TABLE OF CONTENTS
1.0 INTRODUCTION .........................................................1
1.1 SYSTEM COVERAGE ...............................................1
1.2 SIX-STEP TROUBLESHOOTING PROCEDURE ..........................1
2.0 IDENTIFICATION OF SYSTEM .............................................1
3.0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION ......................1
3.1 ADJUSTABLE PEDALS SYSTEM ......................................2
3.2 AIRBAG SYSTEM/OCCUPANT RESTRAINT CONTROLLER SYSTEM AND
OCCUPANT CLASSIFICATION SYSTEM ................................2
3.2.1 DRIVER AIRBAG............................................3
3.2.2 CLOCKSPRING.............................................4
3.2.3 PASSENGER AIRBAG .......................................4
3.2.4 SEAT BELT TENSIONER (SBT) ................................6
3.2.5 SEAT BELT SWITCHES (SBS).................................6
3.2.6 DRIVER KNEE BLOCKER AIRBAG .............................6
3.2.7 FRONT AND SIDE IMPACT SENSOR ...........................6
3.2.8 OCCUPANT CLASSIFICATION SYSTEM ........................6
3.2.9 SPECIAL TOOLS............................................9
3.2.10 DIAGNOSTIC TROUBLE CODES ..............................9
3.2.10.1 ACTIVE CODES ............................................9
3.2.10.2 STORED CODES ...........................................9
3.3 AUDIO SYSTEM ...................................................10
3.3.1 NAVIGATION RADIO........................................10
3.3.2 REMOTE RADIO CONTROLS ................................10
3.3.3 CD CHANGER .............................................11
3.3.4 DVD/CD CHANGER ........................................11
3.4 BODY CONTROL MODULE ..........................................11
3.5 CHIME WARNING SYSTEM .........................................12
3.5.1 CHIME PRIORITY ..........................................12
3.5.2 CHIME ON CONDITIONS....................................12
3.5.3 WARNING LAMP ANNOUNCEMENT ..........................13
3.5.4 OTHER CHIME ON CONDITIONS.............................13
3.6 COMMUNICATION .................................................13
3.7 DOOR AJAR SYSTEM ..............................................15
3.8 EXTERIOR LIGHTING SYSTEM ......................................15
3.8.1 HEADLAMP POWER .......................................15
3.8.2 HEADLAMP SWITCH .......................................15
3.8.3 PARK LAMP RELAY ........................................15
3.8.4 FOG LAMP RELAY .........................................15
3.8.5 FOG LAMPS ..............................................15
3.8.6 EXTERIOR LIGHTING BATTERY SAVER .......................16
3.8.7 AUTO HEADLAMPS ........................................16
3.9 FRONT CONTROL MODULE .........................................16
3.9.1 CONTROLLED POWER FEEDS ..............................16
3.9.2 RELAY CONTROLS ........................................17
3.9.3 ELECTRICAL INPUTS ......................................18
3.10 HEATING & A/C SYSTEM ...........................................19
3.10.1 AUTOMATIC TEMPERATURE CONTROL (ATC) .................19
3.10.1.1 MODULE USAGE ..........................................19
3.10.1.2 SYSTEM AVAILABILITY .....................................19
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TABLE OF CONTENTS - Continued
3.10.1.3 SYSTEM CONTROLS .......................................19
3.10.1.4 SYSTEM REVISIONS .......................................20
3.10.1.5 SYSTEM DIAGNOSTICS ....................................20
3.10.2 MANUAL TEMPERATURE CONTROL (MTC) ....................21
3.10.2.1 MODULE USAGE ..........................................21
3.10.2.2 SYSTEM AVAILABILITY .....................................21
3.10.2.3 SYSTEM CONTROLS .......................................22
3.10.2.4 SYSTEM REVISIONS .......................................23
3.10.2.5 SYSTEM DIAGNOSTICS ....................................23
3.11 CABIN HEATER ...................................................24
3.11.1 GENERAL SAFETY INFORMATION ...........................24
3.11.2 COMPONENT DESCRIPTION AND OPERATION ................25
3.11.2.1 DCHA ASSEMBLY..........................................25
3.11.2.2 COMBUSTION AIR FAN .....................................25
3.11.2.3 BURNER HOUSING ........................................25
3.11.2.4 BURNER INSERT ..........................................25
3.11.2.5 CONTROL UNIT/HEAT EXCHANGER ..........................25
3.11.2.6 DOSING PUMP ............................................25
3.11.3 OPERATION ..............................................25
3.11.3.1 VENTING THE DCHA’S EXHAUST ............................25
3.11.3.2 ACTIVATION ..............................................26
3.11.3.3 HEATING .................................................27
3.11.3.4 DEACTIVATION ............................................27
