window CHRYSLER CARAVAN 2003 Workshop Manual

PASSENGER POWER SEAT SWITCH - GREEN 10 WAY
CAV CIRCUIT FUNCTION
1 Z848 14BK/OR GROUND
2 P44 14LG/VT PASSENGER RECLINER UP SWITCH SENSE
3 P16 14LG/WT PASSENGER HORIZONTAL REARWARD SWITCH
SENSE
4 P42 14LG/GY PASSENGER RECLINER DOWN SWITCH SENSE
5 A210 14OR/RD FUSED B(+)
6 P14 14LG/OR PASSENGER HORIZONTAL FORWARD SWITCH SENSE
7 P20 14LG/LB PASSENGER FRONT DOWN SWITCH SENSE
8 P12 14LG/YL PASSENGER REAR DOWN SWITCH SENSE
9 P10 14LG/TN PASSENGER REAR UP SWITCH SENSE
10 P18 14LG/OR PASSENGER FRONT UP SWITCH SENSE
PASSENGER POWER WINDOW MOTOR - RED 2 WAY
CAV CIRCUIT FUNCTION
1 Q12 16OR/BR PASSENGER WINDOW DRIVER (UP)
2 Q22 16OR/VT PASSENGER WINDOW DRIVER (DOWN)
PASSENGER POWER WINDOW SWITCH - BLACK 8 WAY
CAV CIRCUIT FUNCTION
1 F304 12WT/PK FUSED WINDOW CIRCUIT BREAKER OUTPUT
2 Q26 12OR/GY MASTER WINDOW SWITCH PASSENGER (DOWN)
3 Q16 12OR/TN MASTER WINDOW SWITCH RIGHT PASSENGER (UP)
4- -
5 Q22 14OR/VT PASSENGER WINDOW DRIVER (DOWN)
6 F304 16WT/PK FUSED WINDOW CIRCUIT BREAKER OUTPUT
7 Z422 20BK/BR GROUND
8 Q12 14OR/BR PASSENGER WINDOW DRIVER (UP)
PASSENGER SEAT BELT SWITCH-2WAY
CAV CIRCUIT FUNCTION
1 R60 18LB/TN PASSENGER SEAT BELT SWITCH LINE 1
2 R58 18LB/GY PASSENGER SEAT BELT SWITCH LINE 2
RS8W-80 CONNECTOR PIN-OUTS8W - 80 - 101
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POWER MIRROR SWITCH - BLACK 13 WAY
CAV CIRCUIT FUNCTION
1 P70 20TN/LB RIGHT MIRROR COMMON DRIVER (RIGHT/DOWN)
1 P70 20TN/LB (MEMORY) RIGHT MIRROR COMMON DRIVER (RIGHT/DOWN)
2- -
3- -
4- -
5- -
6 P73 20TN/VT LEFT MIRROR COMMON DRIVER (RIGHT/DOWN)
6 P73 20TN/VT (MEMORY) LEFT MIRROR COMMON DRIVER (RIGHT/DOWN)
7 P75 20TN/LG LEFT MIRROR LEFT DRIVER
7 P75 20TN/LG (MEMORY) LEFT MIRROR LEFT DRIVER
8 P74 20TN/DB RIGHT MIRROR LEFT DRIVER
8 P74 20TN/DB (MEMORY) RIGHT MIRROR LEFT DRIVER
9 A108 20LG/RD FUSED B(+)
10 - -
11 Z408 18BK/LG GROUND
12 P71 20TN/DG LEFT MIRROR UP DRIVER
12 P71 20TN/DG (MEMORY) LEFT MIRROR UP DRIVER
13 P72 20TN/GY RIGHT MIRROR UP DRIVER
13 P72 20TN/GY (MEMORY) RIGHT MIRROR UP DRIVER
POWER OUTLET (EXCEPT LOWLINE) - BLACK 3 WAY
CAV CIRCUIT FUNCTION
1 A105 16DB/RD FUSED B(+)
2- -
3 Z738 16BK/WT GROUND
POWER SEAT CIRCUIT BREAKER (30A) - GRAY 2 WAY
CAV CIRCUIT FUNCTION
1 A110 12OR/RD FUSED B(+)
2 A210 14OR/RD FUSED SEAT SWITCH DRIVER
2 A210 14OR/RD FUSED SEAT SWITCH DRIVER
POWER WINDOW CIRCUIT BREAKER (25A) - GRAY 2 WAY
CAV CIRCUIT FUNCTION
1 F30 12PK/YL FUSED ACCESSORY RELAY OUTPUT
2 F304 12WT/PK FUSED WINDOW CIRCUIT BREAKER OUTPUT
8W - 80 - 104 8W-80 CONNECTOR PIN-OUTSRS
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POWER WINDOW SWITCH (LHD LOWLINE) - BLACK 8 WAY
CAV CIRCUIT FUNCTION
1 F304 16WT/PK FUSED WINDOW CIRCUIT BREAKER OUTPUT
