Chrysler Town, Dodge Caravan. Manual — part 104
TEMPERATURE GAUGE DIAGNOSIS
CONDITION
POSSIBLE CAUSES
CORRECTION
NO POINTER
MOVEMENT.
1. INTERNAL CLUSTER
FAILURE.
1. PERFORM CLUSTER SELF-DIAGNOSTIC TEST
AND CHECK.
•
IF TEMPERATURE GAUGE POINTER MOVES TO
CALIBRATION POINTS, LOOK FOR ANOTHER
POSSIBLE CAUSE OF FAILURE.
•
IF THE POINTER DOESN’T MOVE DURING TEST,
VERIFY POWER AND GROUND ARE BEING
PROVIDED TO THE CLUSTER. IF YES, REPLACE
CLUSTER. IF NO, DETERMINE CAUSE OF NO
POWER OR NO GROUND.
2. NO PCI
TEMPERATURE
MESSAGE OR COLD PCI
BUS MESSAGE FROM
THE POWERTRAIN
CONTROL MODULE.
2.A. CHECK PCM FAULT CODES USING A DRB III
T
SCAN TOOL. IF THERE ARE NO FAULTS, GO TO
STEP 2.B. IF THERE ARE FAULTS, REFER TO THE
PROPER POWERTRAIN DIAGNOSTIC
PROCEDURES MANUAL TO PROPERLY DIAGNOSE
AND REPAIR.
2.B. REFER TO FUEL, COOLANT TEMPERATURE
SENSOR, DIAGNOSIS AND TESTING. REPAIR
SENSOR AS NEEDED.
ERRATIC POINTER
MOVEMENT.
1. BAD PCI BUS
MESSAGE FROM THE
POWERTRAIN CONTROL
MODULE.
1.A. CHECK PCM FAULT CODES USING A DRB III
T
SCAN TOOL. IF THERE ARE NO FAULTS, GO TO
STEP 1.B. IF THERE ARE FAULTS, REFER TO THE
PROPER POWERTRAIN DIAGNOSTIC
PROCEDURES MANUAL TO PROPERLY DIAGNOSE
AND REPAIR.
1.B. REFER TO FUEL, COOLANT TEMPERATURE
SENSOR, DIAGNOSIS AND TESTING. REPAIR
SENSOR AS NEEDED.
2. INTERNAL CLUSTER
FAILURE.
2. PERFORM CLUSTER SELF-DIAGNOSTIC TEST
AND CHECK FOR FAULT CODES.
•
IF THE POINTER MOVES DURING TEST BUT
STILL APPEARS ERRATIC, REPLACE CLUSTER
ASSEMBLY.
TEMPERATURE GAUGE
INACCURATE.
1. TEMPERATURE
GAUGE OUT OF
CALIBRATION.
1. PERFORM CLUSTER SELF-DIAGNOSTIC TEST.
•
IF POINTER IS ACCURATE TO THE CALIBRATION
POINTS LOOK FOR ANOTHER POSSIBLE CAUSE
OF FAILURE.
•
IF POINTER IS INACCURATE TO THE
CALIBRATION POINTS, REPLACE CLUSTER
ASSEMBLY.
2. COOLANT SENSOR
OUT OF CALIBRATION.
2. REFER TO FUEL, COOLANT TEMPERATURE
SENSOR FOR TEST AND REPAIR PROCEDURE.
8J - 8
INSTRUMENT CLUSTER
RS
INSTRUMENT CLUSTER (Continued)
ODOMETER DIAGNOSIS
CONDITION
POSSIBLE CAUSES
CORRECTION
NO DISPLAY.
1. NO PCI BUS
ODOMETER MESSAGE
FROM BCM.
1. USE A DRB III
T
SCAN TOOL TO CHECK THE
BCM. REFER TO THE PROPER BODY DIAGNOSTIC
PROCEDURES MANUAL TO PROPERLY DIAGNOSE
AND REPAIR.
2. INTERNAL CLUSTER
FAILURE.
2. PERFORM CLUSTER SELF-DIAGNOSTIC TEST
AND CHECK FOR FAULT CODES.
•
IF ODOMETER PASSES THE SEGMENT CHECK,
LOOK FOR ANOTHER POSSIBLE CAUSE OF
FAILURE. IF IT FAILS VERIFY POWER AND
GROUND ARE BEING PROVIDED TO THE
CLUSTER. IF YES, REPLACE CLUSTER. IF NO,
DETERMINE CAUSE OF NO POWER OR GROUND.
ERRATIC DISPLAY
1. INTERNAL CLUSTER
FAILURE.
1. PERFORM CLUSTER SELF-DIAGNOSTIC TEST
AND CHECK FOR FAULT CODES.
•
IF ODOMETER PASSES THE SEGMENT TEST,
FAILURE MAY NOT BE IN THE CLUSTER. LOOK
FOR ANOTHER POSSIBLE CAUSE OF FAILURE.
2. VERIFY GOOD POWER AND GROUND
CONNECTIONS. IF CONNECTIONS ARE GOOD AND
NO OTHER PROBLEMS ARE FOUND, REPLACE
CLUSTER ASSEMBLY.
2. BAD PCI BUS
MESSAGE FROM THE
BCM.
2. USE A DRB III
T
SCAN TOOL TO CHECK THE
BCM. REFER TO THE PROPER BODY DIAGNOSTIC
PROCEDURES MANUAL TO PROPERLY DIAGNOSE
AND REPAIR.
