2001-2007 Dodge Grand Caravan Service & Repair Manual

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 AIRBAG SYSTEM ...................................................2 3.1.1 DRIVER AIRBAG............................................2 3.1.2 CLOCKSPRING.............................................4 3.1.3 PASSENGER AIRBAG .......................................4 3.1.4 SEAT BELT TENSIONER (SBT) ................................5 3.1.5 SEAT BELT SWITCHES (SBS).................................5 3.1.6 SIDE IMPACT AIRBAG CONTROL MODULE (SIACM) .............5 3.1.7 SEAT AIRBAGS (SAB) .......................................6 3.1.8 DIAGNOSTIC TROUBLE CODES ..............................6 3.1.9 SPECIAL TOOLS............................................7 3.1.10 ACTIVE CODES ............................................7 3.1.11 STORED CODES ...........................................7 3.2 AUDIO SYSTEM ....................................................7 3.2.1 REMOTE RADIO CONTROLS .................................8 3.2.2 CD CHANGER..............................................8 3.3 BODY CONTROL MODULE ...........................................8 3.4 CHIME WARNING SYSTEM...........................................9 3.4.1 CHIME PRIORITY ...........................................9 3.4.2 CHIME ON CONDITIONS....................................10 3.4.3 WARNING LAMP ANNOUNCEMENT ..........................10 3.4.4 OTHER CHIME ON CONDITIONS.............................10 3.5 COMMUNICATION .................................................11 3.6 DOOR AJAR SYSTEM ..............................................12 3.7 EXTERIOR LIGHTING SYSTEM ......................................12 3.7.1 HEADLAMP POWER .......................................12 3.7.2 HEADLAMP SWITCH .......................................12 3.7.3 PARK LAMP RELAY ........................................12 3.7.4 FOG LAMP RELAY .........................................12 3.7.5 FOG LAMPS ..............................................12 3.7.6 EXTERIOR LIGHTING BATTERY SAVER .......................13 3.7.7 AUTO HEADLAMPS ........................................13 3.8 FRONT CONTROL MODULE .........................................13 3.8.1 CONTROLLED POWER FEEDS ..............................13 3.8.2 RELAY CONTROLS ........................................14 3.8.3 ELECTRICAL INPUTS ......................................15 3.9 HEATING & A/C ...................................................16 3.9.1 AUTOMATIC TEMPERATURE CONTROL (ATC) .................16 3.9.1.1 SYSTEM OPERATION ......................................16 3.9.1.2 SYSTEM OPERATION ......................................16 3.9.1.2 BLOWER MOTOR OPERATION ..............................16 3.9.1.3 INFRARED SENSORS ......................................16 3.9.1.4 REAR ATC SWITCH ........................................16 3.9.1.5 COOLDOWN TESTING .....................................16 3.9.1.6 ACTIVE AND STORED TROUBLE CODES .....................17 i

