ABS CHRYSLER CARAVAN 2003 Manual PDF
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Page 328 of 2177
fuel pump and the heating element in each oxygen
sensor.
The PCM contains a voltage converter that
changes battery voltage to a regulated 8.0 volts. The
8.0 volts power the camshaft position sensor, crank-
shaft position sensor and vehicle speed sensor. The
PCM also provides a 5.0 volts supply for the engine
coolant temperature sensor, intake air temperature
sensor, manifold absolute pressure sensor and throt-
tle position sensor.
The PCM engine control strategy prevents reduced
idle speeds until after the engine operates for 320 km
(200 miles). If the PCM is replaced after 320 km (200
miles) of usage, update the mileage in new PCM. Use
the DRBIIItscan tool to change the mileage in the
PCM. Refer to the appropriate Powertrain Diagnostic
Manual and the DRBIIItscan tool.
TRANSMISSION CONTROL (2.4L MODELS ONLY)
CLUTCH VOLUME INDEX (CVI)
An important function of the PCM is to monitor
Clutch Volume Index (CVI). CVIs represent the vol-
ume of fluid needed to compress a clutch pack.
The PCM monitors gear ratio changes by monitor-
ing the Input and Output Speed Sensors. The Input,
or Turbine Speed Sensor sends an electrical signal to
the PCM that represents input shaft rpm. The Out-
put Speed Sensor provides the PCM with output
shaft speed information.
By comparing the two inputs, the PCM can deter-
mine transaxle gear ratio. This is important to the
CVI calculation because the PCM determines CVIs
by monitoring how long it takes for a gear change to
occur (Fig. 10).
Gear ratios can be determined by using the DRB
Scan Tool and reading the Input/Output Speed Sen-
sor values in the ªMonitorsº display. Gear ratio can
be obtained by dividing the Input Speed Sensor value
by the Output Speed Sensor value.
For example, if the input shaft is rotating at 1000
rpm and the output shaft is rotating at 500 rpm,
then the PCM can determine that the gear ratio is
2:1. In direct drive (3rd gear), the gear ratio changesto 1:1. The gear ratio changes as clutches are applied
and released. By monitoring the length of time it
takes for the gear ratio to change following a shift
request, the PCM can determine the volume of fluid
used to apply or release a friction element.
The volume of transmission fluid needed to apply
the friction elements are continuously updated for
adaptive controls. As friction material wears, the vol-
ume of fluid need to apply the element increases.
Certain mechanical problems within the clutch
assemblies (broken return springs, out of position
snap rings, excessive clutch pack clearance, improper
assembly, etc.) can cause inadequate or out-of-range
clutch volumes. Also, defective Input/Output Speed
Sensors and wiring can cause these conditions. The
following chart identifies the appropriate clutch vol-
umes and when they are monitored/updated:
CLUTCH VOLUMES
ClutchWhen Updated
Proper Clutch
Volume
Shift Sequence Oil Temperature Throttle Angle
L/R2-1 or 3-1 coast
downshift>70É <5É 35to83
2/4 1-2 shift
> 110É5 - 54É20 to 77
OD 2-3 shift 48 to 150
UD 4-3 or 4-2 shift > 5É 24 to 70
Fig. 10 Example of CVI Calculation
1 - OUTPUT SPEED SENSOR
2 - OUTPUT SHAFT
3 - CLUTCH PACK
4 - SEPARATOR PLATE
5 - FRICTION DISCS
6 - INPUT SHAFT
7 - INPUT SPEED SENSOR
8 - PISTON AND SEAL
RSELECTRONIC CONTROL MODULES8E-13
POWERTRAIN CONTROL MODULE (Continued)
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Page 330 of 2177
OPERATION - SENSOR RETURN - PCM INPUT
The sensor return circuit provides a low electrical
noise ground reference for all of the systems sensors.
The sensor return circuit connects to internal ground
circuits within the Powertrain Control Module
(PCM).
OPERATION - DATA BUS COMMUNICATION
RECEIVE - PCM INPUT
The PCM uses the SCI communication bus to pre-
form engine diagnostics and flash operations. The
transmission side of the PCM uses the SCI commu-
nication bus to flash new software. However, diagnos-
tics is performed via the vehicles J1850 bus for the
transmission side of the PCM.
