integrated power module CHRYSLER CARAVAN 2005 Manual PDF

INTEGRATED POWER MODULE C8 - ORANGE 10 WAY
CAV CIRCUIT FUNCTION
1 W3 14BR/WT FRONT WIPER HIGH/LOW RELAY LOW SPEED OUT-
PUT
2 N1 16DB/OR (DIESEL) FUEL HEATER RELAY OUTPUT
2 N1 18DB/OR (GAS) FUEL PUMP RELAY OUTPUT
3 A108 18LG/RD (EXCEPT EXPORT) FUSED B(+)
3 A108 20LG/RD (EXPORT) FUSED B(+)
3 A108 20LG/RD (EXPORT) FUSED B(+)
4 A103 18GY/RD FUSED B(+)
5 L77 18WT/BR FUSED PARK LAMP RELAY OUTPUT (LEFT)
6 W4 14BR/OR FRONT WIPER HIGH/LOW RELAY HIGH SPEED OUT-
PUT
7 C51 12LB/BR (3 ZONE HVAC) FUSED REAR BLOWER MOTOR RELAY OUTPUT
8- -
9 L78 18WT/OR FUSED PARK LAMP RELAY OUTPUT (RIGHT)
10 L60 18WT/TN RIGHT FRONT TURN SIGNAL DRIVER
INTEGRATED POWER MODULE C9 - BLACK 10 WAY
CAV CIRCUIT FUNCTION
1 A116 14YL/RD (HIGHLINE AUDIO) FUSED B(+)
2 F20 18PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
3 C15 12DB/WT FUSED DEFOGGER RELAY OUTPUT
4 A105 18DB/RD FUSED B(+)
5 L61 20WT/LB LEFT FRONT TURN SIGNAL DIVER
6 A701 18BR/RD FUSED B(+) (HAZARD)
6 A701 16BR/RD FUSED B(+) (HAZARD)
7 F306 16DB/PK FUSED ACCESSORY RELAY OUTPUT
8 F30 12PK/YL (POWER WINDOWS) FUSED ACCESSORY RELAY OUTPUT
9 A115 12YL/RD FUSED B(+)
10 F302 18GY/PK FUSED ACCESSORY RELAY OUTPUT
KNOCK SENSOR (EXCEPT EXPORT) - BLACK 2 WAY
CAV CIRCUIT FUNCTION
1 K42 18DB/YL KS SIGNAL
2 K942 18BR/LG KS RETURN
RS8W-80 CONNECTOR PIN-OUTS8W-80-85

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Engine Coolant Temp Sensor
(Gas)BK On Cylinder Block N/S
Engine Oil Pressure Sensor
(Diesel)BK Rear of Engine 16
Engine Coolant Temp Sensor
(Diesel)BL On Cylinder Block 15
Engine Oil Pressure Switch (Gas) LTGN On Cylinder Block 12, 18
Engine Starter Motor At Starter Motor 13, 15, 18
EVAP/Purge Solenoid (Gas) BK Right Motor Mount 10, 17
Evaporator Temperature Sensor BK Right Side of HVAC N/S
Floor Console Lamp BK At Lamp N/S
Floor Console Power Outlet RD At Front Console N/S
Front Blower Module C1 (ATC) BK On HVAC N/S
Front Blower Module C2 (ATC) BK On HVAC N/S
Front Cigar Lighter RD/NAT Rear of Lighter 20, 23, 25
Front Control Module BK In Integrated Power Module N/S
Front Intrusion Sensor (United
Kingdom)BK At Sensor N/S
Front Reading Lamps/Switch BK At Switch N/S
Fuel Heater (Diesel) BK Left Rear Engine Compartment N/S
Fuel Injector No.1 (2.4L/3.3L/
3.8L)BK At Fuel Injector N/S
Fuel Injector No.1 (Diesel) BK At Fuel Injector 15
Fuel Injector No.2 (2.4L/3.3L/
3.8L)BK At Fuel Injector N/S
Fuel Injector No.2 (Diesel) BK At Fuel Injector 15
Fuel Injector No.3 (2.4L/3.3L/
3.8L)BK At Fuel Injector N/S
Fuel Injector No.3 (Diesel) BK At Fuel Injector 15
Fuel Injector No.4 (2.4L/3.3L/
3.8L)BK At Fuel Injector N/S
Fuel Injector No.4 (Diesel) BK At Fuel Injector 15