2 Z421 12BK/BR GROUND
3 Z421 12BK/BR GROUND
4- -
5 Q26 12OR/GY MASTER WINDOW SWITCH PASSENGER (DOWN)
6 F304 16WT/PK FUSED WINDOW CIRCUIT BREAKER OUTPUT
7 Z421 20BK/BR GROUND
8 Q16 12OR/TN MASTER WINDOW SWITCH PASSENGER (UP)
POWERTRAIN CONTROL MODULE C1 (NGC) - BLACK 38 WAY
CAV CIRCUIT FUNCTION
1- -
2- -
3- -
4- -
5- -
6- -
7- -
8- -
9 Z130 18BK/BR GROUND
10 - -
11 F202 20PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START)
12 F1 18PK/WT (EXCEPT EXPORT) FUSED IGNITION SWITCH OUTPUT (RUN-START)
13 N7 18DB/OR (MTX) VEHICLE SPEED SIGNAL
14 - -
15 - -
16 - -
17 - -
18 Z131 18BK/DG GROUND
19 - -
20 G6 16VT/GY OIL PRESSURE SIGNAL
21 - -
22 G31 18VT/LG AAT SIGNAL
23 - -
24 - -
25 D20 20WT/LG SCI RECEIVE (PCM)
26 D123 20WT/BR FLASH PROGRAM ENABLE
27 - -
28 - -
29 A109 18OR/RD FUSED B(+)
30 T751 18YL FUSED IGNITION SWITCH OUTPUT (START)
31 K141 18DB/YL O2 1/2 SIGNAL
32 K904 18DB/DG O2 RETURN (DOWN)
33 - -
34 - -
35 - -
36 D21 20WT/BR SCI TRANSMIT (PCM)
37 D15 18DG/YL SCI TRANSMIT (TCM)
38 D25 18WT/VT PCI BUS
RS8W-80 CONNECTOR PIN-OUTS8W - 80 - 105
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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 REAR PILLAR SPEAKER - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 X158 20GY/YL RIGHT REAR PILLAR SPEAKER (-)
2 X152 20GY/WT RIGHT REAR PILLAR SPEAKER (+)
RIGHT REAR READING LAMP (LUXURY) - GRAY 3 WAY
CAV CIRCUIT FUNCTION
1 M22 20YL/OR COURTESY LAMPS DRIVER
2 Z327 20BK/OR GROUND
3 M27 20YL/LB READING LAMPS DRIVER
RIGHT REAR SPEAKER (LOWLINE)-3WAY
CAV CIRCUIT FUNCTION
1 X58 22GY/OR RIGHT REAR SPEAKER (-)
2- -
3 X52 20GY/DB RIGHT REAR SPEAKER (+)
RIGHT REAR SPEAKER (MIDLINE/HIGHLINE) - BLACK/RED 6 WAY
CAV CIRCUIT FUNCTION
1 X152 20GY/WT (HIGHLINE) RIGHT REAR PILLAR SPEAKER (+)
2 X15 16GY/DG (HIGHLINE) AMPLIFIED SPEAKER GROUND
3 X158 20GY/YL (HIGHLINE) RIGHT REAR PILLAR SPEAKER (-)
4 X52 20GY/DB RIGHT REAR SPEAKER (+)
5 X13 16DG/GY (HIGHLINE) NAME BRAND SPEAKER RELAY OUTPUT
6 X58 22GY/OR RIGHT REAR SPEAKER (-)
RIGHT REAR VENT MOTOR - NATURAL 3 WAY
CAV CIRCUIT FUNCTION
1- -
2 Q14 16OR/BR (LHD EXCEPT EXPORT) PASSENGER SIDE REAR WINDOW CLOSE
2 Q13 16OR/DB (RHD) DRIVER SIDE REAR WINDOW CLOSE
2 Q14 16OR/BR (LHD EXPORT) PASSENGER SIDE REAR WINDOW CLOSE
3 Q23 16OR/LB (RHD) DRIVER SIDE REAR WINDOW OPEN
3 Q24 16OR/DG (LHD) PASSENGER SIDE REAR WINDOW OPEN
RS8W-80 CONNECTOR PIN-OUTS8W - 80 - 125
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CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Driver Blend Actuator (ATC) GY On HVAC N/S
Driver Blend Actuator (MTC) GY On HVAC N/S
Driver Door Courtesy Lamp GY At Lamp 42
Driver Door Lock Switch BK At Switch 42
Driver Heated Seat Back GN At Seat N/S
