brake CHRYSLER CARAVAN 2003 Service Manual

RIGHT COMBINATION RELAY (TRAILER TOW) - BLACK 5 WAY
CAV CIRCUIT FUNCTION
1 L62 18WT/BR RIGHT REAR TURN SIGNAL DRIVER
1 L62 18WT/BR RIGHT REAR TURN SIGNAL DRIVER
2 Z1 18BK/DG GROUND
3 L50 18WT/TN BRAKE LAMP SWITCH OUTPUT
4 L605 18DG RIGHT COMBINATION SIGNAL
5- -
RIGHT CYLINDER LOCK SWITCH (EXPORT) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 Z462 20BK/WT GROUND
2 G162 20VT/WT RIGHT CYLINDER LOCK SWITCH MUX
RIGHT DOOR SPEAKER (LOWLINE)-3WAY
CAV CIRCUIT FUNCTION
1 X56 20GY/BR RIGHT FRONT SPEAKER (-)
2- -
3 X54 20GY RIGHT FRONT SPEAKER (+)
RIGHT DOOR SPEAKER (MIDLINE/HIGHLINE) - BLACK/RED 6 WAY
CAV CIRCUIT FUNCTION
1 X154 20GY/YL (HIGHLINE) RIGHT INSTRUMENT PANEL SPEAKER (+)
2 X15 16GY/DG (HIGHLINE) AMPLIFIED SPEAKER GROUND
3 X156 20GY/LB (HIGHLINE) RIGHT INSTRUMENT PANEL SPEAKER (-)
4 X54 20GY RIGHT FRONT SPEAKER (+)
5 X13 16DG/GY (HIGHLINE) NAME BRAND SPEAKER RELAY OUTPUT
6 X56 20GY/BR RIGHT FRONT SPEAKER (-)
8W - 80 - 120 8W-80 CONNECTOR PIN-OUTSRS
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RIGHT PARK LAMP (EXPORT) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 Z344 16BR GROUND
2 L78 16BK FUSED PARK LAMP RELAY OUTPUT (RIGHT)
RIGHT POWER MIRROR - BLACK 12 WAY
CAV CIRCUIT FUNCTION
1 P174 20TN/LB (EXPORT) RIGHT FOLDING MIRROR UNFOLD DRIVER
2- -
3- -
4 P68 20TN/YL (MEMORY) RIGHT MIRROR HORIZONTAL POSITION SIGNAL
5 P66 20TN/LG (MEMORY) RIGHT MIRROR SENSOR GROUND
6 P67 20TN/OR (MEMORY) RIGHT MIRROR VERTICAL POSITION SIGNAL
7 P160 20TN/LG (LHD EXPORT) PASSENGER FOLDING MIRROR RELAY OUTPUT
7 P159 20TN/DG (RHD) DRIVER FOLDING MIRROR FOLD DRIVER
8 Z216 20BK/DB (HEATED MIRRORS) GROUND
9 C16 20DB/GY (HEATED MIRRORS) FUSED REAR WINDOW DEFOGGER RELAY OUTPUT
10 P70 20TN/LB RIGHT MIRROR COMMON DRIVER (RIGHT/DOWN)
11 P72 20TN/GY RIGHT MIRROR UP DRIVER
12 P74 20TN/DB RIGHT MIRROR LEFT DRIVER
RIGHT REAR LAMP ASSEMBLY - BLACK 6 WAY
CAV CIRCUIT FUNCTION
1 Z362 18BK/BR (EXPORT) GROUND
1 L62 18WT/BR (EXCEPT EXPORT) RIGHT REAR TURN SIGNAL DRIVER
2 L62 18WT/BR (EXPORT) RIGHT REAR TURN SIGNAL DRIVER
3 L50 18WT/TN (EXPORT) BRAKE LAMP SWITCH OUTPUT
3 L78 18WT/OR (EXCEPT EXPORT) FUSED PARK LAMP RELAY OUTPUT (RIGHT)
4 L1 18WT/LG BACK-UP LAMP DRIVER
5 L38 20WT/YL (EXPORT) REAR FOG LAMP SWITCH OUTPUT
5 Z362 18BK/BR (EXCEPT EXPORT) GROUND
6 L50 18WT/TN (EXCEPT EXPORT) PRIMARY BRAKE SWITCH SIGNAL
6 L78 18WT/OR (EXPORT) FUSED PARK LAMP RELAY OUTPUT (RIGHT)
8W - 80 - 124 8W-80 CONNECTOR PIN-OUTSRS
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RIGHT SPEED CONTROL SWITCH - WHITE 2 WAY
CAV CIRCUIT FUNCTION
A V37 20VT (EXCEPT 2.4L) SPEED CONTROL SWITCH SIGNAL
