DODGE TOWN AND COUNTRY 2001 Service Manual

(11) Install the lower steering column cover. Refer
to Body, Instrument Panel, Lower Steering Column
Cover, Installation.
(12) Connect the battery negative cable.
CLUSTER LENS
REMOVAL
(1) Remove the instrument cluster. Refer to Elec-
trical, Instrument Cluster, Removal.
(2) Remove the screws holding the lens to the
instrument cluster.
(3) Press down on the snap features of the lens
and remove the lens from the cluster.
INSTALLATION
(1) Insert the lens snap features into the cluster.
(2) Install the screws holding the lens to the
instrument cluster.
(3) Install the instrument cluster. Refer to Electri-
cal, Instrument Cluster, Installation.
MECHANICAL TRANSMISSION
RANGE INDICATOR
REMOVAL
(1) Remove the instrument cluster and disconnect
the range indicator cable at both attaching points.
Refer to Electrical, Instrument Cluster, Removal.
(2) From the backside of the cluster, remove two
screws holding the mechanical transmission rangeindicator and then remove it fromt instrument clus-
ter.
INSTALLATION
(1) Insert the mechanical transmission range indi-
cator into the backside of the instrument cluster and
install the two screws.
(2) Install the instrument cluster. Refer to Electri-
cal, Instrument Cluster, Installation.
RED BRAKE WARNING
INDICATOR
DESCRIPTION
The red BRAKE warning indicator (lamp) is
located in the instrument panel cluster and is used to
indicate a low brake fluid condition or that the park-
ing brake is applied. In addition, the brake warning
indicator is turned on as a bulb check by the ignition
switch every time the ignition switch is placed in the
crank position.
OPERATION
The red BRAKE warning indicator (lamp) is sup-
plied a 12-volt ignition feed anytime the ignition
switch is on. The bulb is then illuminated by com-
pleting the ground circuit either through the switch
on the parking brake lever, the brake fluid level
switch in the master cylinder reservoir, or the igni-
tion switch when it is placed in the crank position.
8J - 12 INSTRUMENT CLUSTERRS
INSTRUMENT CLUSTER (Continued)
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INSTRUMENT CLUSTER
TABLE OF CONTENTS
page page
INSTRUMENT CLUSTER
DESCRIPTION............................1OPERATION.............................1
INSTRUMENT CLUSTER
DESCRIPTION
WATER IN FUEL LAMP
The Water In Fuel Lamp is located in the instru-
ment cluster. When moisture is found within the fuel
system, the sensor sends a message via the PCI data
bus to the instrument cluster. The sensor is located
underneath the vehicle, directly above the rear axle.
The sensor is housed within the fuel filter/water sep-
arator assembly cover. The sensor is not serviced sep-
arately. If found defective, the entire assembly cover
must be replaced.
OPERATION
WATER IN FUEL LAMP
The Water In Fuel Sensor is a resistive type
switch. It is calibrated to sense the different resis-
tance between diesel fuel and water. When water
enters the fuel system, it is caught in the bottom of
the fuel filter/water separator assembly, where the
sensor is located. Water has less resistance than die-
sel fuel. The sensor then sends a PCI data bus mes-
sage to the instrument cluster to illuminate the
lamp.
If the lamp is inoperative, perform the self diag-
nostic test on the instrument cluster to check the
lamp operation before continuing diagnosis.