Driver Heated Seat Cushion BK At Seat N/S
Driver Heated Seat Module C1 GY Driver Heated Seat N/S
Driver Heated Seat Module C2 GY Driver Heated Seat Back N/S
Driver Heated Seat Module C3 GN At Seat N/S
Driver Power Seat Front Riser
MotorRD At Seat N/S
Driver Power Seat Front Riser
Position SensorBK At Seat N/S
Driver Power Seat Horizontal
MotorBK At Seat N/S
Driver Power Seat Horizontal
Position SensorBK At Seat
Driver Power Seat Rear Riser
MotorRD At Seat N/S
Driver Power Seat Rear Riser
Position SensorBK At Seat N/S
Driver Power Seat Recliner Motor GN At Seat N/S
Driver Power Seat Recliner
Position SensorBK At Seat N/S
Driver Power Seat Switch GN At Switch N/S
Driver Power Window Motor RD At Motor 42
Driver Power Window Switch GN At Switch 42
Driver Power Window Switch
(RHD)NAT At Switch N/S
Driver Seat Belt Switch WT At Switch on Seat Harness N/S
Driver Seat Belt Tensioner On Seat Harness N/S
DVD Player BK Below Radio 19
DVD Screen BK Headliner
DVD/CD Changer Below Radio 19
EGR Solenoid (Diesel) BK Above Transmission
Right Side of EngineN/S
EGR Solenoid GY Above Transmission
Right Side of Engine10, 11, 15, 17
Engine Control Module C1
(Diesel)BK Right Side of Engine 15
Engine Control Module C2
(Diesel)BK Right Side of Engine 15
Engine Coolant Temp Sensor
(Gas)BK On Cylinder Block N/S
8W - 91 - 4 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
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CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Memory Seat Horizontal Position
SensorBK Under Seat N/S
Memory Seat Rear Vertical Motor RD Under Seat N/S
Memory Seat Rear Vertical
Position SensorBK Under Seat N/S
Memory Seat Recliner Motor GN Under Seat N/S
Memory Seat Recliner Position
SensorBK Under Seat N/S
Memory Seat Switch BK At Switch Driver Door 42
Message Center WT Rear of Message Center 19, 20, 27
Mode Door Actuator GY Left Side of HVAC N/S
Multi Function Switch BK At Steering Column 19, 20, 21, 22, 30
Natural Vacuum Leak Detection
AssemblyBK Top of Engine 12
Output Speed Sensor GY Front of Transmission 14, 18
Overhead Console BK Front of Console N/S
Oxygen Sensor 1/1 Upstream BK Rear of Engine 10,11, 12, 18
Oxygen Sensor 1/2 Downstream BK Rear of Engine 10, 11, 12,18
Park/Neutral Positon Switch BK Front of Transmission 11
Passenger Airbag YL Passenger Side of Instrument Panel 19, 22, 23 28
Passenger Blend Door Actuator On HVAC N/S
Passenger Door Courtesy Lamp BK At Lamp 43
Passenger Door Lock Switch BK At Switch 43
Passenger Folding Mirror Relay BL Left Kick Panel 7
Passenger Heated Seat Back GN At Seat N/S
Passenger Heated Seat Cushion BK At Seat N/S
Passenger Heated Seat Module
C1GY At Heated Seat N/S
Passenger Heated Seat Module