3.11.3.5 SYSTEM REVISIONS .......................................27
3.11.4 DIAGNOSTICS ............................................27
3.12 INSTRUMENT CLUSTER ............................................27
3.12.1 INSTRUMENT CLUSTER SELF TEST .........................28
3.12.2 MESSAGE CENTER (EXPORT ONLY) .........................28
3.13 INTERIOR LIGHTING ...............................................28
3.13.1 COURTESY LAMP CONTROL ................................28
3.13.2 ILLUMINATED ENTRY ......................................28
3.13.3 INTERIOR LIGHTING BATTERY SAVER .......................28
3.14 MEMORY SYSTEM.................................................28
3.14.1 POWER SEAT .............................................29
3.14.2 MEMORY MIRROR .........................................29
3.15 OVERHEAD CONSOLE .............................................29
3.15.1 VEHICLE INFORMATION DISPLAY............................30
3.15.2 TRAVELER DISPLAY FUNCTIONS ............................31
3.15.3 SETTING MAGNETIC ZONE VARIANCE .......................31
3.15.4 COMPASS CALIBRATION ...................................32
3.15.5 SELF-CHECK DIAGNOSTICS ................................32
3.15.6 AMBIENT TEMPERATURE SENSOR ..........................32
3.15.7 AMBIENT TEMPERATURE SENSOR FAULT CODES .............33
3.15.8 HOMELINKT UNIVERSAL TRANSMITTER ......................33
3.15.9 TIRE PRESSURE MONITORING SYSTEM (TPMS)...............33
3.15.9.1 TRAINING THE SKREEM....................................33
3.15.9.2 PRESSURE THRESHOLDS ..................................34
3.15.9.3 ACTIVE FAULT AND SYSTEM ALERTS ........................34
3.16 PARK ASSIST SYSTEM .............................................34
3.17 POWER DOOR LOCK SYSTEM ......................................34
3.17.1 DOOR LOCK INHIBIT .......................................34
3.17.2 AUTOMATIC DOOR LOCKS .................................35
3.17.3 REMOTE KEYLESS ENTRY (RKE) ............................35
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TABLE OF CONTENTS - Continued
3.17.3.1 PANIC FUNCTION .........................................35
3.17.3.2 ROLLING CODE ...........................................35
3.17.3.3 PROGRAMMABLE DOOR LOCK FEATURES ...................35
3.18 POWER FOLDING MIRRORS ........................................36
3.19 POWER LIFTGATE SYSTEM .........................................36
3.19.1 POWER LIFTGATE .........................................36
3.19.2 DIAGNOSTIC FEATURES ...................................36
3.19.3 SYSTEM INHIBITORS ......................................36
3.20 POWER SLIDING DOOR SYSTEM ....................................36
3.20.1 POWER SLIDING DOOR ....................................36
3.20.2 DIAGNOSTIC FEATURES ...................................37
3.20.3 SYSTEM INHIBITORS ......................................37
3.21 REAR WINDOW DEFOG/HEATED MIRROR/FRONT WIPER DE-ICE (IF
EQUIPPED) .......................................................37
3.22 TELECOMMUNICATIONS ...........................................37
3.22.1 HANDS FREE PHONE ......................................37
3.23 VEHICLE THEFT SECURITY SYSTEM .................................38
3.23.1 THATCHAM ALARM SYSTEM (EXPORT ONLY) .................38
3.24 WIPER SYSTEM ...................................................38
3.24.1 FRONT WIPER ............................................38
3.24.2 SPEED SENSITIVE INTERMITTENT WIPE MODE ...............39
3.24.3 PULSE WIPE ..............................................39
3.24.4 PARK AFTER IGNITION OFF.................................39
3.24.5 WIPE AFTER WASH ........................................39
3.24.6 REAR WIPER .............................................39
3.24.7 SPEED SENSITIVE INTERMITTENT WIPE MODE ...............39
3.24.8 WIPE AFTER WASH ........................................39
3.25 USING THE DRBIIIT ................................................39
3.26 DRBIIIT ERROR MESSAGES ........................................39
3.27 DRBIIIT DOES NOT POWER UP (BLANK SCREEN)......................39
3.28 DISPLAY IS NOT VISIBLE ...........................................39
4.0 DISCLAIMERS, SAFETY, WARNINGS ......................................40
4.1 DISCLAIMERS.....................................................40
4.2 SAFETY ..........................................................40
4.2.1 TECHNICIAN SAFETY INFORMATION .........................40
4.2.2 VEHICLE PREPARATION FOR TESTING .......................40
4.2.3 SERVICING SUB-ASSEMBLIES ..............................40
4.2.4 DRBIIIT SAFETY INFORMATION .............................40
4.3 WARNINGS .......................................................41
4.3.1 VEHICLE DAMAGE WARNINGS ..............................41
4.3.2 ROAD TESTING A COMPLAINT VEHICLE......................41
5.0 REQUIRED TOOLS AND EQUIPMENT .....................................41