RGINSTRUMENT CLUSTER8Ja-1
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LAMPS
TABLE OF CONTENTS
page page
LAMPS/LIGHTING - EXTERIOR............... 1LAMPS/LIGHTING - INTERIOR............... 17
LAMPS/LIGHTING - EXTERIOR
TABLE OF CONTENTS
page page
LAMPS/LIGHTING - EXTERIOR
DESCRIPTION............................2
OPERATION.............................2
DIAGNOSIS AND TESTING..................3
LAMPS/LIGHTING - EXTERIOR.............3
SPECIFICATIONS.........................7
BRAKE LAMP SWITCH
DESCRIPTION............................7
OPERATION.............................7
DIAGNOSIS AND TESTING..................7
BRAKE LAMP SWITCH...................7
REMOVAL...............................8
INSTALLATION............................8
CENTER HIGH MOUNTED STOP LAMP
REMOVAL...............................9
INSTALLATION............................9
CENTER HIGH MOUNTED STOP LAMP UNIT
REMOVAL...............................9
INSTALLATION............................9
FOG LAMP
REMOVAL...............................9
INSTALLATION............................9
FOG LAMP UNIT
REMOVAL..............................10
INSTALLATION...........................10
ADJUSTMENTS..........................10
HEADLAMP
REMOVAL..............................11
INSTALLATION...........................11HEADLAMP SWITCH
DIAGNOSIS AND TESTING.................11
HEADLAMP SWITCH....................11
REMOVAL..............................11
INSTALLATION...........................11
HEADLAMP UNIT
REMOVAL..............................12
INSTALLATION...........................12
ADJUSTMENTS..........................12
LICENSE PLATE LAMP
REMOVAL..............................14
INSTALLATION...........................14
MULTI-FUNCTION SWITCH
DESCRIPTION...........................14
OPERATION.............................15
DIAGNOSIS AND TESTING.................15
MULTI-FUNCTION SWITCH...............15
REMOVAL..............................15
INSTALLATION...........................15
PARK/TURN SIGNAL LAMP
REMOVAL..............................15
INSTALLATION...........................15
TAIL LAMP
REMOVAL..............................16
INSTALLATION...........................16
TAIL LAMP UNIT
REMOVAL..............................16
INSTALLATION...........................16
RSLAMPS8L-1
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LAMPS/LIGHTING - EXTERIOR
DESCRIPTION
LAMP SYSTEMS
RS vehicles use lighting on the interior and exte-
rior of the vehicle for illuminating and indicating
purposes. Lighting circuits are protected by fuses.
Lighting circuits require an overload protected power
source, on/off device, lamps and body ground to oper-
ate properly. Plastic lamps require a wire in the har-
ness to supply body ground to the lamp socket.
Replace sockets and bulbs that are corroded.
Some of the interior and exterior lighting functions
are governed by the Body Control Module. The head-
lamp, dome, and the door ajar switches provide sig-
nals to the Body Control Module. The Body Control
Module in turn sends a J1850 message to the Front
Control Module (FCM) to enable the necessary driv-
ers to set the required illumination configuration.
Wire connectors can make intermittent contact or
become corroded. Before coupling wire connectors,
inspect the terminals inside the connector. Male termi-
nals should not be bent or disengaged from the insu-
lator. Female terminals should not be sprung open or
disengaged from the insulator. Bent and sprung termi-
nals can be repaired using needle nose pliers and pick
tool. Corroded terminals appear chalky or green. Cor-
roded terminals should be replaced to avoid recur-
rence of the problem symptoms.
Begin electrical system failure diagnosis by testing
related fuses in the fuse block and intelligent power
module. Verify that bulbs are in good condition and
test continuity of the circuit ground. Refer to the
appropriate wiring information. The wiring informa-
tion includes wiring diagrams, proper wire and con-
nector repair procedures, details of wire harness
routing and retention, connector pin-out information
and location views for the various wire harness con-
nectors, splices and grounds.
AUTOMATIC HEADLAMP SYSTEM
The Automatic Headlamp system turns the instru-
mentation and exterior illumination lamps ON when
the ambient light levels are Night and OFF when
light levels are Day.
DAYTIME RUNNING LAMPS
Operating the high-beam headlamps at reduced
power provides daytime running lamps, which are
required on all new Canadian vehicles.
HEADLAMPS ON WITH WINDSHIELD WIPERS
For vehicles equipped with the Automatic Head-
lamp System, the instrumentation and exterior illu-
mination lamps will be turned ON when theheadlamp switch is in the AUTO position, RPM >
450 and the windshield wipers have been in the
intermittent, low or high mode of operation for more
than ten seconds. When the windshield wipers are
turned OFF the Body Control Module will determine
if the instrumentation and exterior illumination
lamps should remain ON base upon the current
ambient light level.