A V37 20VT (2.4L) S/C SWITCH SIGNAL
B Z23 20BK/VT RIGHT SPEED CONTROL SWITCH GROUND
RIGHT STOP/TURN SIGNAL RELAY (TRAILER TOW) - BLACK 5 WAY
CAV CIRCUIT FUNCTION
1 L50 18WT/TN BRAKE LAMP SWITCH OUTPUT
1 L50 18WT/TN BRAKE LAMP SWITCH OUTPUT
2 Z1 18BK/DG GROUND
2 Z1 18BK/DG GROUND
3 L74 18LG RIGHT STOP SIGNAL
4 L62 18WT/BR RIGHT REAR TURN SIGNAL DRIVER
5 L605 18DG RIGHT COMBINATION SIGNAL
RIGHT TURN SIGNAL LAMP (EXPORT) - ORANGE 2 WAY
CAV CIRCUIT FUNCTION
1 Z344 16BR GROUND
2 L60 16YL RIGHT FRONT TURN SIGNAL DRIVER
RIGHT VISOR/VANITY LAMP (EXCEPT BASE) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
A Z327 20BK/OR GROUND
B M27 20YL/LB READING LAMPS DRIVER
RS8W-80 CONNECTOR PIN-OUTS8W - 80 - 129
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SENTRY KEY IMMOBILIZER MODULE - BLACK 6 WAY
CAV CIRCUIT FUNCTION
1- -
2 D25 20WT/VT PCI BUS
3- -
4 F20 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
5 Z120 22BK/WT GROUND
6 A114 20GY/RD (LHD) FUSED B(+) (I.O.D.)
6 A114 18GY/RD (RHD) FUSED B(+) (I.O.D.)
SIREN (UNITED KINGDOM) - BLACK 4 WAY
CAV CIRCUIT FUNCTION
1 D97 18WT/OR SIREN SIGNAL OUTPUT
2 D96 18WT/LB SIREN SIGNAL CONTROL
3 A600 18RD/LB SIREN SUPPLY
4 G944 18LB/BR SIREN SIGNAL RETURN
SOLENOID/PRESSURE SWITCH ASSY (EATX) - BLACK 8 WAY
CAV CIRCUIT FUNCTION
1 T47 18YL/DG 2-4 PRESSURE SWITCH SENSE
2 T50 18YL/TN LOW/REVERSE PRESSURE SWITCH SENSE
3 T9 18DG/TN OVERDRIVE PRESSURE SWITCH SENSE
4 T16 18YL/OR TRANSMISSION CONTROL RELAY OUTPUT
5 T59 18YL/LB UNDERDRIVE SOLENOID CONTROL
6 T60 18YL/GY OVERDRIVE SOLENOID CONTROL
7 T20 18DG/WT LOW/REVERSE SOLENOID CONTROL
8 T19 18YL/DB 2-4 SOLENOID CONTROL
SPEED CONTROL SERVO (GAS) - BLACK 4 WAY
CAV CIRCUIT FUNCTION
1 V36 18VT/YL (3.3L/3.8L) SPEED CONTROL VACUUM SOLENOID CONTROL
1 V36 18VT/YL (2.4L) S/C VACUUM CONTROL
2 V35 18VT/OR (2.4L) S/C VENT CONTROL
2 V35 18VT/OR (3.3L/3.8L) SPEED CONTROL VENT SOLENOID CONTROL
3 V30 20VT/WT SPEED CONTROL BRAKE SWITCH OUTPUT
4 Z155 18BK/LG GROUND
8W - 80 - 130 8W-80 CONNECTOR PIN-OUTSRS
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8W-91 CONNECTOR/GROUND/SPLICE LOCATION
TABLE OF CONTENTS
page
CONNECTOR/GROUND/SPLICE LOCATION
DESCRIPTION..........................1
CONNECTOR/GROUND/SPLICE
LOCATION
DESCRIPTION
This section provides illustrations identifying con-
nector, ground, and splice locations in the vehicle.
Connector, ground, and splice indexes are provided.Use the wiring diagrams in each section for connec-
tor, ground, and splice identification. Refer to the
appropriate index for the proper figure number. For
items that are not shown in this section N/S is placed
in the Fig. column.