C2GY At Heated Seat Back N/S
Passenger Heated Seat Module
C3GN At Heated Seat N/S
Passenger Power Seat Front
Riser MotorRD Under Seat N/S
Passenger Power Seat Horizontal
MotorBK Under Seat N/S
Passenger Power Seat Rear
Riser MotorRD Under Seat N/S
Passenger Power Seat Recliner
MotorGN Under Seat N/S
Passenger Power Seat Switch GN At Switch N/S
Passenger Power Window Motor RD At Motor 43
Passenger Power Window Switch BK At Switch 43
Passenger Seat Belt Switch On Seat Harness N/S
Passenger Seat Belt Tensioner On Seat Harness N/S
8W - 91 - 8 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
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CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Power Folding Mirror Switch BK Near Steering Column 30
Power Liftgate Module C1 BK Left Quarter 45, 46
Power Liftgate Module C2 BK/RD Left Quarter 45, 46
Power Liftgate Motor BK Left Quarter 46
Power Mirror Switch BK Rear of Switch 29
Power Outlet NAT Instrument Panel 19, 22, 24
Power Seat Circuit Breaker GY Under Seat N/S
Powertrain Control Module C1 GY/BK Left Front Engine Compartment 11
Powertrain Control Module C2 GY Left Front Engine Compartment 11
Powertrain Control Module C3 BK Left Front Engine Compartment 11
Powertrain Control Module C4 DKGN Left Front Engine Compartment 11
Power Window Circuit Breaker GY Left Side Kick Panel 40 41
Power Window Switch BK Driver Door 42
Radiator Fan No.1 BK Left Side At Motor 1
Radiator Fan No.1 (Diesel) GY Left Side At Motor 2
Radiator Fan No.2 BK Right Side At Motor 1, 2
Radiator Fan No.2 (Diesel) GY Right Side At Motor N/S
Radiator Fan Relay BK Top of Left Front Frame Rail 1
Radiator Fan Relay No. 1
(Diesel)BL Left Front Engine Compartment 2
Radiator Fan Relay No. 2
(Diesel)BL Left Front Engine Compartment 2
Radiator Fan Relay No. 3
(Diesel)BL Left Front Engine Compartment 2
Radio C1 GY Rear of Radio 19
Radio C2 BK Rear of Radio 19
Rear A/C-Heater Unit LT/GN Right Quarter Panel 47
Rear Automatic Temperature
Control Switch (ATC)BK Rear of Switch 39
Rear Blower Front Control Switch BK Rear of Switch N/S
Rear Blower Motor Power Module
C1Right Quarter N/S
Rear Blower Motor Power Module
C2Right Quarter N/S
Rear Blower Rear Control Switch
C1Overhead 49
Rear Blower Rear Control Switch
C2Overhead 49
Rear Dome Lamp GY At Lamp N/S
Rear Intrusion Sensor At Sensor N/S
Rear Power Outlet RD Left Quarter Panel 46
Rear Temperature Motor Right Quarter N/S
Rear Washer Pump Motor BK Right Fender Well 3
Rear Wiper Motor GY At Motor 48
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-9
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
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SPLICE NUMBER LOCATION FIG.
