DODGE TOWN AND COUNTRY 2003 Service Manual

Fig. 47 RIGHT QUARTER
8W - 91 - 56 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
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Fig. 48 LIFTGATE
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-57
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
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Fig. 49 HEADLINER
8W - 91 - 58 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
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8W-97 POWER DISTRIBUTION SYSTEM
TABLE OF CONTENTS
page page
POWER DISTRIBUTION SYSTEM
DESCRIPTION..........................1
OPERATION............................1
SPECIAL TOOLS
POWER DISTRIBUTION SYSTEMS.........2
ACCESSORY RELAY
DESCRIPTION..........................2
OPERATION............................2
DIAGNOSIS AND TESTING
DIAGNOSIS & TESTING - ACCESSORY
RELAY...............................2
REMOVAL.............................3
INSTALLATION..........................3
INTEGRATED POWER MODULE
DESCRIPTION..........................3OPERATION............................3
REMOVAL.............................4
INSTALLATION..........................4
IOD FUSE
DESCRIPTION..........................4
OPERATION............................5
REMOVAL.............................5
INSTALLATION..........................5
POWER OUTLET
DESCRIPTION..........................5
OPERATION............................5
DIAGNOSIS AND TESTING
DIAGNOSIS & TESTING - POWER OUTLET . . 6
REMOVAL.............................6
INSTALLATION..........................6
POWER DISTRIBUTION
SYSTEM
DESCRIPTION
This group covers the various standard and
optional power distribution components used on this
model. The power distribution system for this vehicle
consists 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
²RelaysFollowing are general descriptions of the major
components in the power distribution system. See the
owner's manual in the vehicle glove box for more
information on the features and use of all of the
power distribution system components.
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 the
electrical current needed to operate many accessories
that the vehicle owner may choose to have installed
in the aftermarket.
RS8W-97 POWER DISTRIBUTION SYSTEM8W-97-1
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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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to the fused B(+) fuse in the IPM that feeds the
accessories when the relay is energized by the igni-
tion switch. There should be continuity between the
IPM cavity for relay terminal 87 and the fused B(+)
fuse in the IPM at all times. If OK, go to Step 4. If
not OK, repair the open fused B(+) circuit to the IPM
fuse as required.
(4) The coil ground terminal (85) is connected to
the electromagnet in the relay. It receives battery
feed to energize the accessory relay when the ignition
switch is in the Accessory or On positions. Turn the
ignition switch to the On position. Check for battery
voltage at the fused ignition switch output (acc/run)
circuit cavity for relay terminal 85 in the IPM recep-
tacle for the accessory relay. If OK, go to Step 5. If
not OK, repair the open fused ignition switch output
(acc/run) circuit to the ignition switch as required.
(5) The coil battery terminal (86) is connected to
the electromagnet in the relay. The IPM cavity for
this terminal should have continuity to ground at all
times. If not OK, repair the open ground circuit to
ground as required.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the Integrated Power Module (IPM)
cover from the IPM.
(3) Remove the accessory relay from the IPM.
Refer to the IPM cover for relay location.
INSTALLATION
(1) Position the accessory relay in the proper
receptacle in the Integrated Power Module (IPM).
(2) Push in firmly on the accessory relay until the
terminals are fully seated in the terminal cavities in
the IPM receptacle.
(3) Install the IPM cover.
(4) Reconnect the battery negative cable.
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 on this
model (Fig. 2). The power distribution center mates
directly with the Front Control Module (FCM) to
form the IPM Fuse and Relay Center. The power dis-
tribution center (PDC) is a printed circuit board
based module that contains fuses and relays, while
the front control module contains the electronics con-
trolling the IPM and other functions. This IPM con-
nects directly to the battery positive via a four pinconnector. The ground connection is via two other
connectors. The IPM provides the primary means of
voltage distribution and protection for the entire
vehicle.