CONNECTORS
CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
A/C Compressor Clutch LTGY Top of A/C Compressor 10, 11, 15, 17, 18
A/C-Heater Control C1 (MTC) BK/RD Rear of Control 19, 22, 24
A/C-Heater Control C2 (MTC) BK/BL Rear of Control 19, 22, 24
A/C Pressure Sensor GY At Throttle Body 10, 15, 16, 17
Accelerator Pedal Position
Sensor (Diesel)BK At Accelerator Pedal 41
Adjustable Pedals Module Near Brake Lamp Switch 40
Adjustable Pedals Switch Left Side Instrument Panel 20
Adjustable Pedals Relay Left Side Engine Compartment 6
Airbag Control Module YL/RD Right Side of Instrument Panel 19, 23, 24
Ambient Temperature Sensor BK On Radiator Closure Panel 1
ATC Remote Sensor Above ATC Control N/S
Automatic Day/Night Mirror BK At Mirror N/S
Autostick Switch BK Rear of Switch 20, 21, 22
Auto Temperature Control C1
(ATC)WT Rear of Control N/S
Auto Temperature Control C2
(ATC)BK Rear of Control N/S
Auto Temperature Control C3
(ATC)Rear of Control N/S
Back-Up Lamp Switch BK On Transmission 16
Battery Temperature Sensor BK At Battery N/S
Blower Motor Resistor C1 (MTC) BK Right Side of HVAC N/S
Blower Motor Resistor C2 (MTC) Right Side of HVAC N/S
Body Control Module C1 BK Under Left Instrument Panel 40, 41
Body Control Module C2 BK/GN Under Left Instrument Panel 40, 41
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-1
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CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Body Control Module C3 BK/WT Under Left Instrument Panel 40, 41
Body Control Module C4 BK/GY Under Left Instrument Panel 19, 20, 29
Body Control Module C5 BK Under Left Instrument Panel 19, 20, 29
Boost Pressure Sensor (Diesel) BK Top Left of Engine N/S
Brake Fuid Level Switch BK On Master Cylinder 6
Brake Lamp Switch BK At Top Of Brake Pedal 40, 41
Brake Transmission Shift
Interlock Solenoid (EATX)BK Near Steering Column 19, 20, 21, 30
C100 BK Left Fender Shield 5, 11
C101 LTGY Left Fender Shield 5
C102 (2.4L) BK Top Front of Engine 11
C102 (3.3/3.8L) BK At Fuel Rail 17
C103 (Diesel) BK Left Side Engine Compartment 5
C106 (Export) BK Near Left Headlamp Leveling Motor N/S
C107 (Export) BK Near Right Headlamp Leveling
MotorN/S
C110 (2.4L) BK Left Front Engine 11
C111 (2.4L) BK Left Front Engine 11
C200 GY Left Side Instrument Panel 19, 20, 29, 40, 41
C201 YL Left Side Instrument Panel 19, 20, 29, 40, 41
C202 GY Right Side Instrument Panel A/C
Heatrer Unit19, 23, 28
C203 (United Kingdom) WT Right Side of Instrument Panel N/S
C204 Rear of Radio 49
C300 (LHD) BK Left Front Door Lower 35, 42
C300 (RHD) BK Right Front Door Lower N/S
C301 LTGY Left Front Door Upper 35, 42
C302 LTGY Right Front Door Upper 8, 38, 43
C303 (LHD) BK Right Front Door Lower 8, 43
C303 (RHD) BK Left Front Door Lower 38, 43
C304 YL Left Wire Track Seat to Body 31
C305 GY Left Wire Track Seat to Body 31
C306 YL Right Wire Track Seat to Body 32
C307 GY Right Wire Track Seat to Body 32
C308 BL Left Rear Sliding Door 39
C309 GN Right Rear Sliding Door 31, 32, 38
C310 BK At Front Console 33
C311 GY Rear A/C Switch N/S
C312 GY At Dome Lamp 32, 38, 49
C313 BK At Rear Console 33
C314 BK Left Side Liftgate 48
C315 BK Right Side Liftgate 48
C316 BK Wire Track to Sliding Door N/S
8W - 91 - 2 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
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CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
C317 BK Right Sliding Door 31
C318 (Trailer Tow) BK Left Quarter N/S
C319 Left Side Liftgate N/S
C320 DKGY Driver Power Seat on Seat Harness N/S
C321 DKGY Under Passenger Seat N/S
C322 BK On Seat Harness to Body 31
C324 BK Left Sliding Door N/S
C325 BK Right Sliding Door 31
C326 YL At Driver Side Airbag N/S
C327 YL At Passenger Side Airbag N/S
C328 Front of Left Quarter 46
C329 (Diesel) BK Near Fuel Tank 33
C330 (Diesel) LTGY Left Rear Engine Compartment N/S
