch........................8W-15-12
Power Outlet............................8W-15-10
Power Window Switch.......................8W-15-16
Powertrain Control Module...................8W-15-2, 3
Radiator Fan No. 1.........................8W-15-5
Radiator Fan No. 2.........................8W-15-5
Radiator Fan Relay.........................8W-15-5
Radiator Fan Relay No. 3......................8W-15-5
Radio................................8W-15-14
Rear Auto Temp Control Switch..................8W-15-19
Rear Blower Front Control Switch................8W-15-12
Rear Blower Motor Power Module..............8W-15-12, 27
Rear Blower Rear Control Switch.................8W-15-19
Rear Dome Lamp.........................8W-15-23
Rear Power Outlet.........................8W-15-27
Rear Window Defogger Grid....................8W-15-28
Rear Wiper Motor.........................8W-15-28
Remote Keyless Entry Module...................8W-15-11
Right B-Pillar Switch.......................8W-15-24
Right Cinch/Release Motor....................8W-15-21
Right Combination Relay.....................8W-15-26
Right Cylinder Lock Switch....................8W-15-22
Right Door Speaker........................8W-15-14
Right Fog Lamp.........................8W-15-6, 7
Right Front Door Ajar Switch...................8W-15-22
Right Front Door Lock Motor/Ajar Switch............8W-15-22
Right Front Park/Turn Signal Lamp................8W-15-6
Right Full Open Switch......................8W-15-21
Right Headlamp..........................8W-15-20
Right Headlamp Leveling Motor..................8W-15-7
Right High Beam Lamp......................8W-15-20
Right Liftgate Flood Lamp....................8W-15-28
Right Low Beam Lamp......................8W-15-20
Right Mid Reading Lamp.....................8W-15-23
Right Park Lamp..........................8W-15-20
Right Power Mirror........................8W-15-11
Right Rear Lamp Assembly....................8W-15-27
Right Rear Reading Lamp.....................8W-15-23
Right Rear Speaker........................8W-15-14
Right Side Impact Airbag Control Module............8W-15-13
Right Sliding Door Control Module................8W-15-21
Right Sliding Door Latch Sensing Switch.............8W-15-21
Right Sliding Door Lock Motor..................8W-15-21
Right Sliding Door Lock Motor/Ajar Switch...........8W-15-21
Right Sliding Door Motor.....................8W-15-21
Right Stop/Turn Signal Relay...................8W-15-26
Right Turn Signal Lamp......................8W-15-20
Right Visor/Vanity Lamp.....................8W-15-23
Sentry Key Immobilizer Module..................8W-15-11
Speed Control Servo.........................8W-15-8
Sunroof Module..........................8W-15-26
Sunroof Switch...........................8W-15-23
Traction Control Switch......................8W-15-11
Trailer Tow Connector.......................8W-15-26
Transmission Control Module....................8W-15-3
Transmission Control Relay...................8W-15-2, 3
Washer Fluid Level Switch....................8W-15-6, 7
Wiper Module...........................8W-15-19
RS8W-15 GROUND DISTRIBUTION8W-15-1
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Page 774 of 2177
8W-39 VEHICLE THEFT SECURITY SYSTEM
Component Page
Body Control Module.... 8W-39-2, 3, 4, 7, 8, 9, 10,
11, 12, 13, 14, 15
Clockspring........................ 8W-39-6
Driver Door Lock Switch........... 8W-39-12, 13
Front Control Module............... 8W-39-4, 6
Front Intrusion Sensor................ 8W-39-5
Fuse 8............................ 8W-39-6
Fuse 14............................ 8W-39-2