The molded plastic IPM housing includes a base
and cover. The IPM cover is easily opened or removed
for service access by squeezing the two marked cover
latches and has a fuse and relay layout map integral
to the inside surface of the cover. This IPM housing
base and cover are secured in place by an IPM
mounting bracket. This mounting bracket is designed
to allow the IPM to rotate counter-clockwise once the
locking tab is disengaged. The IPM mounting bracket
is secured in place by bolts threaded into the left
front wheel house.
Replaceable components of the IPM assembly are
broken down into the following components: the
Power Distribution Center (PDC) (without fuses or
relays), the IPM cover, the Front Control Module
(FCM), the IPM mounting bracket, IPM bracket
retaining clips and the IPM assembly which includes
the power distribution center, the cover and FCM.
Refer to the Front Control Module in the Elec-
tronic Control Module sectionof this service
manual for information on the FCM.
OPERATION
All of the current from the battery and the gener-
ator output enters the Integrated Power Module
(IPM) via a four- pin connector on the bottom of the
Fig. 2 BATTERY THERMAL GUARD
1 - BATTERY THERMAL GUARD
2 - INTEGRATED POWER MODULE
3 - FRONT CONTROL MODULE
RS8W-97 POWER DISTRIBUTION SYSTEM8W-97-3
ACCESSORY RELAY (Continued)
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module. The IPM cover is unlatched and opened or
removed to access the fuses or relays. Internal con-
nections of all of the power distribution center cir-
cuits is accomplished by a combination of bus bars
and a printed circuit board. Refer to the Wiring sec-
tion of the service manual for complete IPM circuit
schematics.
REMOVAL
(1) Disconnect the negative and positive battery
cables.
(2) Remove the battery thermal guard from the
vehicle. Refer to the Battery section for the proce-
dure.
(3) Remove the battery from the vehicle. Refer to
the Battery section for the procedure.
(4) Using a flat-bladed screwdriver, twist the Inte-
grated Power Module (IPM) bracket retaining latch
outward to free the intelligent power module from its
mounting bracket (Fig. 3).
(5) Rotate the IPM counter-clockwise to access and
disconnect the various electrical connectors (Fig. 4).
(6) Free the IPM from its mounting bracket by
removing the IPM bracket clips from the hinge. A
screwdriver slipped up from under the hinge will free
the clips.
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. Care must be
taken that the Connector Positive Assurance (CPA)on the five-pin B+ connector is positively engaged to
prevent generating a Diagnostic Trouble Code (DTC).
NOTE: IPM electrical connectors are color coded to
ease location reference.
(2) Being certain no wires are stressed or pinched,
rotate the IPM clock-wise until secured in mounting
bracket. An audible click may be heard.
(3) Install the battery in the vehicle. Refer to the
Battery section for the procedure.
(4) Install the battery thermal guard in the vehi-
cle. Refer to the Battery section for the procedure.
(5) Connect the negative and positive battery
cables.
(6) Using a diagnostic scan tool, check for any
stored diagnostic trouble codes and correct, check
that all vehicle options are operational before return-
ing the vehicle to service.
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.
Fig. 3 RELEASING INTEGRATED POWER MODULE
FROM ITS MOUNTING BRACKET
Fig. 4 DISCONNECTING IPM
1 - INTEGRATED POWER MODULE FUSE & RELAY CENTER
8W - 97 - 4 8W-97 POWER DISTRIBUTION SYSTEMRS
INTEGRATED POWER MODULE (Continued)
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The IPM has a molded plastic cover that can be
removed to provide service access to all of the fuses
and relays in the IPM. An integral latch and hinges
are molded into the IPM cover for easy removal. A
fuse layout map is integral to the underside of the
IPM cover to ensure proper fuse and relay identifica-
tion. The IOD fuse is a 20 ampere blade-type mini
fuse and, when removed, it is stored in a fuse cavity
adjacent to the washer fuse within the IPM.