OPERATION - IGNITION SENSE - PCM INPUT
The ignition sense input informs the Powertrain
Control Module (PCM) that the ignition switch is in
the crank or run position.
OPERATION - PCM GROUND
Ground is provided through multiple pins of the
PCM connector. Depending on the vehicle there may
be as many as two different ground pins. There are
power grounds and sensor grounds.
The power grounds are used to control the ground
side relays, solenoids, ignition coil or injectors. The
signal ground is used for any input that uses sensor
return for ground, and the ground side of any inter-
nal processing component.
The PCM case is shielded to prevent RFI and EMI.
The PCM case is grounded and must be firmly
attached to a good, clean body ground.
Internally all grounds are connected together, how-
ever there is noise suppression on the sensor ground.
For EMI and RFI protection the housing and cover
are also grounded separately from the ground pins.
OPERATION
OPERATION - 8-VOLT SUPPLY - PCM OUTPUT
- SBEC CONTROLLER
The PCM supplies 8 volts to the crankshaft posi-
tion sensor, camshaft position sensor.
OPERATION - 5 VOLT SUPPLY - PCM OUTPUT
The PCM supplies 5 volts to the following sensors:
²A/C pressure transducer
²Ambient Temperature sensor
²Battery temperature
²Camshaft Position Sensor (NGC)
²Crankshaft Position Sensor (NGC)
²Electronic Throttle Control (1.6L)²Engine coolant temperature sensor
²Inlet Air Temperature Sensor
²Knock sensor
²Linear EGR solenoid (if equipped)
²Manifold absolute pressure sensor
²Oil Pressure Switch
²Pedal Position Sensor (1.6L)
²Throttle position sensor
²Vehicle Speed Sensor
STANDARD PROCEDURE
STANDARD PROCEDURE - OBTAINING
DIAGNOSTIC TROUBLE CODES
BULB CHECK
Key on: Bulb illuminated until vehicle starts, as
long as all once per trip (readiness) monitors com-
pleted. If monitors havenotbeen completed, then:
Key on: bulb check for about 5 to 8 seconds, lamp
then flashes if once per trip (readiness) monitors
havenotbeen completed until vehicle is started,
then MIL is extinguished.
OBTAINING DTC'S USING DRB SCAN TOOL
(1) Connect the DRB scan tool to the data link
(diagnostic) connector. This connector is located in
the passenger compartment; at the lower edge of
instrument panel; near the steering column.
(2) Turn the ignition switch on and access the
ªRead Faultº screen.
(3) Record all the DTC's and ªfreeze frameº infor-
mation shown on the DRB scan tool.
(4) To erase DTC's, use the ªErase Trouble Codeº
data screen on the DRB scan tool.Do not erase any
DTC's until problems have been investigated
and repairs have been performed.
STANDARD PROCEDURE - PINION FACTOR
SETTING
NOTE: This procedure must be performed if the
PCM/TCM has been replaced with a NEW or
replacement unit. Failure to perform this procedure
will result in an inoperative or improperly calibrated
speedometer.
The vehicle speed readings for the speedometer are
taken from the output speed sensor. The PCM/TCM
must be calibrated to the different combinations of
equipment (final drive and tires) available. Pinion
Factor allows the technician to set the Powertrain/
Transmission Control Module initial setting so that
the speedometer readings will be correct. To properly
RSELECTRONIC CONTROL MODULES8E-15
POWERTRAIN CONTROL MODULE (Continued)
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Page 341 of 2177
²Battery Holddown- The battery holddown
hardware secures the battery in the battery tray in
the engine compartment.
²Battery Thermowrap- The battery thermow-
rap insulates the battery to protect it from engine
compartment temperature extremes.
²Battery Tray- The battery tray provides a
secure mounting location in the vehicle for the bat-
tery and an anchor point for the battery holddown
hardware.
For battery system maintenance schedules and
jump starting procedure, see the owner's manual in
the vehicle glove box. Optionally, refer to the Lubri-
cation and Maintenance section of this manual for
the recommended battery maintenance schedules and
for the proper battery jump starting procedure. While
battery charging can be considered a maintenance
procedure, the battery charging procedure and
related information are located later in this section of
this service manual. This was done because the bat-
tery must be fully-charged before any battery system
diagnosis or testing procedures can be performed.