HEADLAMP SYSTEM
The configuration of the headlamp system of head-
lamps, park lamps and fog lamps is determined by
the BCM. The BCM determines the lighting configu-
ration as a result of the inputs from the ignition
switch, headlamp switch and multifunction switch. A
J1850 is transmitted from the BCM to the FCM to
enable the necessary drivers to set the illumination
configuration. Four wires are connected between the
headlamp switch and the BCM. The first wire con-
tains information regarding the position of the head-
lamp switch (Off, Automatic Headlamps, Automatic
Headlamp switch fog, Park with Fog, Head, or Head
with Fog Lamps). The second wire contains informa-
tion regarding the position of the dimmer switch
(Dome Lamp, Daytime Brightness, Dimming Level or
Off). The third wire is a dedicated signal return
(ground) wire. The fourth wire provides power to the
front fog lamp indicator.
HEADLAMP TIME DELAY SYSTEM
The headlamp time delay system is controlled by
the Body Control Module (BCM) via a J1850 message
transmitted by the BCM to the FCM to turn off the
headlamps.
OPERATION
AUTOMATIC HEADLAMP SYSTEM
Automatic headlamps are controlled by the Body
Control Module (BCM). With the headlamp switch in
the AUTO position, the BCM will control the head-
lamp, parking, side marker, tail and instrumentation
lamps based on ambient light levels. Ambient light
levels are monitored by the BCM using the Day/
Night signal and Electrochromatic Mirror (ECM)
present from the Compass Mini Trip (CMTC) located
on the front windshield in front of the rear view mir-
ror (ECM). Ambient light readings are averaged to
limit cycling the lamps ON and OFF when passing
through areas with varying light levels. The auto-
matic headlamps will only function when the engine
is running with RPM > 450. When the headlamp
switch is in the AUTO position (Automatic mode), the
Headlamp Time Delay system will function when the
ignition switch is placed in any position other than
run/start.
8L - 2 LAMPS/LIGHTING - EXTERIORRS
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DAYTIME RUNNING LAMPS
Power is reduced using pulse-width modulation to
the high beams, where by the power is switched on
and off rapidly instead of remaining on continuously.
The duration and interval of the power pulses is pro-
grammed into the Front Control Module (FCM).
HEADLAMP SYSTEM
The headlamp system will default to headlamps
ON position when ignition switch is ON and when an
open or short circuit failure occurs on the headlamp
switch input. The system will return to normal oper-
ation when the open or short is repaired. A fault will
be reported by the BCM when a failure occurs on the
dimmer or headlamp switch input.
If the exterior lamps are ON and the headlamp
switch is in any position other than OFF or AUTO
and with the ignition switch OFF (LOCK) after 3
minutes the BCM sends a message via J1850 to the
FCM informing the FCM to turn off the headlamps,
park lamps and fog lamps. This feature prevents the
vehicle battery from being discharged when the vehi-
cle lights have been left ON.
HEADLAMP TIME DELAY SYSTEM
The headlamp time delay system is activated by
turning the headlamps ON (high or low beam) while
the engine is running, turning the ignition switch
OFF, and then turning the headlamp switch OFF
within 45 seconds. The system will not activate if
more than 45 seconds elapse between ignition switch
OFF and headlamp switch OFF. The BCM will allow
the headlamps to remain ON for 90 seconds (config-
urable) before they automatically turn off (If the key
is in the ignition during the headlamp time delay
mode, then both the headlamps and park lamps
(including panel dimming) will be ON). Refer to the
Owner's Manual for more information.
If the headlamp switch is in the Auto Headlamp
Position, the headlamps are ON due to the night sig-
nal from the CMTC and the ignition switch is in any
position other than run/start, the BCM shall enter a
90 second (configurable) Auto Headlamps time delay
mode. If the key is in the ignition during the head-
lamp time delay mode, then both the headlamps and
park lamps (including panel dimming) will be ON. If
the key is not in the ignition, then only the head-
lamps will be ON. The BCM will allow the head-
lamps to remain ON for 90 seconds before they
automatically turn OFF. Refer to the Owner's Man-
ual for more information.
LAMP OUTAGE
If one or more of the following lamps (Low and/or
High beams) are out, then a ªlamps outº indicator
located in the cluster will illuminate.
OPTICAL HORN/HIGH BEAMS
When the multifunction switch is pulled to the first
detent (optical horn) signal, the headlamps are ON,
key-in the ignition the BCM shall send a message via
J1850 to the FCM to turn on the headlamps drivers
to illuminate all four filaments (Low and High
beams). When the multifunction switch is pulled to
the second detent (high beam) signal and the head-
lamps are ON, the BCM shall send a message via
J1850 to the FCM to turn on the headlamps drivers.