OPERATION
The term ignition-off draw identifies a normal con-
dition 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 functions for
some of the electronic modules in the vehicle as well
as various other accessories that require battery cur-
rent 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 operation so that the
vehicle can be loaded, unloaded and moved as needed
by both vehicle transportation company and dealer
personnel.
The IOD fuse is removed from the 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 transparent 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 ser-
vice or diagnosis of any vehicle system or condition,
other than the same purpose 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 about thirty days. However, it must be
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 about thirty
days, the battery negative cable should be discon-
nected to eliminate normal IOD; and, the battery
should be tested and recharged at regular intervals
during the vehicle storage period to prevent the bat-
tery from becoming discharged or damaged. Refer to
Battery Systemfor additional service information.
REMOVAL
(1) Turn the ignition switch to the Off position.(2) Unlatch and open the cover of the intelligent
power module.
(3) Remove the IOD fuse from fuse location
markedIODof the Integrated Power Module (IPM).
(4) Store the removed IOD fuse by installing it in
the unused fuse storage markedSPAREof the IPM.
(5) Close and latch the IPM.
INSTALLATION
(1) Be certain the ignition switch is in the Off posi-
tion.
(2) Unlatch and open the cover of the Integrated
Power Module (IPM).
(3) Use a thumb to press the IOD fuse firmly down
into IPM fuse cavity markedIOD.
(4) Close and latch the IPM cover.
POWER OUTLET
DESCRIPTION
Accessory power outlets are standard equipment on
this model. Two power outlets are installed in the
instrument panel center lower bezel, which is located
near the bottom of the instrument panel center stack
area. Two additional power outlets are also incorpo-
rated into the vehicle, one on the left rear C-pillar
trim and the other in the center console, if equipped.
The power outlets bases are secured by a snap fit in
the appropriate bezels. A hinged plug flips closed to
conceal and protect the power outlet base when the
power outlet is not being used.
The power outlet receptacle unit and the power
outlet plugs are each available for service replace-
ment.
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.
RS8W-97 POWER DISTRIBUTION SYSTEM8W-97-5
IOD FUSE (Continued)
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DIAGNOSIS AND TESTING
DIAGNOSIS & TESTING - POWER OUTLET
For complete circuit diagrams, refer toCigar
Lighter/Power Outletin Wiring Diagrams.
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.
(2) Check for battery voltage at the fused B(+) fuse
in the IPM. If OK, go to Step 3. If not OK, repair the
open fused B(+) circuit to the IPM fuse as required.
(3)
Open the power outlet door. Check for continuity
between the inside circumference of the power outlet
receptacle and a good ground. There should be continu-
ity. If OK, go to Step 4. If not OK, go to Step 5.
(4) Check for battery voltage at the insulated con-
tact located at the back of the power outlet recepta-
cle. If not OK, go to Step 5.
(5) Disconnect and isolate the battery negative
cable. Remove the appropriate bezel. Check for conti-
nuity between the ground circuit cavity of the power
outlet wire harness connector and a good ground.
There should be continuity. If OK, go to Step 6. If not
OK, repair the open ground circuit to ground as
required.
(6) Connect the battery negative cable. Check for
battery voltage at the fused B(+) circuit cavity of the
power outlet wire harness connector. If OK, replace
the faulty power outlet receptacle. If not OK, repair
the open fused B(+) circuit to the IPM fuse as
required.
REMOVAL
(1)Disconnect and isolate the battery negative cable.
(2) Look inside and note position of the retaining
bosses (Fig. 5).
(3) Using external snap ring pliers with 90 degree
tips. Insert pliers with tips against bosses and
squeeze forcing bosses out of base.
(4) Pull out the base through mounting ring by
gently rocking pliers. A tool can be made to do the
same. Refer to (Fig. 6).
(5) Disconnect the base wires.
(6) Set base aside. Remove light ring and discon-
nect wire.