TABLE OF CONTENTS - Continued 3.9.2 MANUAL TEMPERATURE CONTROL..........................17 3.9.2.1 SYSTEM AVAILABILITY .....................................17 3.9.2.2 CABIN HEATER ...........................................17 3.9.2.3 ZONE CONTROL ..........................................17 3.9.2.4 FRONT HVAC UNIT ........................................17 3.9.2.5 REAR HVAC UNIT .........................................17 3.9.2.6 A/C – HEATER CONTROL MODULE, SWITCH OPERATION .......17 3.9.2.7 REAR BLOWER REAR CONTROL ............................19 3.9.2.8 HVAC DIAGNOSTICS .......................................19 3.10 CABIN HEATER ...................................................19 3.10.1 GENERAL SAFETY INFORMATION ...........................20 3.10.2 COMPONENT DESCRIPTION AND OPERATION ................20 3.10.2.1 DCHA ASSEMBLY..........................................20 3.10.2.2 COMBUSTION AIR FAN .....................................20 3.10.2.3 BURNER HOUSING ........................................20 3.10.2.4 BURNER INSERT ..........................................21 3.10.2.5 CONTROL UNIT/HEAT EXCHANGER ..........................21 3.10.2.6 DOSING PUMP ............................................21 3.10.3 OPERATION ..............................................21 3.10.3.1 ACTIVATION ..............................................21 3.10.3.2 HEATING .................................................22 3.10.3.3 DEACTIVATION ............................................22 3.10.4 DIAGNOSTICS ............................................22 3.11 INSTRUMENT CLUSTER ............................................22 3.11.1 INSTRUMENT CLUSTER SELF TEST .........................22 3.11.2 MESSAGE CENTER ........................................23 3.12 INTERIOR LIGHTING ...............................................23 3.12.1 COURTESY LAMP CONTROL ................................23 3.12.2 ILLUMINATED ENTRY ......................................23 3.12.3 INTERIOR LIGHTING BATTERY SAVER .......................23 3.13 MEMORY SYSTEM.................................................23 3.13.1 POWER SEAT .............................................23 3.13.2 MEMORY MIRRORS........................................24 3.14 OVERHEAD CONSOLE .............................................24 3.14.1 VEHICLE INFORMATION DISPLAY............................24 3.14.2 TRAVELER DISPLAY FUNCTIONS ............................25 3.14.3 SETTING MAGNETIC ZONE VARIANCE .......................26 3.14.4 COMPASS CALIBRATION ...................................26 3.14.5 SELF-CHECK DIAGNOSTICS ................................27 3.14.6 AMBIENT TEMPERATURE SENSOR ..........................27 3.14.7 AMBIENT TEMPERATURE SENSOR FAULT CODES .............27 3.14.8 HOMELINKT UNIVERSAL TRANSMITTER ......................28 3.14.9 TIRE PRESSURE MONITORING SYSTEM (TPM) ................28 3.14.9.1 TRAINING THE EVIC .......................................28 3.14.9.2 PRESSURE THRESHOLDS ..................................29 3.14.9.3 CRITICAL AND NON-CRITICAL SYSTEM ALERTS ...............29 3.14.9.4 SYSTEM FAULTS ..........................................29 3.14.9.5 SPARE WHEEL AUTO-DETECT ..............................29 3.14.9.6 DIAGNOSING AND CLEARING SYSTEM FAULTS ...............29 3.14.9.7 SYSTEM TEST ............................................30 3.15 POWER DOOR LOCK SYSTEM ......................................30 3.15.1 DOOR LOCK INHIBIT .......................................30 3.15.2 AUTOMATIC DOOR LOCKS .................................30 ii

TABLE OF CONTENTS - Continued 3.15.3 REMOTE KEYLESS ENTRY (RKE) ............................30 3.16 POWER FOLDING MIRRORS ........................................31 3.17 POWER LIFTGATE SYSTEM .........................................31 3.17.1 POWER LIFTGATE .........................................31 3.17.2 DIAGNOSTIC FEATURES ...................................31 3.17.3 SYSTEM INHIBITORS ......................................31 3.18 POWER SLIDING DOOR SYSTEM ....................................31 3.18.1 POWER SLIDING DOOR ....................................31 3.18.2 DIAGNOSTIC FEATURES ...................................32 3.18.3 SYSTEM INHIBITORS ......................................32 3.19 REAR WINDOW DEFOG/HEATED MIRROR/FRONT WIPER DE-ICE ........32 3.20 VEHICLE THEFT SECURITY SYSTEM .................................32 3.20.1 THATCHAM ALARM SYSTEM (EXPORT ONLY) .................33 3.21 WIPER SYSTEM ...................................................33 3.21.1 FRONT WIPER ............................................33 3.21.2 SPEED SENSITIVE INTERMITTENT WIPE MODE ...............33 3.21.3 PULSE WIPE ..............................................33 3.21.4 PARK AFTER IGNITION OFF.................................33 3.21.5 WIPE AFTER WASH ........................................33 3.21.6 REAR WIPER .............................................33 3.21.7 SPEED SENSITIVE INTERMITTENT WIPE MODE ...............34 3.21.8 WIPE AFTER WASH ........................................34 3.22 USING THE DRBIIIT ................................................34 3.23 DRBIIIT ERROR MESSAGES ........................................34 3.24 DRBIIIT DOES NOT POWER UP (BLANK SCREEN)......................34 3.25 DISPLAY IS NOT VISIBLE ...........................................34 4.0 DISCLAIMERS, SAFETY, WARNINGS ......................................34 4.1 DISCLAIMERS.....................................................34 4.2 SAFETY ..........................................................34 4.2.1 TECHNICIAN SAFETY INFORMATION .........................34 4.2.2 VEHICLE PREPARATION FOR TESTING .......................35 4.2.3 SERVICING SUB-ASSEMBLIES ..............................35 4.2.4 DRBIIIT SAFETY INFORMATION .............................35 4.3 WARNINGS .......................................................36 4.3.1 VEHICLE DAMAGE WARNINGS ..............................36 4.3.2 ROAD TESTING A COMPLAINT VEHICLE......................36 5.0 REQUIRED TOOLS AND EQUIPMENT .....................................36 6.0 GLOSSARY OF TERMS..................................................36 7.0 DIAGNOSTIC INFORMATION AND PROCEDURES ...........................39 AIRBAG ACCELEROMETER 1 ....................................................40 ACCELEROMETER 2 ....................................................40 INTERNAL 1 ...........................................................40 INTERNAL 2 ...........................................................40 OUTPUT DRIVER 1 .....................................................40 OUTPUT DRIVER 2 .....................................................40 STORED ENERGY FIRING 1..............................................40 AIRBAG WARNING INDICATOR OPEN .....................................42 iii