OPERATION
The battery system is designed to provide a safe,
efficient, reliable and mobile means of delivering and
storing electrical energy. This electrical energy is
required to operate the engine starting system, as
well as to operate many of the other vehicle acces-
sory systems for limited durations while the engine
and/or the charging system are not operating. The
battery system is also designed to provide a reserve
of electrical energy to supplement the charging sys-
tem for short durations while the engine is running
and the electrical current demands of the vehicle
exceed the output of the charging system. In addition
to delivering, and storing electrical energy for the
vehicle, the battery system serves as a capacitor and
voltage stabilizer for the vehicle electrical system. It
absorbs most abnormal or transient voltages caused
by the switching of any of the electrical components
or circuits in the vehicle.
DIAGNOSIS AND TESTING - BATTERY SYSTEM
The battery, starting, and charging systems in the
vehicle operate with one another and must be tested
as a complete system. In order for the engine to start
and the battery to maintain its charge properly, all of
the components that are used in these systems must
perform within specifications. It is important that
the battery, starting, and charging systems be thor-
oughly tested and inspected any time a battery needs
to be charged or replaced. The cause of abnormal bat-
tery discharge, overcharging or early battery failure
must be diagnosed and corrected before a battery is
replaced and before a vehicle is returned to service.
The service information for these systems has been
separated within this service manual to make it eas-
ier to locate the specific information you are seeking.
However, when attempting to diagnose any of these
systems, it is important that you keep their interde-
pendency in mind.
The diagnostic procedures used for the battery,
starting, and charging systems include the most
basic conventional diagnostic methods, to the more
sophisticated On-Board Diagnostics (OBD) built into
the Powertrain Control Module (PCM). Use of an
induction-type milliampere ammeter, a volt/ohmme-
ter, a battery charger, a carbon pile rheostat (load
tester) and a 12-volt test lamp may be required. All
OBD-sensed systems are monitored by the PCM.
Each monitored circuit is assigned a Diagnostic Trou-
ble Code (DTC). The PCM will store a DTC in elec-
tronic memory for any failure it detects. Refer to
Charging System for the proper charging system on-
board diagnostic test procedures.
MICRO 420 BATTERY TESTER
The Micro 420 automotive battery system tester is
designed to help the dealership technicians diagnose
the cause of a defective battery. Follow the instruc-
tion manual supplied with the tester to properly
diagnose a vehicle. If the instruction manual is not
available refer to the standard procedure in this sec-
tion, which includes the directions for using the
Micro 420 battery tester.
8F - 2 BATTERY SYSTEMRS
BATTERY SYSTEM (Continued)
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Page 407 of 2177
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - SELF-DIAGNOSTICS
The instrument clusters are equipped with a self
diagnostic test feature to help identify electronic prob-
lems. Prior to any test, perform the Self-Diagnostic
Test. The self diagnostic system displays instrument
cluster stored fault codes in the odometer display,
sweeps the gauges to the calibration points, and bulb
checks the warning indicators. When the key is in the
ON position with the engine not running, the MIL will
remain illuminated for regulatory purposes.
To activate the Self-Diagnostic program:
(1) With the ignition switch in the OFF position,
depress the TRIP ODOMETER RESET button.
(2) Continue to hold the TRIP ODOMETER
RESET button untilSofand a number (software ver-
sion number (i.e.Sof 3.2) appears in the odometer
window then release the button. If a fault code is
present, the cluster will display it in the odometer
display. When all fault codes have been displayed,
the cluster will displayªendºin the odometer dis-
play. Refer to the INSTRUMENT CLUSTER DTC'S
table to determine what each trouble code means.