C331 (Diesel) BK Left Rear Engine Compartment N/S
Cabin Heater RHD) At Heater N/S
Cabin Heater Assist C1 (Diesel) BK Top of Engine 15, 16
Cabin Heater Assist C2 (Diesel) BK Top of Engine 15, 16
Camshaft Position Sensor (Gas) BK Rear of Cylinder Head
Right Side of Engine11
Camshaft Position Sensor
(Diesel)BK Rear of Cylinder Head 15, 16
CD Changer Behind CD Changer N/S
Center Dome Lamp GY At Lamp N/S
Center High Mounted Stop Lamp BK At Lamp 48
Clockspring - C1 WT Steering Column 19, 20, 21, 22, 30
Clockspring - C2 YL Steering Column 19, 20, 21, 22, 30
Clockspring - C3 BK Steering Column N/S
Clockspring - C4 BK Steering Column N/S
Clockspring - C5 YL Steering Column N/S
Clutch Pedal Interlock Switch
(Diesel)RD At Switch/Driver Side 41
Clutch Pedal Upstop Switch
(Diesel)BK At Switch/Driver Side 41
Controller Anti-Lock Brake BK Right Side of Engine Compartment 11, 16, 17, 18
Crank Case Ventilation Heater
(Diesel)BK Top of Cylinder Head 15
Crankshaft Position Sensor
(Diesel)BK Rear of Engine 16
Crankshaft Position Sensor (Gas) BK Rear of Engine 13, 17
Data Link Connector WT Lower Instrument Panel Near
Steering Column40, 41
Dosing Pump BK Top of Engine N/S
Driver Airbag Squib1 BN Steering Column N/S
Driver Airbag Squib2 BK Steering Column N/S
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-3
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
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CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Right Sliding Door Lock
Motor/Ajar SwitchBK At Latch N/S
Right Sliding Door Motor BK At Sliding Door 44
Right Speed Control Switch BK At Steering Wheel N/S
Right Stop/Turn Signal Relay BK LT Quarter Panel N/S
Right Turn Signal Lamp OR At Lamp N/S
Right Visor/Vanity Lamp BK At Lamp N/S
Sentry Key Immobilizer Module BK At Steering Column 19, 20, 21, 22, 30
Siren (United Kingdom) BK Left Front Body N/S
Solenoid/Pressure Switch
Assembly (EATX)BK Side of Transmission 14, 18
Speed Control Servo BK Near Controller Antilock Brake 11, 18
Sunroof Module BK At Sunroof N/S
Sunroof Switch Nat Near Overhead Console N/S
Thatcham Alarm Module C1 BK Top Right Side of Instrument Panel
Near SpeakerN/S
Thatcham Alarm Module C1 WT Top Right Side of Instrument Panel
Near SpeakerN/S
Throttle Position Sensor GY On Throttle Body 10, 11, 17
Torque Converter Clutch Solenoid BK Front of Transmission 11
Traction Control Switch BK Rear of Swtich 20, 21, 30
Trailer Tow Connector BK Left Quarter Panel N/S
Transmission Control Module BK Left Engine Compartment 5
Transmission Range Sensor GY Top of Transmission 14, 18
Turbo boost Pressure Sensor On Cylinder Block 15
Vehicle Speed Sensor BK Rear of Transmission 10, 16
Washer Fluid Level Switch BK Bottom of Reservoir 3
Water in Fuel Sensor (Diesel) Left Rear Engine Compartment N/S
Wiper Module BK Left Side Cowl 6
GROUNDS
GROUND NUMBER LOCATION FIG.
G100 Body Ground Near Powertrain Control Module N/S
G101 Above Starter 11, 13
G102 Left Headlamp Area 1
G103 Above Starter 11, 13
G200 Right Side of Instrument Panel 19, 23, 28
G201 Right Side of Instrument Panel 19, 23, 28
G202 Near Radio N/S
G300 Left B Pillar 31
G301 Right B Pillar 32, 38
G302 Left Rear Quarter 46
G400 Liftgate Ground N/S
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-11
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
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INTAKE MANIFOLD
DESCRIPTION
The intake manifold is a two piece aluminum cast-
ing (Fig. 101) that attaches to the cylinder head with
fasteners. The manifold is a long branch design to
enhance low and mid-range torque
DIAGNOSIS AND TESTING - INTAKE
MANIFOLD LEAKS
An intake manifold air leak is characterized by
lower than normal manifold vacuum. Also, one or
more cylinders may not be functioning.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
(1) Start the engine.