TABLE OF CONTENTS - Continued AIRBAG WARNING INDICATOR SHORT ....................................42 CALIBRATION MISMATCH................................................44 CLUSTER MESSAGE MISMATCH .........................................46 CONFIGURATION ERROR ...............................................48 DRIVER SEAT BELT SWITCH OPEN .......................................50 DRIVER SEAT BELT SWITCH SHORTTO BATTERY ..........................52 DRIVER SEAT BELT SWITCH SHORT TO GROUND ..........................54 DRIVER SEAT BELT TENSIONER CIRCUIT OPEN ............................57 DRIVER SEAT BELT TENSIONER CIRCUIT SHORT ..........................59 DRIVER SEAT BELT TENSIONER SHORT TO BATTERY.......................61 DRIVER SEAT BELT TENSIONER SHORT TO GROUND .......................63 DRIVER SQUIB 1 CIRCUIT OPEN .........................................65 DRIVER SQUIB 1 CIRCUIT SHORT ........................................68 DRIVER SQUIB 1 SHORT TO BATTERY ....................................70 DRIVER SQUIB 1 SHORT TO GROUND ....................................73 DRIVER SQUIB 2 CIRCUIT OPEN .........................................76 DRIVER SQUIB 2 CIRCUIT SHORT ........................................79 DRIVER SQUIB 2 SHORT TO BATTERY ....................................82 DRIVER SQUIB 2 SHORT TO GROUND ....................................85 INTERROGATE LEFT SIACM .............................................88 INTERROGATE RIGHT SIACM ............................................90 LOSS OF IGNITION RUN ONLY ...........................................92 LOSS OF IGNITION RUN-START ..........................................94 MODULE NOT CONFIGURED FOR SAB ....................................96 NO CLUSTER MESSAGE ................................................98 NO LEFT SIACM MESSAGE .............................................100 NO ODOMETER MESSAGE .............................................102 NO PCI TRANSMISSION ................................................104 NO RIGHT SIACM MESSAGE ............................................107 ORC RUN - START DRIVER OVER CURRENT ..............................109 ORC RUN - START DRIVER OVER TEMP ..................................109 ORC RUN - START DRIVER SHORT TO GROUND ..........................109 ORC RUN - START DRIVER OPEN .......................................109 ORC RUN - START DRIVER OVER VOLT ..................................109 ORC RUN ONLY DRIVER OPEN ..........................................114 ORC RUN ONLY DRIVER OVER CURRENT ................................114 ORC RUN ONLY DRIVER OVER TEMP ....................................114 ORC RUN ONLY DRIVER OVER VOLT ....................................114 ORC RUN ONLY DRIVER SHORT TO GROUND .............................114 PASSENGER SEAT BELT SWITCH OPEN ..................................119 PASSENGER SEAT BELT SWITCH SHORTTO BATTERY .....................121 PASSENGER SEAT BELT SWITCH SHORTTO GROUND .....................123 PASSENGER SEAT BELT TENSIONER CIRCUIT OPEN ......................126 PASSENGER SEAT BELT TENSIONER CIRCUIT SHORT .....................128 PASSENGER SEAT BELT TENSIONER SHORT TO BATTERY .................130 PASSENGER SEAT BELT TENSIONER SHORT TO GROUND .................132 PASSENGER SQUIB 1 CIRCUIT OPEN ....................................134 PASSENGER SQUIB 1 CIRCUIT SHORT ...................................137 PASSENGER SQUIB 1 SHORT TO BATTERY ...............................139 PASSENGER SQUIB 1 SHORT TO GROUND ...............................141 PASSENGER SQUIB 2 CIRCUIT OPEN ....................................143 PASSENGER SQUIB 2 CIRCUIT SHORT ...................................146 PASSENGER SQUIB 2 SHORT TO BATTERY ...............................148 iv