Fuel Injector No.5 (3.3L/3.8L) BK At Fuel Injector N/S
Fuel Injector No.6 (3.3L/3.8L) BK At Fuel Injector N/S
Fuel Pressure Sensor (Diesel) BK Top Left of Engine 15
Fuel Pressure Solenoid (Diesel) Right Front Engine 15
Fuel Pump Module LTGY Side of Fuel Tank 34
Generator BK Rear of Generator 11, 15, 17, 18
Glow Plug No.1 (Diesel) Top of Engine N/S
Glow Plug No.2 (Diesel) Top of Engine 15
Glow Plug No.3 (Diesel) Top of Engine 15
Glow Plug No.4 (Diesel) Top of Engine 15
Glow Plug Relay (Diesel) BK Near Transmission 15, 16
Hands Free Module C1 Instrument Panel N/S
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-5
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Hands Free Module C2 BK Instrument Panel N/S
Hands Free Module C3 Instrument Panel N/S
Headlamp Switch BK Rear of Switch 20, 21, 30
Headlamp Washer Pump Motor
(Export)BK At Motor 3
High Note Horn BK Left Frame Rail 5
Hood Ajar Switch (Export) BK Left Fender 6
Idle Air Control Motor (Gas) BK On Throttle Body 10, 11 17
Ignition Coil (2.4L) BK Top of Valve Cover 10, 11
Ignition Coil (3.3L/ 3.8L) DKGY Top of Engine 17, 18
Ignition Switch BK Rear of Switch at Steering Column 20, 21, 22, 23, 31
Inlet Air Temperature Sensor BK Top Left of Engine 9, 10, 11, 17
Input Speed Sensor GY Front of Transmission 14, 19
Instrument Cluster BK Rear of Cluster 20, 21, 28
Instrument Panel Switch Bank
(Heated Seats)BK Right Center of Instrument Panel 20, 23, 25
Instrument Panel Switch Bank
(Except Heated Seats)Right Center of Instrument Panel 20, 23, 25
Integrated Power Module C1 Left Fender Shield 7
Integrated Power Module C2 GN/BL Left Fender Shield 7
Integrated Power Module C3 Left Fender Shield 7, 11
Integrated Power Module C4 BL Left Fender Shield 7, 11
Integrated Power Module C5 BK Left Fender Shield 7
Integrated Power Module C6 NAT Left Fender Shield 7
Integrated Power Module C7 Left Fender Shield 7
Integrated Power Module C8 OR Left Fender Shield 7
Integrated Power Module C9 BK Left Fender Shield 7
Knock Sensor (Except Export) BK At Engine Block 11
Left B Pillar Switch (Power
Sliding Door)GY Left B Pillar 40
Left Cinch/Release Motor (Power
Sliding Door)GY Left Sliding Door N/S
Left Curtain Airbag Squib Rear of Left Roof Rail 47
Left Cylinder Lock Switch BK At Switch 43
Left Door Speaker BK At Speaker 43
Left Fog Lamp BK At Lamp 5
Left Front Door Ajar Switch
(Base)BK At Switch N/S
Left Front Door Lock Motor/Ajar
Switch (Except Base)BK Left Door 43
Left Front Impact Sensor BK Near T/O for C101 5
Left Front Park/Turn Signal Lamp
(Except Export)DKGY At Lamp 1
Left Front Wheel Speed Sensor GY Left Fender Side Shield 5, 11
8W - 91 - 6 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

SPLICES
SPLICE NUMBER LOCATION FIG.