G102.............................. 8W-39-6
G200.............................. 8W-39-3
G300........... 8W-39-7, 8, 9, 10, 11, 12, 13, 14
G301.............. 8W-39-7, 8, 9, 10, 11, 12, 13
G302............................. 8W-39-15
G303.......................... 8W-39-14, 15
High Note Horn..................... 8W-39-6
Hood Ajar Switch................... 8W-39-14
Horn Relay......................... 8W-39-6
Horn Switch........................ 8W-39-6
Ignition Switch.................... 8W-39-3, 4
Integrated Power Module.......... 8W-39-2, 4, 6
Left Cylinder Lock Switch......... 8W-39-12, 13
Left Front Door Ajar Switch............ 8W-39-7
Left Front Door Lock Motor/Ajar
Switch........................ 8W-39-7, 8
Left Sliding Door Control Module..... 8W-39-9, 10
Left Sliding Door Latch Sensing Switch . . . 8W-39-9Component Page
Left Sliding Door Lock Motor.......... 8W-39-10
Left Sliding Door Lock Motor/Ajar
Switch.......................... 8W-39-11
Liftgate Ajar Switch................. 8W-39-15
Liftgate Cinch/Release Motor.......... 8W-39-15
Liftgate Cylinder Lock Switch......... 8W-39-14
Low Note Horn...................... 8W-39-6
Passenger Door Lock Switch........ 8W-39-12, 13
Power Liftgate Module............... 8W-39-15
Rear Intrusion Sensor................ 8W-39-5
Remote Keyless Entry Module.......... 8W-39-2
Right Cylinder Lock Switch........ 8W-39-12, 13
Right Front Door Ajar Switch........... 8W-39-7
Right Front Door Lock Motor/Ajar
Switch........................ 8W-39-7, 8
Right Sliding Door Control Module.... 8W-39-9, 10
Right Sliding Door Latch Sensing
Switch.......................... 8W-39-9
Right Sliding Door Lock Motor......... 8W-39-10
Right Sliding Door Lock Motor/Ajar
Switch.......................... 8W-39-11
Sentry Key Immobilizer Module....... 8W-39-2, 3
Siren............................. 8W-39-4
Thatcham Alarm Indicator............. 8W-39-5
Thatcham Alarm Module............ 8W-39-4, 5
RS8W-39 VEHICLE THEFT SECURITY SYSTEM8W-39-1
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Page 846 of 2177
8W-45 BODY CONTROL MODULE
Component Page
A/C-Heater Control............... 8W-45-16, 19
Auto Temp Control............... 8W-45-16, 19
Automatic Day/Night Mirror........... 8W-45-11
Body Control Module....... 8W-45-2, 3, 4, 5, 6, 7,
8, 9, 10, 11, 12, 13, 15,
16, 17, 18, 19, 20
CD Changer....................... 8W-45-17
Center Dome Lamp................. 8W-45-13
Center Dome Lamp.................. 8W-45-9
Clockspring........................ 8W-45-17
Controller Antilock Brake............. 8W-45-13
Driver Door Courtesy Lamp........... 8W-45-15
Driver Door Lock Switch............. 8W-45-12
Driver Door Lock Switch............. 8W-45-15
Driver Heated Seat Module........... 8W-45-11
DVD/CD.......................... 8W-45-17
Floor Console Lamp................. 8W-45-13
Front Cigar Lighter................. 8W-45-17
Front Control Module................. 8W-45-3
Front Reading Lamps/Switch....... 8W-45-13, 15
Fuel Pump Module.................. 8W-45-15
Fuse 14............................ 8W-45-3
Fuse 19............................ 8W-45-2
Fuse 20............................ 8W-45-2
Fuse 24............................ 8W-45-2
G301............................ 8W-45-2, 8
Headlamp Switch............. 8W-45-11, 16, 20
Hood Ajar Switch................... 8W-45-12
Ignition Switch...................... 8W-45-3
Instrument Cluster............ 8W-45-16, 18, 19
Instrument Panel Switch
Bank.................. 8W-45-10, 11, 17, 19
Integrated Power Module..... 8W-45-2, 3, 5, 6, 13
Left B-Pillar Switch.................. 8W-45-9
Left Cylinder Lock Switch............ 8W-45-10