TABLE OF CONTENTS - Continued PASSENGER SQUIB 2 SHORT TO GROUND ...............................150 SEAT SQUIB CIRCUIT OPEN ............................................152 SEAT SQUIB CIRCUIT SHORT ...........................................155 SEAT SQUIB SHORT TO BATTERY .......................................158 SEAT SQUIB SHORT TO GROUND .......................................161 SIACM RUN - START DRIVER OPEN......................................164 SIACM RUN - START DRIVER OVER CURRENT ............................164 SIACM RUN - START DRIVER OVER TEMP ................................164 SIACM RUN - START DRIVER SHORT TO GROUND.........................164 SIACM RUN - START DRIVER OVER VOLT ................................164 VEHICLE BODY STYLE UNKNOWN.......................................170 *AIRBAG INDICATOR ON WITHOUT ACM TROUBLE CODES .................172 AUDIO ALL OUTPUTS SHORT .................................................173 CASSETTE PLAYER INOP ..............................................176 CD MECHANICAL FAILURE .............................................176 REAR TRANSMITTER FAILURE ..........................................176 *AM/FM SWITCH INOPERATIVE ..........................................176 *ANY STATION PRESET SWITCH INOPERATIVE ............................176 *BALANCE INOPERATIVE ...............................................176 *CD EJECT SWITCH INOPERATIVE.......................................176 *EQUALIZER INOPERATIVE .............................................176 *FADER INOPERATIVE .................................................176 *FF/RW SWITCH INOPERATIVE ..........................................176 *HOUR/MINUTE SWITCHES INOPERATIVE ................................176 *PAUSE/PLAY SWITCH INOPERATIVE ....................................176 *PWR SWITCH INOPERATIVE ...........................................176 *SCAN SWITCH INOPERATIVE ..........................................176 *SEEK SWITCH INOPERATIVE ...........................................176 *SET SWITCH INOPERATIVE ............................................176 *TAPE EJECT SWITCH INOPERATIVE.....................................176 *TIME SWITCH INOPERATIVE ...........................................176 *TUNE SWITCH INOPERATIVE...........................................176 CD CHANGER MECHANICAL FAILURE ....................................178 CD CHANGER READ FAILURE...........................................179 CD CHANGER TEMPERATURE HIGH .....................................180 CD READ FAILURE ....................................................181 CD TEMPERATURE HIGH ...............................................182 NBS OUTPUT 1 OPEN..................................................183 NBS OUTPUT 2 OPEN..................................................183 NBS OUTPUT 1 SHORT TO BATT ........................................185 NBS OUTPUT 2 SHORT TO BATT ........................................185 NO ANTENNA CONNECTION ............................................187 POWER AMP SHUTDOWN ..............................................188 REMOTE RADIO SWITCH STUCK ........................................191 *REMOTE RADIO CONTROLS INOPERATIVE ..............................194 AUTOMATIC TEMPERATURE CONTROL AC PRESSURE TOO HIGH (ACTIVE)......................................197 AC PRESSURE TOO HIGH (STORED).....................................198 DRIVER BLEND DOOR NOT RESPONDING (STORED) ......................198 DRIVER BLEND DOOR RANGE TOO LARGE (STORED) .....................198 v

2001-2007 Dodge Grand Caravan Service & Repair Manual

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