S101 (Gas) Near T/O for Radiator Fan No.1 1
S103 (Diesel) Between T/O for Battery Temperature Sensor and T/O
for C10215
S106 (2.5L) Near T/O for Battery Temperature Sensor 15
S106 (3.3L/3.8L) Near T/O for G103 18
S107 (Gas) Near T/O for Integrated Power Module C3 11
S107 (Diesel) In T/O for Integrated Power Module C3 7
S111 (2.4L) Near T/O for C101 11
S111 (Diesel) In T/O for Battery (-) N/S
S111 (3.3L/3.8L) Near T/O for Battery Temperature Sensor N/S
S112 (Gas) Near T/O for Integrated Power Module - C3 19, 5, 11
S113 (2.4L) Near T/O for Park/Neutral Position Switch 11
S114 (2.4L) Near T/O for Powertrain Control Module C4 11
S114 (3.3L/3.8L) In T/O to Transmission Control Module N/S
S115 (2.4L) Near T/O for Powertrain Control Module C4 11
S115 (3.3L/3.8L) In T/O to Transmission Control Module N/S
S116 (2.4L) 180mm from T/O for Torque Converter Clutch Solenoid 11, 13
S116 (Diesel) Near T/O for Mass Air Flow Sensor 16
S116 (3.3L/3.8L) Near T/O for G103 18
S118 (2.4L) Near T/O for Knock Sensor 11, 13
S119 (Diesel) Near T/O for Engine Starter Motor 15
S121 (3.3L/3.8L) Near T/O for Output Speed Sensor 18
S122 (2.4L) In T/O to Engine Starter Motor 13
S122 (3.3L/3.8L) In T/O to Engine Starter Motor 18
S124 (2.4L) Near T/O for Fuel Injector No.2 N/S
S124 (3.3L/3.8L) Near T/O for Fuel Injector No.5 and No.6 N/S
S125 (2.4L) In T/O for Manifold Absolute Pressure Sensor N/S
S126 In Right Headlamp Leveling Assembly N/S
S127 (Diesel) In T/O for Engine Starter Motor N/S
S128 (Diesel) Near T/O for Engine Starter Motor N/S
S129 (Diesel) Near T/O for Battery (+) N/S
S130 (Diesel) Near T/O for Battery (+) N/S
S131 (2.4L) Near T/O for Transmission Control Module 11
S131 (3.3L/3.8L) Near T/O for C110 N/S
S132 (Diesel) Near T/O for Battery (+) N/S
S134 (Diesel) IN T/O for Engine Control Module N/S
S135 (Diesel) Near T/O for Glow Plug No.2 N/S
S136 (Diesel) In T/O for Radiator Fan Relays 2
S137 (Diesel) Above Starter 15
S138 (Diesel) Between T/O for Radiator Fan No.2 and T/O for G102 N/S
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-13
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

SPLICE NUMBER LOCATION FIG.