The High Beams are illuminated and the Low Beams
and Fog Lamps (if ON) are extinguished. If the head-
lamps were in the high beam configuration when
power was removed from the headlamps, the head-
lamps will be configured as low beam the next time
they are activated.
DIAGNOSIS AND TESTING
WARNING: EYE PROTECTION SHOULD BE USED
WHEN SERVICING GLASS COMPONENTS. PER-
SONAL INJURY CAN RESULT.
CAUTION: Do not touch the glass of halogen bulbs
with fingers or other possibly oily surface, reduced
bulb life will result. Do not use bulbs other than
those indicated in the Bulb Application table. Dam-
age to lamp and/or Daytime Running Lamp Module
can result. Do not use fuses, circuit breakers or
relays having greater amperage value than indi-
cated on the fuse panel or in the Owners Manual.
When a vehicle experiences problems with the
headlamp system, verify the condition of the battery
connections, fuses, charging system, headlamp bulbs,
wire connectors, relay, high beam switch, dimmer
switch, and headlamp switch. Refer to the appropri-
ate 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 connec-
tors, splices and grounds.
Each vehicle is equipped with various lamp assem-
blies. A good ground is necessary for proper lighting
operation. Grounding is provided by the lamp socket
when it comes in contact with the metal body, or
through a separate ground wire.
When changing lamp bulbs check the socket for
corrosion. If corrosion is present, clean it with a wire
brush.
When it is necessary to remove components to ser-
vice another, it should not be necessary to apply
excessive force or bend a component to remove it.
Before damaging a trim component, verify hidden
fasteners or captured edges are not holding the com-
ponent in place.
RSLAMPS/LIGHTING - EXTERIOR8L-3
LAMPS/LIGHTING - EXTERIOR (Continued)
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HEADLAMPS
CONDITION POSSIBLE CAUSES CORRECTION
HEADLAMPS ARE DIM
WITH ENGINE IDLING1. Loose or corroded battery cables. 1. Clean and secure battery cable clamps
and posts.
OR IGNITION TURNED
OFF2. Loose or worn generator drive belt. 2. Adjust or replace generator drive belt.
3. Charging system output too low. 3. Test and repair charging system, refer
to Electrical, Charging
4. Battery has insufficient charge. 4. Test battery state-of -charge, refer to
Electrical, Battery System.
5. Battery is sulfated or shorted. 5. Load test battery, refer to Electrical,
Battery System.
6. Poor lighting circuit Z343/Z344-
ground.6. Test for voltage drop across Z343/Z344-
ground locations, refer to Electrical, Wiring
Diagram Information.
HEADLAMP BULBS BURN
OUT FREQUENTLY1. Intelligent Power Module (IPM) not
controlling voltage.1. Test and repair Intelligent Power
Module.
2. Loose or corroded terminals or
splices in circuit.2. Inspect and repair all connectors and
splices. Refer to Electrical, Wiring
Information.
HEADLAMPS ARE DIM
WITH ENGINE RUNNING
ABOVE IDLE1. Charging system output too low. 1. Test and repair charging system, refer
to Electrical, Wiring Information.
2. Poor lighting circuit Z343/Z344-
ground.2. Test for voltage drop across Z343/Z344-
ground locations, refer to Electrical, Wiring
Information.
3. High resistance in headlamp
circuit.3. Test amperage draw of headlamp
circuit.
HEADLAMPS FLASH
RANDOMLY1. Poor lighting circuit Z343/Z344-
ground.1. Test for voltage drop across Z343/Z344-
ground locations, refer to Electrical, Wiring
Information.
2. Variable resistance in headlamp
circuit.2. Test amperage draw of headlamp
circuit.
3. Loose or corroded terminals or
splices in circuit.3. Inspect and repair all connectors and
splices, refer to Electrical, Wiring
Information.
4. Faulty headlamp switch. 4. Replace headlamp switch.
HEADLAMPS DO NOT
ILLUMINATE1. No voltage to headlamps. 1. Repair open headlamp circuit, refer to
Electrical, Wiring Information.
2. No Z343/Z344-ground at
headlamps.2. Repair circuit ground, refer to Electrical,
Wiring Information.