S340 Near T/O for Passenger Power Window Switch 43
S342 (LHD) Near T/O for Passenger Power Window Motor 43
S343 (LHD) Near T/O for Driver Power Window Motor 42, 43
S344 In T/O to Right Sliding Door Control Module C2 45
S345 Near T/O for Right Sliding Door Motor 45
S346 Near T/O for Driver Power Window Switch 42
S347 Near T/O for Right Sliding Door Lock Motor 45
S348 Near T/O for Left Sliding Door Lock Motor 45
S349 In T/O to Left Sliding Door Control Module - C2 45
S350 Near T/O for Left Sliding Door Motor 45
S351 Near T/O for Liftgate Cylinder Lock Switch 48
S352 Near T/O for Liftgate Cinch/Release Motor 48
S353 Near T/O for C318 46
S354 (Export) Near T/O for C301 35, 36
S354 (Except Export) Near T/O for Driver Heated Seat Module N/S
S355 Near T/O for Passenger Heated Seat Module N/S
S356 (Export) In Floor Pan Track Wiring 36
S356 (Except Export) Near T/O for Passenger Heated Seat Back N/S
S358 (Export) In T/O for Data Link Connector N/S
S359 In Floor Pan Track Wiring 36
S364 (RHD) Near T/O for Passenger Power Window Window 43
S365 (LHD) Near T/O for Driver Power Window Window 43
S366 In Passenger Power Heated Seat Wiring Assembly N/S
S367 In Floor Pan Track Wiring 36
S368 Near T/O for C101 34, 35
S370 In T/O for Integrated Power Module C6 7
S371 In T/O to Power Window Switch N/S
S372 Near T/O for Data Link Connector 40
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-15
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
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SPECIAL TOOLS
POWER DISTRIBUTION SYSTEMS
ACCESSORY RELAY
DESCRIPTION
The accessory relay is an electromechanical device
that switches fused battery current to the accessory
powered vehicle circuits when the ignition switch is
turned to the Accessory or On positions. The delay
feature will maintain power to the accessories for 45
seconds after the ignition is shut off or until a door is
opened. This allows sufficient time to close windows
and park the windshield wipers. The accessory relay
is located in the Integrated Power Module (IPM) in
the engine compartment.
The accessory relay is a International Standards
Organization (ISO) relay. Relays conforming to the
ISO specifications have common physical dimensions,
current capacities, terminal patterns, and terminal
functions.
The accessory relay cannot be repaired or adjusted
and, if faulty or damaged, it must be replaced.
OPERATION
The ISO relay consists of an electromagnetic coil, a
resistor or diode, and three (two fixed and one mov-
able) electrical contacts. The movable (common feed)
relay contact is held against one of the fixed contacts
(normally closed) by spring pressure. When the elec-
tromagnetic coil is energized, it draws the movable
contact away from the normally closed fixed contact,
and holds it against the other (normally open) fixed
contact.
When the electromagnetic coil is de-energized,
spring pressure returns the movable contact to the
normally closed position. The resistor or diode is con-
nected in parallel with the electromagnetic coil in therelay, and helps to dissipate voltage spikes that are
produced when the coil is de-energized.
DIAGNOSIS AND TESTING
DIAGNOSIS & TESTING - ACCESSORY RELAY
The accessory relay (Fig. 1) is located in the Inte-
grated Power Module (IPM), in the engine compart-
ment. For complete circuit diagrams, refer toWiring
Diagrams.
(1) Remove the accessory relay from the IPM.
Refer toAccessory Relayin the Removal and
Installation section of this group for the procedure.
(2) A relay in the de-energized position should
have continuity between terminals 87A and 30, and
no continuity between terminals 87 and 30. If OK, go
to Step 3. If not OK, replace the faulty relay.
(3) Resistance between terminals 85 and 86 (elec-
tromagnet) should be 75   5 ohms. If OK, go to Step
4. If not OK, replace the faulty relay.
(4) Connect a battery to terminals 85 and 86.
There should now be continuity between terminals
30 and 87, and no continuity between terminals 87A
and 30. If OK, perform the Relay Circuit Test that
follows. If not OK, replace the faulty relay.
DIAGNOSIS & TESTING - RELAY CIRCUIT TEST
(1) The relay common feed terminal cavity (30) of
the IPM is connected to battery voltage and should
be hot at all times. Check for battery voltage at the
fused B(+) circuit cavity in the IPM receptacle for the
accessory relay. If OK, go to Step 2. If not OK, repair
the fused B(+) circuit to the IPM fuse as required.
(2) The relay normally closed terminal (87A) is
connected to terminal 30 in the de-energized position,
but is not used for this application. Go to Step 3.
(3) The relay normally open terminal (87) is con-
nected to the common feed terminal (30) in the ener-
gized position. This terminal supplies battery voltage
Terminal Pick Kit 6680
Fig. 1 Accessory Relay
8W - 97 - 2 8W-97 POWER DISTRIBUTION SYSTEMRS
POWER DISTRIBUTION SYSTEM (Continued)
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