S355 In T/O for C307 N/S
S356 (Export) In Floor Pan Track Wiring 37
S356 (Except Export) Near T/O for Passenger Heated Seat Back N/S
S359 Left Quarter Panel 47
S361 Near T/O for C304 N/S
S362 Near T/O for C304 N/S
S363 Near T/O for C331 N/S
S364 (RHD) Near T/O for Passenger Power Window Window 44
S365 (LHD) Near T/O for Driver Power Window Window N/S
S366 In Passenger Power Heated Seat Wiring Assembly N/S
S367 Near T/O for C301 37
S368 (Diesel) Near T/O for C101 35, 36
S370 (Except Export) 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 41
S373 (Except Export In Floor Pan Track Wiring 37
S374 Near T/O for Body Control Module N/S
S376 (Highline Audio) In Floor Pan Track Wiring 34
S378 Near T/O for C301 35, 36, 37
S380 (Highline Audio) Right Quarter Panel 48
S381 (Highline Audio) Right Quarter Panel 48
S382 (Passenger Heated
Seat)Near T/O for Passenger Seat Weight Sensor N/S
S383 (Parktronics) Rear Fascia N/S
S384 (Parktronics) Rear Fascia N/S
8W - 91 - 16 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

Fig. 7 INTEGRATED POWER MODULE
8W - 91 - 22 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)

8W-97 POWER DISTRIBUTION SYSTEM
TABLE OF CONTENTS
page page
POWER DISTRIBUTION SYSTEM
DESCRIPTION..........................1
OPERATION............................1
SPECIAL TOOLS
POWER DISTRIBUTION SYSTEMS.........1
INTEGRATED POWER MODULE
DESCRIPTION..........................1
OPERATION............................2
REMOVAL.............................2
INSTALLATION..........................2IOD FUSE
DESCRIPTION..........................3
OPERATION............................3
POWER OUTLET
DESCRIPTION..........................3
OPERATION............................3
DIAGNOSIS AND TESTING
DIAGNOSIS & TESTING - POWER OUTLET . . 3
REMOVAL.............................4
INSTALLATION..........................4
POWER DISTRIBUTION
SYSTEM
DESCRIPTION
The power distribution system for this vehicle con-
sists of the following components:
²Integrated Power Module (IPM)
²Front Control Module (FCM)
²Power Outlets
Refer to Wiring Diagrams for complete circuit sche-
matics.
The power distribution system also incorporates
various types of circuit control and protection fea-
tures, including:
²Automatic resetting circuit breakers
²Blade-type fuses
²Bus bars
²Cartridge fuses
²Circuit splice blocks
²Flashers
²Fusible links
²Relays
OPERATION
The power distribution system for this vehicle is
designed to provide safe, reliable, and centralized dis-
tribution points for the electrical current required to
operate all of the many standard and optional facto-
ry-installed electrical and electronic powertrain,
chassis, safety, security, comfort and convenience sys-
tems. At the same time, the power distribution sys-
tem was designed to provide ready access to these
electrical distribution points for the vehicle techni-
cian to use when conducting diagnosis and repair of
faulty circuits. The power distribution system can
also prove useful for the sourcing of additional elec-
trical circuits that may be required to provide theelectrical current needed to operate many accessories
that the vehicle owner may choose to have installed.
SPECIAL TOOLS
POWER DISTRIBUTION SYSTEMS
INTEGRATED POWER MODULE
DESCRIPTION
The Integrated Power Module (IPM) is a combina-
tion of the Power Distribution Center (PDC) and the
Front Control Module (FCM). The IPM is located in
the engine compartment, next to the battery. (Fig. 1).
The PDC mates directly with the FCM to form the
IPM. The PDC is a printed circuit board based mod-
ule that contains fuses and relays, while the FCM
contains the electronics controlling the IPM and
other functions. This IPM connects directly to the
battery positive through a four pin connector. The
ground connection is through two other connectors.
Terminal Pick Kit 6680
RS8W-97 POWER DISTRIBUTION SYSTEM8W-97-1

The IPM provides the primary means of voltage dis-
tribution and protection for the entire vehicle.
OPERATION
All of the current from the battery and the gener-
ator output enters the Integrated Power Module
(IPM) through a four- pin connector on the bottom of
the module. Internal connections of all of the power
distribution center circuits is accomplished by a com-
bination of bus bars and a printed circuit board.
REMOVAL
(1) Disconnect the negative and positive battery
cables.
(2) Remove the battery thermal guard.
(3) Remove the battery (Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/BATTERY - REMOVAL).
(4) Using a flat-bladed screwdriver, twist the Inte-
grated Power Module (IPM) bracket retaining latch
outward to free the IPM from its mounting bracket
(Fig. 2).
(5) Rotate the IPM counter-clockwise to access and
disconnect the electrical connectors (Fig. 3).