3. Broken connector terminal or wire
splice in headlamp circuit.3. Repair connector terminal or wire splice.
4. Faulty or burned out bulb. 4. Replace headlamp bulb(s).
5. Body Control Module malfunction. 5. Refer to appropriate Body Control
Module diagnostics.
8L - 4 LAMPS/LIGHTING - EXTERIORRS
LAMPS/LIGHTING - EXTERIOR (Continued)
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CONDITION POSSIBLE CAUSES CORRECTION
6. J1850 Bus Communication 6. Verify messages being transmitted by
BCM and received by FCM.
7. IPM/FCM Malfunction. 7. Refer to appropriate IPM/FCM
diagnostics.
HEADLAMPS ON WITH
IGNITION IN RUN, WITH
HEADLAMP SWITCH OFF1. Faulty headlamp switch. 1. Replace headlamp switch (review BCM
logged faults).
2. Diagnostic tool indicates (4.7 -
5.0V) on headlamp switch input to
BCM.2. Inspect and repair terminals, connectors
and open circuits.
3. J1850 Bus Communication. 3. Verify messages being transmitted by
BCM and received by FCM.
FOG LAMPS
CONDITION POSSIBLE CAUSES CORRECTION
FOG LAMPS ARE DIM
WITH ENGINE IDLING
OR IGNITION TURNED
OFF.1. Loose or corroded battery cables. 1. Clean and secure battery cable clamps
and posts.
2. Loose or worn generator drive belt. 2. Adjust or replace generator drive belt.
3. Charging system output too low. 3. Test and repair charging system. Refer to
Electrical, Charging,
4. Battery has insufficient charge. 4. Test battery state-of -charge. Refer to
Electrical, Battery System.
5. Battery is sulfated or shorted. 5. Load test battery. Refer to Electrical,
Battery System.
6. Poor lighting circuit Z349/Z248
ground.6. Test for voltage drop across Z349/248
ground locations. Refer to Electrical, Wiring
Information.
FOG LAMP BULBS BURN
OUT FREQUENTLY1. Charging system output too high. 1. Test and repair charging system. Refer to
Electrical, Charging.
2. Loose or corroded terminals or
splices in circuit.2. Inspect and repair all connectors and
splices. Refer to Electrical, Wiring
Information.
FOG LAMPS ARE DIM
WITH ENGINE RUNNING
ABOVE IDLE1. Charging system output too low. 1. Test and repair charging system. Refer to
Electrical, Charging.
2. Poor lighting circuit Z349/Z248
ground.2. Test for voltage drop across Z349/Z248
ground locations. Refer to Electrical, Wiring
Information.
3. High resistance in fog lamp circuit. 3. Test amperage draw of fog lamp circuit.
FOG LAMPS FLASH
RANDOMLY1. Poor lighting circuit Z349/Z248
ground.1. Test for voltage drop across Z349/Z248
ground locations. Refer to Electrical, Wiring
Information.
2. Variable resistance in fog lamp
circuit.2. Test amperage draw of fog lamp circuit.
RSLAMPS/LIGHTING - EXTERIOR8L-5
LAMPS/LIGHTING - EXTERIOR (Continued)
ProCarManuals.com

CONDITION POSSIBLE CAUSES CORRECTION
3. Faulty fog lamp switch (part of
headlamp switch).3. Replace headlamp switch.
4. Loose or corroded terminals or
splices in circuit.4. Inspect and repair all connectors and
splices. Refer to Electrical, Wiring
Information.
5. Is relay engaging properly? 5. Verify function of fog lamp relay in IPM.
6. J1850 Bus Communication. 6. Verify J1850 message (fog lamp info)
transmitted from BCM and received by
FCM.
FOG LAMPS DO NOT
ILLUMINATE1. Blown fuse for fog lamp. 1. Replace fuse. Refer to Electrical, Wiring
Information.
2. No Z349/Z248 ground at fog
lamps.2. Repair circuit ground. Refer to Electrical,
Wiring Information.
3. Faulty fog lamp switch (part of
headlamp switch).3. Replace headlamp switch.
4. Broken connector terminal or wire
splice in fog lamp circuit.4. Repair connector terminal or wire splice.