(2) Spray a small stream of water (Spray Bottle) at
the suspected leak area.
(3) If engine RPM'S change, the area of the sus-
pected leak has been found.
(4) Repair as required.
INTAKE MANIFOLD - UPPER
REMOVAL
(1) Disconnect negative cable from battery.
(2) Disconnect connector from inlet air tempera-
ture sensor (Fig. 102).
(3) Disconnect air intake tube at throttle body and
remove upper air cleaner housing.
(4) Disconnect connector from throttle position
sensor (TPS) (Fig. 104).
(5) Disconnect connector from idle air control (IAC)
motor (Fig. 104).
(6)
Disconnect connector from MAP sensor (Fig. 103).
(7) Remove vacuum lines for purge solenoid and
PCV valve at intake manifold.
(8) Remove vacuum lines for power brake booster,
LDP, EGR transducer, and speed control vacuum res-
ervoir (if equipped) at upper intake manifold fittings.
Fig. 101 Intake Manifold - Upper and Lower
1 - UPPER INTAKE MANIFOLD
2 - LOWER INTAKE MANIFOLD
Fig. 102 INLET AIR TEMPERATURE SENSOR - 2.4L
Fig. 103 MAP SENSOR - 2.4L
1 - MAP SENSOR
9 - 58 ENGINE 2.4LRS
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(9) Disconnect throttle and speed control (if
equipped) cables from throttle lever and bracket.
(Refer to 14 - FUEL SYSTEM/FUEL INJECTION/
THROTTLE CONTROL CABLE - REMOVAL)
(10) Remove the EGR tube. (Refer to 25 - EMIS-
SIONS CONTROL/EXHAUST GAS RECIRCULA-
TION/TUBE - REMOVAL)
(11) Remove the upper manifold support bracket
bolt to manifold (Fig. 105).
(12) Remove engine oil dipstick from tube.
(13) Remove upper intake manifold bolts (Fig.
106). Remove upper intake manifold.
CAUTION: Cover intake manifold to prevent foreign
material from entering engine.
INSPECTION
(1) Check manifold surfaces for flatness with
straight edge. Surface must be flat within 0.15 mm
per 300 mm (0.006 in. per foot) of manifold length.
(2) Inspect manifold for cracks or distortion.
Replace manifold if necessary.
INSTALLATION
(1) Clean manifold sealing surfaces.
(2) Apply a 1.5 mm (0.060 in.) bead MopartGas-
ket Maker to the perimeter of the lower intake man-
ifold runner openings.
(3) Install upper intake manifold and tighten fas-
teners to 28 N´m (250 in. lbs.) in sequence shown in
(Fig. 106). Repeat this procedures until all fasteners
are at specified torque.
(4) Install engine oil dipstick.
(5) Install upper bolt in intake manifold to front
support bracket (Fig. 105). Torque to 28 N´m (250 in.
lbs.).
(6) Install EGR tube. (Refer to 25 - EMISSIONS
CONTROL/EXHAUST GAS RECIRCULATION/
TUBE - INSTALLATION)
(7) Install throttle cables in bracket.
(8) Connect throttle and speed control (if equipped)
cables to throttle lever.
(9) Connect vacuum lines for power brake booster,
LDP, EGR transducer, and speed control vacuum res-
ervoir (if equipped) at upper intake manifold fittings.
(10) Connect vacuum lines for purge solenoid and
PCV valve.
(11) Connect electrical connectors for MAP sensor,
throttle position sensor (TPS), and idle air control
(IAC) motor.
(12) Install air cleaner upper housing and air
intake tube to throttle body.
(13) Connect inlet air temperature sensor connec-
tor (Fig. 102).
(14) Connect negative cable to battery.
Fig. 104 Throttle Body Electrical Connectors -
Typical
1 - IDLE AIR CONTROL MOTOR CONNECTOR
2 - TPS CONNECTOR
Fig. 105 Upper Intake Manifold Support Bracket
1 - NUT - BRACKET TO CYLINDER HEAD COVER
2 - BOLT - BRACKET TO UPPER INTAKE MANIFOLD
3 - UPPER INTAKE MANIFOLD SUPPORT BRACKET
Fig. 106 Upper Intake Manifold Tightening Sequence
- 2.4L
RSENGINE 2.4L9-59
INTAKE MANIFOLD - UPPER (Continued)
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