Left Front Door Lock Motor/Ajar
Switch........................ 8W-45-4, 7
Left Liftgate Flood Lamp............. 8W-45-12
Left Mid Reading Lamp............ 8W-45-9, 14
Left Power Mirror................... 8W-45-20
Left Rear Lamp Assembly........... 8W-45-5, 6
Left Rear Reading Lamp........... 8W-45-9, 14
Left Remote Radio Switch............ 8W-45-17
Left Repeater Lamp................. 8W-45-20
Left Sliding Door Control Module..... 8W-45-8, 10
Left Sliding Door Lock Motor........... 8W-45-7Component Page
Left Sliding Door Lock Motor/Ajar
Switch........................ 8W-45-7, 8
Left Stop/Turn Signal Relay............ 8W-45-5
Left Visor/Vanity Lamp.............. 8W-45-13
License Lamp....................... 8W-45-8
Liftgate Ajar Switch................. 8W-45-12
Liftgate Cinch/Release Motor.......... 8W-45-12
Liftgate Cylinder Lock Switch.......... 8W-45-9
Memory Set Switch.................. 8W-45-4
Message Center.................... 8W-45-18
Multi-Function Switch............... 8W-45-16
Name Brand Speaker Relay............ 8W-45-3
Overhead Console................. 8W-45-4, 11
Passenger Door Courtesy Lamp........ 8W-45-15
Passenger Door Lock Switch........ 8W-45-12, 15
Passenger Folding Mirror Relay........ 8W-45-20
Passenger Heated Seat Module........ 8W-45-11
Power Folding Mirror Switch.......... 8W-45-20
Power Liftgate Module............. 8W-45-8, 12
Radio............................ 8W-45-17
Rear Auto Temp Control Switch..... 8W-45-10, 19
Rear Blower Rear Control Switch....... 8W-45-10
Rear Dome Lamp.................... 8W-45-9
Rear Wiper Motor.................... 8W-45-8
Remote Keyless Entry Module....... 8W-45-4, 16
Right B-Pillar Switch................. 8W-45-9
Right Combination Relay.............. 8W-45-5
Right Cylinder Lock Switch........... 8W-45-10
Right Front Door Lock Motor/Ajar
Switch........................ 8W-45-7, 9
Right Liftgate Flood Lamp............ 8W-45-12
Right Mid Reading Lamp........... 8W-45-9, 14
Right Power Mirror................. 8W-45-20
Right Rear Lamp Assembly.......... 8W-45-5, 6
Right Rear Reading Lamp.......... 8W-45-9, 14
Right Remote Radio Switch........... 8W-45-17
Right Repeater Lamp................ 8W-45-20
Right Sliding Door Control Module.... 8W-45-8, 10
Right Sliding Door Lock Motor.......... 8W-45-7
Right Sliding Door Lock Motor/Ajar
Switch........................ 8W-45-7, 8
Right Visor/Vanity Lamp............. 8W-45-13
Sentry Key Immobilizer Module......... 8W-45-3
Thatcham Alarm Module............. 8W-45-10
Traction Control Switch.............. 8W-45-17
RS8W-45 BODY CONTROL MODULE8W-45-1
ProCarManuals.com
Page 984 of 2177
Component Page
Front Intrusion Sensor (United
Kingdom)....................... 8W-80-68
Front Reading Lamps/Switch.......... 8W-80-68
Front Washer Pump Motor............ 8W-80-68
Fuel Heater (Diesel)................. 8W-80-68
Fuel Injector No. 1 (2.4L/3.3L/3.8L)..... 8W-80-69
Fuel Injector No. 1 (Diesel)............ 8W-80-69
Fuel Injector No. 2 (2.4L/3.3L/3.8L)..... 8W-80-69
Fuel Injector No. 2 (Diesel)............ 8W-80-69
Fuel Injector No. 3 (2.4L/3.3L/3.8L)..... 8W-80-70
Fuel Injector No. 3 (Diesel)............ 8W-80-70
Fuel Injector No. 4 (2.4L/3.3L/3.8L)..... 8W-80-70
Fuel Injector No. 4 (Diesel)............ 8W-80-70
Fuel Injector No. 5 (3.3L/3.8L)......... 8W-80-71
Fuel Injector No. 6 (3.3L/3.8L)......... 8W-80-71
Fuel Pressure Sensor (Diesel).......... 8W-80-71
Fuel Pressure Solenoid (Diesel)........ 8W-80-71
Fuel Pump Module.................. 8W-80-72
Generator......................... 8W-80-72
Glow Plug Relay (Diesel)............. 8W-80-72