INSTRUMENT CLUSTER DTC'S
DTC DESCRIPTION
100.0 LOOP-BACK FAILURE
100.1 ABS COMMUNICATION FAULT
100.2 BCM COMMUNICATION FAULT
100.3 EATX COMMUNICATION FAULT
100.4 FCM COMMUNICATION FAULT
100.5 ORC COMMUNICATION FAULT
100.6SBEC/DEC/MCM COMMUNICATION
FAULT
200.0 AIRBAG LED SHORT
200.1 AIRBAG LED OPEN
200.2 ABS LED SHORT
200.3 ABS LED OPEN
200.6 EL INVERTER TIME-OUT
200.7 EATX MISMATCH
400.0 EEPROM READ/WRITE FAILURE
400.1IMPROPER POWER DOWN
DETECTED
CALIBRATION TEST
The CLUSTER CALIBRATION table contains the
proper calibration points for each gauge. If the gauge
pointers are not calibrated, a problem exists in the
cluster. If any gauge is out of calibration, replace the
cluster.
CLUSTER CALIBRATION
SPEEDOMETER CALIBRATION POINT
1 0 MPH (0 KM/H)
2 20 MPH (40 KM/H)
3 60 MPH (100 KM/H)
4 100 MPH (160 KM/H)
TACHOMETER
1 0 RPM
2 1000 RPM
3 3000 RPM
4 6000 RPM
FUEL GAUGE
1 EMPTY
2 1/4 FILLED
3 1/2 FILLED
4 FULL
TEMPERATURE
GAUGE
1 COLD
2 1/4
3 3/4
4 HOT
ODOMETER SEGMENT TEST
If a segment in the odometer does not illuminate
normally, a problem exists in the display.
ELECTRONIC TRANSMISSION RANGE INDICATOR
SEGMENT TEST
If a segment in the transmission range indicator
does not illuminate normally, a problem exists in the
display.
DIAGNOSIS AND TESTING - CLUSTER
DIAGNOSIS
CONDITIONS
Refer to the following tables for possible problems,
causes, and corrections.
²INSTRUMENT CLUSTER DIAGNOSIS
²SPEEDOMETER DIAGNOSIS
²TACHOMETER DIAGNOSIS
²FUEL GAUGE DIAGNOSIS
²TEMPERATURE GAUGE DIAGNOSIS
²ODOMETER DIAGNOSIS
²ELECTRONIC GEAR INDICATOR DISPLAY
DIAGNOSIS
NOTE: Always check the functionality of the cluster
by running the self test prior to troubleshooting.
8J - 2 INSTRUMENT CLUSTERRS
INSTRUMENT CLUSTER (Continued)
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Page 421 of 2177
(b) Install the switch in its bracket by aligning
the index tab on the switch with the slot in the
mounting bracket.
(c) When the switch is fully seated in its
bracket, rotate the switch clockwise approximately
30É to lock the switch into place.
(d) With the brake pedal in the fully released
position, move the lever on the back of the brake
lamp switch from the angled non-adjusted position
to the full vertical position as shown (Fig. 4). This
will adjust the brake lamp switch to the vehicle.(2) Install silencer panel below steering column
knee blocker.
(3) Reconnect the battery negative terminal.
(4) Check the stop lamps to verify they are operat-
ing properly and not staying on when the pedal is in
the released position.
(5) Road test the vehicle to ensure proper opera-
tion of the brakes including ABS and speed control (if
equipped).
CENTER HIGH MOUNTED
STOP LAMP
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove two retaining screws (Fig. 5).
(3) Twist socket counter-clockwise and remove
from lamp.
(4) Pull bulb from socket (Fig. 7).
INSTALLATION
(1) Push bulb into socket.
(2) Install socket into the lamp unit.
(3) Install the retaining screws.
(4) Reconnect the battery negative cable.
CENTER HIGH MOUNTED
STOP LAMP UNIT
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the two retaining screws (Fig. 5).
(3) Disconnect the rear window washer nozzle
assembly (Fig. 6).
Fig. 3 Brake Lamp Switch And Pedal With Bracket
1 - BRAKE LAMP SWITCH
2 - WIRING CONNECTOR
3 - PEDAL AND BRACKET
Fig. 4 Adjustment Lever Movement
Fig. 5 CHMSL UNIT
1 - CHMSL UNIT
2 - LIFTGATE
8L - 6 LAMPS/LIGHTING - EXTERIORRS
BRAKE LAMP SWITCH (Continued)
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Page 437 of 2177
PARK/TURN SIGNAL LAMP -
EXPORT
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the headlamp unit (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING - EXTERIOR/HEAD-
LAMP UNIT - EXPORT - REMOVAL).