5. Faulty or burned out bulb. 5. Replace bulb.
6. Is relay engaging? 6. Verify function of fog lamp relay in IPM.
7. J1850 Bus Communication. 7. Verify J1850 message (fog lamp info)
transmitted from BCM and received by
FCM.
DAYTIME RUNNING LAMP (CANADA ONLY)
CONDITION POSSIBLE CAUSES CORRECTION
DAYTIME RUNNING
LAMPS DO NOT
WORK
1. Parking brake engaged. 1. Disengage parking brake.
2. Parking brake circuit shorted to
ground.2. Check cluster telltale, refer to the appropriate
wiring information. The wiring information
includes wiring diagrams, proper wire and
connector repair procedures, further details on
wire harness routing and retention, as well as
pin-out and location views for the various wire
harness connectors, splices and grounds.
3. Headlamp circuit shorted to ground. 3. Refer to the appropriate wiring information.
The wiring information includes wiring
diagrams, proper wire and connector repair
procedures, further details on wire harness
routing and retention, as well as pin-out and
location views for the various wire harness
connectors, splices and grounds.
4. Faulty DRL relay. 4. Replace DRL relay.
5. Body controller not programed with
Canadian country code.5. Check country code.
8L - 6 LAMPS/LIGHTING - EXTERIORRS
LAMPS/LIGHTING - EXTERIOR (Continued)
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SPECIFICATIONS
EXTERIOR LAMPS
CAUTION: Do not use bulbs other than those listed
in the Bulb Application Table. Damage to lamp can
result.
CAUTION: Do not touch halogen bulbs with fingers
or other oily surfaces. Bulb life will be reduced.
BULB APPLICATION TABLE
LAMP BULB
BACK-UP 3057
CENTER HIGH
MOUNTED STOP921
FRONT SIDE MARKER/
PARK/TURN3157A
FOG LAMP 9040
HEADLAMP 9007
LICENSE 168
TAIL, STOP 3057
TURN SIGNAL 3057
BRAKE LAMP SWITCH
DESCRIPTION
The brake lamp switch is located under the instru-
ment panel, at the brake pedal arm (Fig. 3). It has
three internal switches controlling various functions
of the vehicle. It's main function is to control opera-
tion of the vehicle's brake lamps. Other functions
include speed control deactivation, brake sense for
the antilock brake system and brake sense for the
brake transmission shift interlock.
CAUTION: The switch can only be adjusted once.
That is during initial installation of the switch. If the
switch is not adjusted properly or has been
removed for some service, a new switch must be
installed and adjusted.
OPERATION
When the brake pedal is pressed, the plunger on
the outside of the brake lamp switch extends out-
ward. This action opens or closes the contacts of the
three switches inside the brake lamp switch.
With the brake pedal is pressed down (plunger
extended), the switch for terminals 1 and 2 is closedcompleting the circuit. The switch for terminals 3
and 4 is open and so is the switch for 5 and 6.
When the brake pedal is released (plunger pushed
in), the three switches assume the opposite positions.
The switch for terminals 1 and 2 is now open while
the other two switches are now closed, completing
their circuits.
DIAGNOSIS AND TESTING - BRAKE LAMP
SWITCH
NOTE: Before proceeding with this diagnostic test,
verify the adjustment of the brake lamp switch to
rule out misadjustment. If misadjusted, replace the
switch. It cannot be readjusted.
If the electrical circuit has been tested and the
brake lamp switch is suspected of being faulty, it can
be tested using the following method.
(1) Remove the switch from the vehicle. Refer to
Removal And Installation in this section.
(2) With the switch in the released position (plung-
er extended), use an ohmmeter to test each of the
three internal switches as shown (Fig. 1). You should
achieve the results as listed in the figure.
(3) Gently push the plunger on the brake lamp
switch in until it stops.
(4) With the switch in this depressed position
(plunger pushed in), use an ohmmeter to test each of
the three internal switches as shown (Fig. 2). You
should achieve the results as listed in the figure.
If you do not achieve the results as listed in both
figures, the switch is faulty and must be replaced.
Refer to Removal And Installation in this section.
If the switch is found to be operating properly, do
not reinstall it, replace the switch. Refer to Removal
And Installation in this section.
Fig. 1 Switch Test - Released Position
RSLAMPS/LIGHTING - EXTERIOR8L-7
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