INSTALLATION
(1) Position the mounting ring on the instrument
panel and feed the wires through the ring. Index the
cap and the mounting ring with the index tab at the
9 o'clock position to the key in the instrument panel.
Install the ring.
(2) Connect the wires to the base. Orientate the
base alignment rib at the 11 o'clock position to mate
the groove in the mounting ring to the base.
(3)
Push the base into the bezel until it locks in place.
(4) Check operation of outlet or element and
install the 12 volt outlet cap.
Fig. 5 Outlet Base Removal
1 - RETAINING BOSSES-ENGAGE PLIERS HERE
2 - PARTIALLY REMOVED
3 - EXTERNAL SNAP-RING PLIERS
4 - PULL BASE OUT-THROUGH MOUNTING RING
Fig. 6 Tool For Outlet Removal
1 - 2.5MM (3/32 INS.)
2 - WELD
3 - 100MM (4 INS.)
4 - 22.25 TO 22.45MM (7/8 TO 57/64 INS.)
8W - 97 - 6 8W-97 POWER DISTRIBUTION SYSTEMRS
POWER OUTLET (Continued)
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ENGINE
TABLE OF CONTENTS
page page
ENGINE 2.4L.............................. 1ENGINE 3.3/3.8L......................... 74
ENGINE 2.4L
TABLE OF CONTENTS
page page
ENGINE 2.4L
DESCRIPTION..........................3
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION............3
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - PERFORMANCE............4
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - MECHANICAL..............6
DIAGNOSIS AND TESTING - ENGINE OIL
LEAK INSPECTION.....................8
DIAGNOSIS AND TESTING - CYLINDER
COMPRESSION PRESSURE TEST.........9
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE
TEST................................9
STANDARD PROCEDURE
STANDARD PROCEDURE - ENGINE CORE
AND OIL GALLERY PLUGS..............10
STANDARD PROCEDURE - REPAIR OF
DAMAGED OR WORN THREADS.........10
STANDARD PROCEDURE - HYDROSTATIC
LOCKED ENGINE.....................10
STANDARD PROCEDURE - FORM-IN-
PLACE GASKETS AND SEALERS.........11
STANDARD PROCEDURE - ENGINE
GASKET SURFACE PREPARATION........11
STANDARD PROCEDURE - MEASURING
BEARING CLEARANCE USING
PLASTIGAGE........................12
REMOVAL - ENGINE ASSEMBLY...........13
INSTALLATION - ENGINE ASSEMBLY........16
SPECIFICATIONS
SPECIFICATIONS - 2.4L ENGINE.........17
SPECIFICATIONS - TORQUE............20
SPECIAL TOOLS
2.4L ENGINE.........................21AIR CLEANER ELEMENT
REMOVAL.............................24
INSTALLATION.........................24
AIR CLEANER HOUSING
REMOVAL.............................24
INSTALLATION.........................24
CYLINDER HEAD
DESCRIPTION.........................24
DIAGNOSIS AND TESTINGÐCYLINDER HEAD
GASKET............................24
REMOVAL - CYLINDER HEAD.............25
CLEANING............................26
INSPECTION..........................26
INSTALLATION - CYLINDER HEAD..........26
CAMSHAFT OIL SEAL(S)
REMOVAL.............................27
INSTALLATION.........................28
CAMSHAFT(S)
DESCRIPTION.........................28
OPERATION...........................28
STANDARD PROCEDURE - MEASURING
CAMSHAFT END PLAY.................29
REMOVAL.............................29
CLEANING............................29
INSPECTION..........................30
INSTALLATION.........................30
CYLINDER HEAD COVER
REMOVAL.............................31
CLEANING............................31
INSPECTION..........................31
INSTALLATION.........................31
INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION.........................32
CLEANING............................32
VALVE SPRINGS & SEALS
REMOVAL
REMOVAL - CYLINDER HEAD ON.........32
RSENGINE9-1
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