Headlamp Switch................... 8W-80-72
Headlamp Washer Pump Motor
(Export)........................ 8W-80-73
High Note Horn.................... 8W-80-73
Hood Ajar Switch (Export)............ 8W-80-73
Idle Air Control Motor (Gas)........... 8W-80-73
Ignition Coil (2.4L).................. 8W-80-73
Ignition Coil (3.3L/3.8L).............. 8W-80-74
Ignition Switch..................... 8W-80-74
Inlet Air Temperature Sensor.......... 8W-80-74
Input Speed Sensor (EATX)........... 8W-80-74
Instrument Cluster.................. 8W-80-74
Instrument Panel Switch Bank........ 8W-80-75
Integrated Power Module C1.......... 8W-80-75
Integrated Power Module C2.......... 8W-80-76
Integrated Power Module C3.......... 8W-80-76
Integrated Power Module C4.......... 8W-80-77
Integrated Power Module C5.......... 8W-80-77
Integrated Power Module C6.......... 8W-80-77
Integrated Power Module C7.......... 8W-80-78
Integrated Power Module C8.......... 8W-80-78
Integrated Power Module C9.......... 8W-80-79
Knock Sensor (2.4L)................. 8W-80-79
Knock Sensor (3.3L/3.8L ABS Except
Export)......................... 8W-80-79
Leak Detection Pump (3.3L/3.8L Except
Export)......................... 8W-80-79
Left B-Pillar Switch (Power Sliding
Door).......................... 8W-80-80
Left Cinch/Release Motor (Power Sliding
Door).......................... 8W-80-80
Left Combination Relay (Trailer Tow).... 8W-80-80
Left Cylinder Lock Switch............ 8W-80-80
Left Door Speaker (Lowline)........... 8W-80-81
Left Door Speaker (Midline/Highline).... 8W-80-81Component Page
Left Fog Lamp (Except Export)........ 8W-80-81
Left Fog Lamp (Export).............. 8W-80-81
Left Front Door Ajar Switch (Base)..... 8W-80-81
Left Front Door Lock Motor/Ajar Switch
(Except Base).................... 8W-80-82
Left Front Park/Turn Signal Lamp
(Except Export)................... 8W-80-82
Left Front Wheel Speed Sensor........ 8W-80-82
Left Full Open Switch (Power Sliding
Door).......................... 8W-80-82
Left Headlamp (Except Export)........ 8W-80-83
Left Headlamp Leveling Motor (Export) . . 8W-80-83
Left High Beam Lamp (Export)........ 8W-80-83
Left Instrument Panel Speaker........ 8W-80-83
Left Liftgate Flood Lamp............. 8W-80-84
Left Low Beam Lamp (Export)......... 8W-80-84
Left Mid Reading Lamp (Premium/
Luxury)........................ 8W-80-84
Left Park Lamp (Export)............. 8W-80-84
Left Power Mirror................... 8W-80-84
Left Rear Lamp Assembly............ 8W-80-85
Left Rear Pillar Speaker.............. 8W-80-85
Left Rear Reading Lamp (Luxury)...... 8W-80-85
Left Rear Speaker (Lowline)........... 8W-80-85
Left Rear Speaker (Midline/Highline).... 8W-80-86
Left Rear Vent Motor................ 8W-80-86
Left Rear Wheel Speed Sensor......... 8W-80-86
Left Remote Radio Switch............ 8W-80-86
Left Repeater Lamp (Export).......... 8W-80-87
Left Seat Airbag.................... 8W-80-87
Left Side Impact Airbag Control
Module......................... 8W-80-87
Left Sliding Door Control Module C1
(Power Sliding Door).............. 8W-80-87
Left Sliding Door Control Module C2
(Power Sliding Door).............. 8W-80-88
Left Sliding Door Latch Sensing Switch
(Power Sliding Door).............. 8W-80-88
Left Sliding Door Lock Motor
(Power Sliding Door).............. 8W-80-88
Left Sliding Door Lock Motor/Ajar Switch
(Manual Sliding Door)............. 8W-80-89
Left Sliding Door Motor (Power Sliding
Door).......................... 8W-80-89
Left Speed Control Switch............ 8W-80-89
Left Stop/Turn Signal Relay
(Trailer Tow)..................... 8W-80-89
Left Turn Signal Lamp (Export)........ 8W-80-90