6.0 GLOSSARY OF TERMS..................................................41
iii
TABLE OF CONTENTS - Continued
7.0 DIAGNOSTIC INFORMATION AND PROCEDURES ..........................43
ADJUSTABLE PEDALS
PEDAL SENSOR OPEN/SHORTED TO GROUND.............................44
PEDAL SENSOR SHORTED TO BATTERY ..................................47
PEDAL SW STUCK FORWARD ............................................50
PEDAL SW STUCK REARWARD ..........................................52
*CAN’T ADJUST PEDALS ................................................54
*CAN’T SET/RECALL MEMORY POSITIONS .................................59
AIRBAG
ACCELEROMETER 1 ....................................................61
ACCELEROMETER 2 ....................................................61
INTERNAL 1 ...........................................................61
INTERNAL 2 ...........................................................61
INTERNAL 3 ...........................................................61
INTERNAL 4 ...........................................................61
MODULE NOT CONFIGURED FOR OCS ....................................61
OUTPUT DRIVER 1 .....................................................61
OUTPUT DRIVER 2 .....................................................61
STORED ENERGY FIRING 1..............................................61
AIRBAG WARNING INDICATOR OPEN .....................................64
AIRBAG WARNING INDICATOR SHORT ....................................64
CALIBRATION MISMATCH................................................67
CLUSTER MESSAGE MISMATCH .........................................69
DRIVER KNEE BLOCKER CIRCUIT OPEN ..................................71
DRIVER KNEE BLOCKER CIRCUIT SHORT .................................74
DRIVER KNEE BLOCKER SHORT TO BATTERY .............................77
DRIVER KNEE BLOCKER SHORT TO GROUND .............................80
DRIVER SEAT BELT SWITCH CIRCUIT OPEN ...............................83
DRIVER SEAT BELT SWITCH SHORTTO BATTERY ..........................86
DRIVER SEAT BELT SWITCH SHORT TO GROUND ..........................89
DRIVER SEAT BELT SWITCH SHORT TOGETHER ...........................91
DRIVER SEAT BELT TENSIONER CIRCUIT OPEN ............................93
DRIVER SEAT BELT TENSIONER CIRCUIT SHORT ..........................96
DRIVER SEAT BELT TENSIONER SHORT TO BATTERY.......................99
DRIVER SEAT BELT TENSIONER SHORT TO GROUND ......................102
DRIVER SQUIB 1 CIRCUIT OPEN ........................................105
DRIVER SQUIB 1 CIRCUIT SHORT .......................................108
DRIVER SQUIB 1 SHORT TO BATTERY ...................................111
DRIVER SQUIB 1 SHORT TO GROUND ...................................114
DRIVER SQUIB 2 CIRCUIT OPEN ........................................117
DRIVER SQUIB 2 CIRCUIT SHORT .......................................120
DRIVER SQUIB 2 SHORT TO BATTERY ...................................123
DRIVER SQUIB 2 SHORT TO GROUND ...................................126
INTERROGATE OCM ...................................................129
LEFT CURTAIN OR SEAT SQUIB CIRCUIT OPEN ...........................131
LEFT CURTAIN OR SEAT SQUIB CIRCUIT SHORT ..........................134
LEFT CURTAIN OR SEAT SQUIB SHORTTO BATTERY ......................137
LEFT CURTAIN OR SEAT SQUIB SHORT TO GROUND ......................140
LEFT FRONT IMPACT SENSOR INTERNAL 1 ...............................143
NO LEFT FRONT IMPACT SENSOR COMMUNICATION ......................143
LEFT SIDE IMPACT SENSOR 1 INTERNAL 1 ...............................147
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TABLE OF CONTENTS - Continued
NO LEFT SIDE IMPACT SENSOR 1 COMMUNICATION.......................147
LEFT SIDE IMPACT SENSOR 2 INTERNAL 1 ...............................151
NO LEFT SIDE IMPACT SENSOR 2 COMMUNICATION.......................151
LEFT SIDE IMPACT SENSOR 3 INTERNAL 1 ...............................155
NO LEFT SIDE IMPACT SENSOR 3 COMMUNICATION.......................155
LOSS OF IGNITION RUN - START ........................................159
ORC RUN - START DRIVER OPEN .......................................159
ORC RUN - START DRIVER OVER CURRENT ..............................159
ORC RUN - START DRIVER OVER TEMP ..................................159
ORC RUN - START DRIVER OVER VOLT ..................................159
ORC RUN - START DRIVER SHORT TO GROUND ..........................159
LOSS OF IGNITION RUN ONLY ..........................................165
ORC RUN ONLY DRIVER OPEN..........................................165
ORC RUN ONLY DRIVER OVER CURRENT ................................165
ORC RUN ONLY DRIVER OVER TEMP ....................................165
ORC RUN ONLY DRIVER OVER VOLT ....................................165
ORC RUN ONLY DRIVER SHORT TO GROUND.............................165
NO CLUSTER MESSAGE ...............................................171