(6) Remove the IPM bracket clips from the hinge.
INSTALLATION
(1) Snap the left side of the Integrated Power Mod-
ule (IPM) housing in its mounting bracket and con-
nect the various electrical connectors.NOTE: Ensure that the Connector Positive Assur-
ance (CPA) on the five-pin B+ connector is posi-
tively engaged to prevent generating a Diagnostic
Trouble Code (DTC).
(2) Rotate the IPM clock-wise until secured in
mounting bracket. An audible click may be heard.
(3) Install the battery (Refer to 8 - ELECTRICAL/
BATTERY SYSTEM/BATTERY - INSTALLATION).
(4) Install the battery thermal guard.
Fig. 1 INTEGRATED POWER MODULE
1 - BATTERY THERMAL GUARD
2 - INTEGRATED POWER MODULE
3 - FRONT CONTROL MODULE
Fig. 2 INTEGRATED POWER MODULE
Fig. 3 DISCONNECTING IPM
1 - INTEGRATED POWER MODULE
8W - 97 - 2 8W-97 POWER DISTRIBUTION SYSTEMRS
INTEGRATED POWER MODULE (Continued)

(5) Connect the negative and positive battery
cables.
(6) Using a scan tool, check for any stored diagnos-
tic trouble codes. Ensure that all vehicle options are
operational.
IOD FUSE
DESCRIPTION
All vehicles are equipped with an Ignition-Off
Draw (IOD) fuse that is removed from its normal
cavity in the Integrated Power Module (IPM) when
the vehicle is shipped from the factory. Dealer per-
sonnel are to remove the IOD fuse from the storage
location and install it into the IPM fuse cavity
marked IOD as part of the preparation procedures
performed just prior to new vehicle delivery.
The IOD fuse is a 20 ampere blade-type mini fuse
and, when removed, it is stored in a fuse cavity adja-
cent to the washer fuse within the IPM.
OPERATION
The term ignition-off draw (IOD) identifies a nor-
mal condition where power is being drained from the
battery with the ignition switch in the Off position.
The IOD fuse feeds the memory and sleep mode func-
tions for some of the electronic modules in the vehicle
as well as various other accessories that require bat-
tery current when the ignition switch is in the Off
position, including the clock. The only reason the
IOD fuse is removed is to reduce the normal IOD of
the vehicle electrical system during new vehicle
transportation and pre-delivery storage to reduce
battery depletion, while still allowing vehicle opera-
tion so that the vehicle can be loaded, unloaded and
moved as needed by both vehicle transportation com-
pany and dealer personnel.
The IOD fuse is removed from the Integrated
Power Module (IPM) fuse cavity when the vehicle is
shipped from the assembly plant. Dealer personnel
must install the IOD fuse when the vehicle is being
prepared for delivery in order to restore full electrical
system operation. Once the vehicle is prepared for
delivery, the IOD function of this fuse becomes trans-
parent and the fuse that has been assigned the IOD
designation becomes only another Fused B(+) circuit
fuse. The IOD fuse serves no useful purpose to the
dealer technician in the service or diagnosis of any
vehicle system or condition, other than the same pur-
pose as that of any other standard circuit protection
device.
The IOD fuse can be used by the vehicle owner as
a convenient means of reducing battery depletion
when a vehicle is to be stored for periods not to
exceed approximately thirty days. However, it mustbe remembered that removing the IOD fuse will not
eliminate IOD, but only reduce this normal condition.
If a vehicle will be stored for more than thirty days,
the battery negative cable should be disconnected to
eliminate normal IOD; and, the battery should be
tested and recharged at regular intervals during the
vehicle storage period to prevent the battery from
becoming discharged or damaged.
POWER OUTLET
DESCRIPTION
Two power outlets are installed in the instrument
panel center lower bezel. Two additional power out-
lets are incorporated into the left rear C-pillar and
the center console (if equipped). The power outlets
bases are secured by a snap fit. A hinged plug flips
closed to conceal and protect the power outlet base
when not in use.