(3) Remove the rubber boot cover.
(4) Twist bulb socket and remove from headlamp
unit (Fig. 28).
(5) Depress, then rotate the bulb and remove from
bulb socket.
INSTALLATION
(1) Install bulb into bulb socket.
(2) Install bulb socket to headlamp unit.
(3) Install rubber boot cover.
(4) Install headlamp unit (Refer to 8 - ELECTRI-
CAL/LAMPS/LIGHTING - EXTERIOR/HEADLAMP
UNIT - EXPORT - INSTALLATION).
(5) Connect battery negative cable.
REAR FOG LAMP - EXPORT
DESCRIPTION
The rear fog lamps are incorporated into the tail
lamp unit. (Refer to 8 - ELECTRICAL/LAMPS/
LIGHTING - EXTERIOR/TAIL LAMP - REMOVAL)
for service procedures.
REPEATER LAMP - EXPORT
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Push the side repeater lamp to the right and
release retaining tab on the left.
(3) Pull side repeater lamp out and disengage bulb
socket from lamp.
(4) Depress, then rotate and pull bulb from socket.
INSTALLATION
(1) Install bulb to socket.
(2) Push lamp socket into the side repeater lamp.
(3) Position metal spring clip in fender hole notch.
(4) Position side repeater lamp to hole in fender.
(5) Push side repeater lamp to compress metal
spring clip and seat retaining tab into fender.
(6) Connect battery negative cable.
TAIL LAMP
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the tail lamp unit. (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING - EXTERIOR/TAIL
LAMP UNIT - REMOVAL).
(3) Squeeze the tabs on the bulb socket and
remove from tail lamp unit (Fig. 29).
(4) Pull bulb from lamp socket.
INSTALLATION
(1) Push bulb into the lamp socket.
Fig. 27 PARK/TURN SIGNAL LAMP
1 - PARK/TURN SIGNAL LAMP
2 - LAMP SOCKET
Fig. 28 PARK/TURN SIGNAL LAMP
1 - LOW BEAM HEADLAMP
2 - PARK/TURN SIGNAL LAMP
8L - 22 LAMPS/LIGHTING - EXTERIORRS
PARK/TURN SIGNAL LAMP (Continued)
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Page 438 of 2177
(2) Install bulb socket into the tail lamp unit.
Ensure that both retaining tabs engage with an audi-
ble click.
(3) Install the tail lamp unit. (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING - EXTERIOR/TAIL
LAMP UNIT - INSTALLATION).
(4) Reconnect the battery negative cable.
TAIL LAMP - EXPORT
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the tail lamp unit (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING - EXTERIOR/TAIL
LAMP UNIT - REMOVAL).
(3) Squeeze the tabs on the back plate retaining
the bulbs and remove from the tail lamp unit (Fig.
30).
(4) Remove bulbs by depressing, then turning
counter-clockwise.
INSTALLATION
(1) Install bulbs by turning clockwise.
(2) Install back plate to tail lamp unit making
sure that both tabs are engaged to the housing.
(3) Install the tail lamp unit (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING - EXTERIOR/TAIL
LAMP UNIT - INSTALLATION).
(4) Connect the battery negative cable.
TAIL LAMP UNIT
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Raise the liftgate.(3) Remove the two retaining fasteners by prying
under the head of the fastener with a flat bladed tool
(Fig. 31).
(4) Rotate the lamp away from the vehicle body to
disengage hook from the rubber grommet in the
quarter panel opening.
(5) Disconnect wire harness connector from tail
lamp unit by sliding the red lock, then pressing
release tab (Fig. 32).
INSTALLATION
(1) Reconnect wire harness connector to the tail
lamp. Slide red connector lock into position.
(2) Engage hook into rubber grommet in quarter
panel opening.
(3) Place lamp into position on quarter panel.