NO OCM MESSAGE ....................................................173
NO ODOMETER MESSAGE .............................................175
NO ORC MESSAGE ....................................................178
NO PCI LOOPBACK ....................................................181
PCI BUS SHORT TO BATTERY...........................................181
PCI BUS SHORT TO GROUND ...........................................181
NO PCI TRANSMISSION ................................................187
NO RIGHT FRONT IMPACT SENSOR COMMUNICATION .....................189
RIGHT FRONT IMPACT SENSOR INTERNAL 1 .............................189
NO RIGHT SIDE IMPACT SENSOR 1 COMMUNICATION .....................193
RIGHT SIDE IMPACT SENSOR 1 INTERNAL 1 ..............................193
NO RIGHT SIDE IMPACT SENSOR 2 COMMUNICATION .....................197
RIGHT SIDE IMPACT SENSOR 2 INTERNAL 1 ..............................197
NO RIGHT SIDE IMPACT SENSOR 3 COMMUNICATION .....................201
RIGHT SIDE IMPACT SENSOR 3 INTERNAL 1 ..............................201
OCCUPANT CLASSIFICATION MODULE DATATRANSFER ERROR ............205
OCCUPANT CLASSIFICATION UNDETERMINED ............................207
RE-ZERO INCOMPLETE ................................................207
SEAT NOT CALIBRATED ................................................207
SYSTEM VERIFICATION REQUIRED - OCSVR .............................207
OCM CONFIGURATION MISMATCH.......................................212
PASSENGERAIRBAG OFF INDICATOR CIRCUIT SHORT TO BATTERY ........214
PASSENGER AIRBAG OFF INDICATOR CIRCUIT SHORT TO GROUND.........217
PASSENGER BTS OPEN ................................................222
PASSENGER BTS SHORT TO BATTERY...................................222
PASSENGER BTS SHORT TO GROUND ...................................222
PASSENGER BTS SHORT TOGETHER ....................................222
PASSENGER PRESSURE SENSOR OPEN .................................226
PASSENGER PRESSURE SENSOR SHORT GROUND .......................226
PASSENGER PRESSURE SENSOR SHORT TO BATTERY ....................226
PASSENGER PRESSURE SENSOR SHORT TOGETHER .....................226
PASSENGER SEAT BELT SWITCH CIRCUIT OPEN ..........................229
PASSENGER SEAT BELT SWITCH SHORTTO BATTERY .....................231
PASSENGER SEAT BELT SWITCH SHORTTO GROUND .....................234
PASSENGER SEAT BELT SWITCH SHORT TOGETHER ......................237
v
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2004 Chrysler RS Town & Country, Dodge Caravan and Voyager Service & Repair Manual - !
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Description
This is a comprehensive service and repair manual for the Chrysler RS Town & Country, Dodge Caravan, and Voyager, covering production model years 2004. It contains all the necessary information for repairing, maintaining, rebuilding, refurbishing, or restoring your vehicle. The manual includes detailed illustrations, diagrams, wiring schematics, specifications, and step-by-step instructions. All pages are printable, allowing you to easily reference the information in your garage or workshop. These manuals are invaluable resources for both professional mechanics and DIY enthusiasts.
The manual covers a wide range of topics including lubrication & maintenance, suspension, differential & driveline, brakes, clutch, cooling, audio, electronic control modules, engine systems, heated systems, ignition control, instrument cluster, lamps, power systems, restraints, speed control, vehicle theft security, wipers/washers, wiring, exhaust system, frame & bumpers, fuel system, steering, transmission/transaxle, tires/wheels, body, heating & air conditioning, emissions control, and more. It also includes detailed information on gas powertrain, diesel powertrain, body, chassis, transmission, and a 2.5L diesel supplement.
The manual is in English, consists of more than 3000 pages, and is available in .PDF format. It is compatible with all versions of Windows and Mac operating systems, as well as various devices such as smartphones and tablets. The file is fully printable and bookmarked for easy navigation. It is a complete and intact resource with no missing or corrupt pages/sections.
With detailed illustrations, exploded diagrams, drawings, and photos, this manual provides guidance through every service repair procedure. It can be viewed, zoomed, and printed on any computer. The .PDF format allows for easy storage and accessibility, making it a convenient resource for all your repair needs.
Instant delivery means there are no shipping costs or waiting for a physical manual to arrive. Upon payment completion, you will receive the manual instantly via secure download. Accepted payment methods include all major credit/debit cards and PayPal. By utilizing this manual, you can perform repairs yourself and save money.