OPERATION
The power outlet base or receptacle shell is con-
nected to ground, and an insulated contact in the
bottom of the shell is connected to battery current.
The power outlet on the instrument panel marked
with a battery receives battery voltage from a fuse in
the Integrated Power Module (IPM) at all times. The
other power outlet on the instrument panel marked
with a key receives battery voltage only when the
key is in the on position.
The power outlet located in the center console
receives battery voltage all the time when positioned
between thefront seatsand key-on voltage when
positioned between therear seats. The power outlet
located on the C-pillar receives battery voltage only
when the key is in the ON position.
DIAGNOSIS AND TESTING
DIAGNOSIS & TESTING - POWER OUTLET
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO RESTRAINTS BEFORE ATTEMPT-
ING ANY STEERING WHEEL, STEERING COLUMN,
SEAT OR INSTRUMENT PANEL COMPONENT DIAG-
NOSIS OR SERVICE. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
(1) Check the fused B(+) fuse in the Integrated
Power Module (IPM). If OK, go to Step 2. If not OK,
repair the shorted circuit or component as required
and replace the faulty fuse.
RS8W-97 POWER DISTRIBUTION SYSTEM8W-97-3
INTEGRATED POWER MODULE (Continued)

DIAGNOSIS AND TESTING - TORQUE
CONVERTER HOUSING FLUID LEAKAGE
When diagnosing converter housing fluid leaks,
three actions must be taken before repair:
(1) Verify proper transmission fluid level.
(2) Verify that the leak originates from the con-
verter housing area and is transmission fluid.
(3) Determine the true source of the leak.
F
luid leakage at or around the torque converter area
may originate from an engine oil leak (Fig. 7). The area
should be examined closely. Factory fill fluid is red and,
therefore, can be distinguished from engine oil.
Some suspected converter housing fluid leaks may not
be leaks at all. They may only be the result of residual
fluid in the converter housing, or excess fluid spilled
during factory fill, or fill after repair. Converter housing
leaks have several potential sources. Through careful
observation, a leak source can be identified before
removing the transmission for repair.
Pump seal leaks tend to move along the drive hub
and onto the rear of the converter (Fig. 7). Pump o-ring
or pump body leaks follow the same path as a seal leak.
Pump attaching bolt leaks are generally deposited on
the inside of the converter housing and not on the con-
verter itself. Pump seal or gasket leaks usually travel
down the inside of the converter housing (Fig. 7).
TORQUE CONVERTER LEAKAGE
Possible sources of torque converter leakage are:
²Torque converter weld leaks at the outside diam-
eter weld (Fig. 8).
²Torque converter hub weld (Fig. 8).
REMOVAL
NOTE: If transaxle assembly is being replaced or
overhauled (clutch and/or seal replacement), it is
necessary to perform the ªQuick-Learnº Procedure.
(Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL
MODULES/TRANSMISSION CONTROL MODULE -
STANDARD PROCEDURE)
(1) Disconnect battery cables.
(2) Remove battery shield (Fig. 9).
Fig. 7 Converter Housing Leak Paths
1 - PUMP SEAL
2 - PUMP VENT
3 - PUMP BOLT
4 - PUMP GASKET
5 - CONVERTER HOUSING
6 - CONVERTER
7 - REAR MAIN SEAL LEAK
Fig. 8 Converter Leak Points - Typical
1 - OUTSIDE DIAMETER WELD
2 - TORQUE CONVERTER HUB WELD
3 - STARTER RING GEAR
4 - LUG
Fig. 9 Battery Thermal Guard
1 - BATTERY THERMOWRAP (IF EQUIPPED)
2 - INTEGRATED POWER MODULE
3 - FRONT CONTROL MODULE
RS40TE AUTOMATIC TRANSAXLE21-9
40TE AUTOMATIC TRANSAXLE (Continued)