Fig. 29 TAIL LAMP SOCKET
1 - LAMP SOCKET
2 - TAIL LAMP UNIT
Fig. 30 TAIL LAMP BULBS - EXPORT
1 - TAIL LAMP UNIT
2 - TAIL LAMP
3 - TURN SIGNAL LAMP
4 - BACK UP LAMP
5 - REAR FOG LAMP
Fig. 31 TAIL LAMP UNIT FASTENERS
1 - TAIL LAMP UNIT FASTENER
2 - TAIL LAMP UNIT
RSLAMPS/LIGHTING - EXTERIOR8L-23
TAIL LAMP (Continued)
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LAMPS/LIGHTING - INTERIOR
TABLE OF CONTENTS
page page
LAMPS/LIGHTING - INTERIOR
SPECIFICATIONS
INTERIOR LAMPS.....................25
CENTER CONSOLE LAMP SWITCH
REMOVAL.............................26
INSTALLATION.........................26
CLUSTER ILLUMINATION LAMPS
REMOVAL.............................26
INSTALLATION.........................26
COURTESY LAMP
REMOVAL.............................26
INSTALLATION.........................26
DOME/CARGO LAMP
REMOVAL.............................26INSTALLATION.........................26
GLOVE BOX LAMP SWITCH
REMOVAL.............................26
INSTALLATION.........................26
LIFTGATE LAMP
REMOVAL.............................27
INSTALLATION.........................27
READING LAMP
REMOVAL.............................27
INSTALLATION.........................28
VANITY LAMP
REMOVAL.............................28
INSTALLATION.........................28
LAMPS/LIGHTING - INTERIOR
SPECIFICATIONS
INTERIOR LAMPS
BULB APPLICATION TABLE
LAMP BULB
ABS LED
AIRBAG LED
ALARM SET PC74
AUTOSTICK VFD*
BRAKE SYSTEM
WARNINGLED
CONSOLE 194
CRUISE INDICATOR VFD*
DOME/RAIL LAMPS 578
DOOR AJAR INDICATOR LED
DOOR COURTESY
LAMP578
FRONT DOOR
COURTESY567
GLOVE BOX 194
HIGH BEAM INDICATOR
(BASE CLUSTER)LED
HIGH BEAM INDICATOR PC74
LAMP BULB
CLUSTER
ILLUMINATIONPC74
LIFTGATE 578
LIFTGATE AJAR LED
LOW FUEL INDICATOR LED
LOW WASHER FLUID
INDICATORLED
MIL (BASE CLUSTER) LED
MIL PC74
OIL INDICATOR (BASE
CLUSTER)LED
OIL INDICATOR PC74
OVERHEAD CONSOLE
READINGPC579
OVERDRIVE OFF
INDICATORVFD*
READING 578
SEAT BELT INDICATOR LED
TEMPERATURE
INDICATORLED
TRAC OFF INDICATOR VFD*
TURN SIGNAL
INDICATOR (BASE
CLUSTER)LED
TURN SIGNAL
INDICATORPC74
VISOR VANITY 6501966
RSLAMPS/LIGHTING - INTERIOR8L-25
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Page 467 of 2177
(3) Remove the rear lamp bar assembly from the
vehicle. Refer to the Body section of the service man-
ual for the procedure.
(4) Locate the two wires going to the exterior han-
dle switch. Cut the tie strap and trace the wires to
the large electrical connector and back the wires out
of the large connector and through the grommet.
Refer to the Wiring section of the service manual for
detailed instructions.
(5) Depress the two exterior handle switch retain-
ing tabs and roll the switch out of the light bar
assembly (Fig. 7).
INSTALLATION
(1) Install the handle switch in the light bar
assembly.
(2) Locate the two wires going to the exterior han-
dle switch. Install the wires through the grommet
and in the large connector. Secure with a tie strap.
Refer to the Wiring section of the service manual for
detailed instructions.
NOTE: Be certain wires are reinstalled in the correct
wire cavities. Failure to do so could result in dam-
age to the handle switch. Refer to Wiring Diagrams
if previous notes were not made.
(3) Install the rear light bar. Refer to the Body sec-
tion of the service manual for the procedure.
(4) Install the liftgate trim panel. Refer to the
Body section of the service manual for the procedure.
(5) Connect the negative battery cable.(6) Using an appropriate scan tool, check any
erase any power liftgate control module diagnostic
trouble codes.
(7) Verify power liftgate system and handle switch
operation. Cycle the power liftgate through one com-
plete open and close cycle, this will allow the power
liftgate control module to relearn its cycle with the
new components.