Left Visor/Vanity Lamp (Except Base) . . . 8W-80-90
License Lamp (Manual Release)........ 8W-80-90
License Lamp (Power Liftgate)......... 8W-80-90
License Lamp (Power Release)......... 8W-80-91
Lift Pump Motor (Diesel)............. 8W-80-91
Liftgate Ajar Switch (Manual Release) . . . 8W-80-91
Liftgate Ajar Switch (Power Release).... 8W-80-91
RS8W-80 CONNECTOR PIN-OUTS8W-80-3
ProCarManuals.com
Page 994 of 2177
BODY CONTROL MODULE C3 - BLACK/WHITE 34 WAY
CAV CIRCUIT FUNCTION
1 G23 22VT/DB (POWER SLIDING DOOR) SLIDING DOORS OVERHEAD SWITCH MUX
2 D123 20WT/BR FLASH PROGRAM ENABLE
3 G152 22VT/GY (POWER SLIDING
DOOR)RIGHT SLIDING DOOR WAKE UP SIGNAL
4 G151 22VT/BR (POWER SLIDING
DOOR)LEFT SLIDING DOOR WAKE UP SIGNAL
5 G76 20VT/YL RIGHT SLIDING DOOR AJAR SWITCH SENSE
6 G75 22VT (LHD) LEFT FRONT DOOR AJAR SWITCH SENSE
6 G74 22VT/WT (RHD) RIGHT FRONT DOOR AJAR SWITCH SENSE
7 G75 22VT (RHD) LEFT FRONT DOOR AJAR SWITCH SENSE
7 G74 22VT/WT (LHD) RIGHT FRONT DOOR AJAR SWITCH SENSE
8 G77 22VT/GY LEFT SLIDING DOOR AJAR SWITCH SENSE
9 E10 20OR/DG (3 ZONE ATC/MTC) PANEL LAMPS DRIVER (REAR BLOWER SWITCH)
10 - -
11 L162 20WT/VT (EXPORT) RIGHT SIDE REPEATER LAMP FEED
12 G42 22VT/WT (POWER SLIDING DOOR) RIGHT SLIDING DOOR PILLAR SWITCH MUX
13 G165 20VT/GY (EXPORT) LIFTGATE CYLINDER LOCK SWITCH MUX
14 G163 22VT/LB LEFT CYLINDER LOCK SWITCH MUX
15 G162 22VT/WT (EXCEPT EXPORT) RIGHT CYLINDER LOCK SWITCH MUX
15 G162 22VT/TN (EXPORT) RIGHT CYLINDER LOCK SWITCH MUX
16 - -
17 F503 20WT/PK FUSED IGNITION SWITCH OUTPUT (RUN)
18 G41 22VT/DG (POWER SLIDING DOOR) LEFT SLIDING DOOR PILLAR SWITCH MUX
19 L163 20WT/BR (EXPORT) LEFT SIDE REPEATER LAMP FEED
20 N4 20DB/WT FUEL LEVEL SENSOR SIGNAL
21 G161 22VT/DG (LHD) LEFT DOOR LOCK SWITCH MUX
21 G160 22VT/LG (RHD) RIGHT DOOR LOCK SWITCH MUX
22 G161 22VT/DG (RHD) LEFT DOOR LOCK SWITCH MUX
22 G160 22VT/LG (LHD) RIGHT DOOR LOCK SWITCH MUX
23 D25 20WT/VT PCI BUS
24 - -
25 M11 20YL/VT COURTESY LAMPS DRIVER
26 P31 20TN/YL (POWER RELEASE) LIFTGATE RELEASE DRIVER
27 - -
28 - -
29 G78 20VT/OR LIFTGATE AJAR SWITCH SENSE
30 G70 22VT/LB (EXPORT) HOOD AJAR SWITCH SENSE
31 F500 18DG/PK FUSED IGNITION SWITCH OUTPUT (RUN)
32 - -
33 M21 20YL/BR COURTESY LAMPS DRIVER
34 M27 20YL/LB READING LAMPS DRIVER
RS8W-80 CONNECTOR PIN-OUTS8W-80-13
ProCarManuals.com
Page 1348 of 2177
FRAME & BUMPERS
TABLE OF CONTENTS
page page
BUMPERS
SPECIFICATIONS - TORQUE...............1
FRONT FASCIA
REMOVAL.............................1
INSTALLATION..........................1
FRONT BUMPER REINFORCEMENT
REMOVAL.............................2
INSTALLATION..........................2
REAR FASCIA
REMOVAL.............................2
INSTALLATION..........................2
REAR BUMPER REINFORCEMENT
REMOVAL.............................3
INSTALLATION..........................3
REAR FASCIA - SCUFF PAD
REMOVAL.............................3INSTALLATION..........................4
FRAME
SPECIFICATIONS
FRAME DIMENSIONS...................4
SPECIFICATIONS - TORQUE.............4
FRONT CRADLE CROSSMEMBER
DESCRIPTION
DESCRIPTION - FRONT CRADLE
CROSSMEMBER.......................9
DESCRIPTION - FRONT CRADLE
CROSSMEMBER THREAD REPAIR.........9
REMOVAL.............................9
INSTALLATION.........................11
FRONT CROSSMEMBER MOUNT BUSHINGS
REMOVAL.............................12
INSTALLATION.........................12
BUMPERS
SPECIFICATIONS - TORQUE
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Front bumper reinforcement attaching nut 54 40 Ð
Rear bumper reinforcement attaching nut 27 20 Ð
FRONT FASCIA
REMOVAL
(1) Release hood latch and open hood.