FULL OPEN SWITCH
DESCRIPTION
Vehicles equipped with a power liftgate utilize a
full open switch. This switch is located on the gear
motor housing (Fig. 8) and is used to signal the
power liftgate module when the liftgate is in the full
open position. Two wires are used from the full open
switch contacts to the gear motor assemblies main
electrical connector.
The full open switch is a serviceable component.
Consult your Mopar parts catalog for a specific part
number.
OPERATION
When the power liftgate reaches the full open posi-
tion, the gear motor housing mounted full open
switch electrical contacts come in contact with each
other. This sends a ground signal to the power lift-
Fig. 7 REAR LIGHT BAR
1 - CHIME / THERMISTOR
2 - ELECTRIC RELEASE HANDLE SWITCH
3 - LICENSE PLATE LAMPS
Fig. 8 FULL OPEN SWITCH LOCATION
1 - FULL OPEN SWITCH
2 - GEAR MOTOR ASSEMBLY RETAINING BOLT (1 OF 3)
8N - 12 POWER LIFTGATE SYSTEMRS
EXTERIOR HANDLE SWITCH (Continued)
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Page 503 of 2177
ered. This defeats the day-detect logic. If OK, go to
Step 8. If not OK, replace the faulty mirror unit.
(8) With the mirror darkened, place the transmis-
sion gear selector lever in the Reverse position. The
automatic day/night mirror should return to its nor-
mal reflectance. If not OK, replace the faulty mirror
unit.
Bench testing both mirrors can be done, of care is
exercised. For an inside mirror, the pin closest to he
mount is 12V (+), the next is 12V (-). The third is
reverse override. The fourth is outside mirror (+),
and the fifth is outside mirror (-).Do not apply 12
volts to the fourth and fifth pins.With 12 volts
on pins 1 and 2, the mirror can be tested by blocking
the rear sensor and shining a light into the forward
sensor. For an outside mirror, there is a 2±pin con-
nector. Applying 1.2 volts will cause the mirror to
dim. If the mirror does not dim, the entire glass
assembly can be replaced just as it is when the glass
is broken.
WARNING: Do not apply 12 volts to the outside mir-
ror. Damage to the mirror will result.
POWER FOLDAWAY MIRROR
SWITCH - EXPORT
DESCRIPTION
These vehicles may be equipped with Power Fold-
away Mirrors. This feature allows both the driver
and passenger side view mirrors to fold inward
(retract) on demand. The vehicle has an additional
switch located on the steering column that controls
the folding function of the mirror assembly (Fig. 2).
The fold-away side view mirror is attached to the
vehicle's door in the same manner as mirrors without
the fold-away option. The fold-away mirrors unique
option is the internal motor which allows the mirrors
to fold inward on demand. The fold-away mirror
motor is not serviceable separately and if a motor is
found to be faulty the entire side view mirror must
be replaced.
OPERATION
When the mirror retract switch is depressed, both
of the side view mirrors will fold inward, Thus mak-
ing the overall width of the vehicle the smallest pos-
sible. This can be helpful were parking space is a
absolute minimum.
When the driver's door is opened, only the driver's
door mirror will unfold. If the passenger door is
opened, both mirrors will unfold.
The power fold away mirror system consists of the
following components: mirror switch, side view mir-ror, relay, wires and fuse. Refer to the appropriate
wiring information. The wiring information includes
wiring diagrams, proper wire and connector repair
procedures, details of wire harness routing and
retention, connector pin-out information and location
views for the various wire harness connectors, splices
and grounds.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the upper and lower steering column
shroud (Refer to 19 - STEERING/COLUMN/LOWER
SHROUD - REMOVAL).
(3) Disconnect electrical harness connector.
(4) Remove switch from steering column shroud
(Fig. 3).
Fig. 2 POWER FOLDAWAY MIRROR SWITCH
1 - POWER FOLDAWAY MIRROR SWITCH
2 - STEERING COLUMN
Fig. 3 POWER FOLDING MIRROR SWITCH
1 - STEERING COLUMN SHROUD
2 - POWER FOLDAWAY SWITCH
8N - 48 POWER MIRRORSRS
AUTOMATIC DAY / NIGHT MIRROR (Continued)
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