(2) Remove the headlamp assemblies (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
HEADLAMP - REMOVAL).
(3) Hoist vehicle and support with safety stands.
(4) Remove the five bolts attaching bottom of fas-
cia/air dam to radiator closure panel.
(5) Remove front wheels.
(6) Remove front wheelhouse splash shields fasten-
ers as necessary to gain access to bolts attaching
front fascia to fender. (Refer to 23 - BODY/EXTERI-
OR/ WHEELHOUSE SPLASH SHIELD - REMOV-
AL).
(7) Remove the two bolts and two nuts attaching
fascia to the front fenders (Fig. 1).
(8) Disconnect fog lamp wire connectors, if neces-
sary.
(9) Lower vehicle.(10) Remove two bolts attaching the upper grille
support to the headlamp mounting panel at each side
of the grille.
(11) Remove bumper fascia from vehicle.
INSTALLATION
(1) Position front bumper fascia on vehicle.
(2) Install the two bolts attaching fascia to head-
lamp mounting panel at each side of grille.
(3) Hoist vehicle and support with safety stands.
(4) Install the two bolts and two nuts attaching
fascia to the front fenders (Fig. 1). The fascia should
be flush to fender.
(5) Install front wheelhouse splash shields fasten-
ers. (Refer to 23 - BODY/EXTERIOR/ WHEEL-
HOUSE SPLASH SHIELD - INSTALLATION).
(6) Install front wheels.
(7) Connect fog lamp wire connectors, if necessary.
(8) Install the five bolts attaching bottom of fascia
to radiator closure panel.
(9) Lower the vehicle.
RSFRAME & BUMPERS13-1
ProCarManuals.com
Page 1478 of 2177
Misassembled synchronizer components also cause
shifting problems. Incorrectly installed synchronizer
sleeves, keys, balls, or springs can cause shift prob-
lems.
NOISY OPERATION
Transaxle noise is most often a result of worn or
damaged components. Chipped, broken gear or syn-
chronizer teeth, and brinnelled, spalled bearings all
cause noise.
Abnormal wear and damage to the internal compo-
nents is frequently the end result of insufficient
lubricant.
SLIPS OUT OF GEAR
Transaxle disengagement may be caused by mis-
aligned or damaged shift components, or worn teeth
on the drive gears or synchronizer components. Incor-
rect assembly also causes gear disengagement. Check
for missing snap rings.
LOW LUBRICANT LEVEL
Insufficient transaxle lubricant is usually the
result of leaks, or inaccurate fluid level check or refill
method. Leakage is evident by the presence of oil
around the leak point. If leakage is not evident, the
condition is probably the result of an underfill.
If air±powered lubrication equipment is used to fill
a transaxle, be sure the equipment is properly cali-
brated. Equipment out of calibration can lead to an
underfill condition.
CLUTCH PROBLEMS
Worn, damaged, or misaligned clutch components
can cause difficult shifting, gear clash, and noise.
A worn or damaged clutch disc, pressure plate, or
release bearing can cause hard shifting and gear
clash.
REMOVAL
REMOVAL - 2.4L GAS
(1) Raise hood.
(2) Disconnect gearshift cables from shift levers/
cover assembly (Fig. 10).
(3) Remove gearshift cable retaining clips from
mounting bracket (Fig. 10). Remove cables and
secure out of way.
(4) Remove three (3) right engine mount bracket-
to-transaxle bolts (Fig. 11).
(5) Raise vehicle on hoist.
(6) Remove front wheel/tires and halfshafts.
(7) Drain transaxle fluid into suitable container.
(8) Remove front harness retainer and secure har-
ness out of way.
Fig. 10 Gearshift Cables at Transaxle
1 - SELECTOR CABLE
2 - CABLE RETAINER
3 - CABLE RETAINER
4 - CROSSOVER CABLE
5 - MOUNT BRACKET
Fig. 11 Transaxle Right Mount and Bracket
1 - MOUNT BRACKET
2 - BOLT (3)
3 - MOUNT
4 - BOLT (1)
RST850 MANUAL TRANSAXLE21-31
T850 MANUAL TRANSAXLE (Continued)
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