ODOMETER WON’T GO
INTO TRIP MODE.
TRIP SWITCH DOESN’T
WORK.
IF CLUSTER WILL NOT GO INTO SELF DIAGNOSTIC
MODE AND CANNOT TOGGLE BETWEEN
ODOMETER AND TRIP ODOMETER, REPLACE
CLUSTER.
TRIP ODOMETER WON’T
RESET.
RESET SWITCH
DOESN’T WORK.
IF CLUSTER WILL NOT GO INTO SELF DIAGNOSTIC
MODE AND TRIP ODOMETER WILL NOT RESET,
REPLACE CLUSTER.
RS
INSTRUMENT CLUSTER
8J - 9
INSTRUMENT CLUSTER (Continued)
ELECTRONIC GEAR INDICATOR DISPLAY DIAGNOSIS
CONDITION
POSSIBLE CAUSES
CORRECTION
NO DISPLAY.
1. INTERNAL CLUSTER
FAILURE.
1. PERFORM CLUSTER SELF-DIAGNOSTIC TEST
AND CHECK FOR FAULT CODES.
•
IF PRND3L (PRND1234 IF AUTOSTICK
EQUIPPED) PASSES THE SEGMENT CHECK, THEN
FAILURE MAY NOT BE IN THE CLUSTER. LOOK
FOR ANOTHER POSSIBLE CAUSE OF FAILURE. IF
IT FAILS, REPLACE CLUSTER ASSEMBLY.
ERRATIC DISPLAY.
1. INTERNAL CLUSTER
FAILURE.
1. PERFORM CLUSTER SELF-DIAGNOSTIC TEST
AND CHECK FOR FAULT CODES.
•
IF PRND3L (PRND1234 IF AUTOSTICK
EQUIPPED) PASSES THE SEGMENT CHECK, THEN
FAILURE MAY NOT BE IN THE CLUSTER. LOOK
FOR ANOTHER POSSIBLE CAUSE OF FAILURE.
2. BAD PCI BUS
MESSAGE FROM THE
TCM.
2. USE A DRB III
T
SCAN TOOL TO CHECK THE
TCM. REFER TO THE PROPER TRANSMISSION
DIAGNOSTIC PROCEDURES MANUAL TO
PROPERLY DIAGNOSE AND REPAIR.
ALL SEGMENTS ARE ON.
1. NO PCI BUS
MESSAGE FROM THE
TCM.
1.A. PERFORM CLUSTER SELF-DIAGNOSTIC TEST.
IF PRND3L (PRND1234 IF AUTOSTICK EQUIPPED)
PASSES TEST GO TO STEP 1.B. IF PRND3L
(PRND1234 IF AUTOSTICK EQUIPPED) FAILS TEST,
REPLACE CLUSTER ASSEMBLY.
1.B. CHECK THE TCM USING A DRB III
T
SCAN
TOOL. REFER TO THE PROPER TRANSMISSION
DIAGNOSTIC PROCEDURES MANUAL TO
PROPERLY DIAGNOSE AND REPAIR.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove Over Steering Column Bezel by lifting
it straight up with a firm pull.
(3) Remove the four cluster bezel attaching screws.
(4) Tilt the steering column in the full down posi-
tion.
(5) Pull rearward on the cluster bezel and remove.
(6) Remove the four screws holding instrument
cluster to instrument panel.
(7) Rotate top of cluster outward.
(8) Disconnect the cluster harness connector.
(9) Remove instrument cluster from instrument
panel.
INSTALLATION
(1) Connect the instrument cluster wire connector.
(2) Rotate top of cluster inward as placing into
instrument panel opening.
(3) Install the four screws holding instrument clus-
ter to instrument panel.
(4) Position cluster bezel into place.
(5) Install the four bezel attaching screws.
(6) Install the Over Steering Column Bezel by
firmly snapping into place.
(7) 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.
8J - 10
INSTRUMENT CLUSTER
RS
INSTRUMENT CLUSTER (Continued)
LAMPS
TABLE OF CONTENTS
page
page
LAMPS/LIGHTING - EXTERIOR . . . . . . . . . . . . . . . 1
LAMPS/LIGHTING - INTERIOR . . . . . . . . . . . . . . . 25
LAMPS/LIGHTING - EXTERIOR
TABLE OF CONTENTS
page
page
LAMPS/LIGHTING - EXTERIOR
. . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . . 4
BRAKE LAMP SWITCH
. . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DIAGNOSIS AND TESTING - BRAKE LAMP
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
. . . . . . . . . . . . . . . . . . . . . . . . . . 5
CENTER HIGH MOUNTED STOP LAMP
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . . . . . . . . . . . . . . . . . . . . . . . . 6
CENTER HIGH MOUNTED STOP LAMP UNIT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . . . . . . . . . . . . . . . . . . . . . . . . 7
FRONT FOG LAMP
DIAGNOSIS AND TESTING - FRONT FOG
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
. . . . . . . . . . . . . . . . . . . . . . . . . . 9
FRONT FOG LAMP - EXPORT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
. . . . . . . . . . . . . . . . . . . . . . . . . . 9
FRONT FOG LAMP UNIT
STANDARD PROCEDURE - FRONT FOG
LAMP UNIT ALIGNMENT . . . . . . . . . . . . . . . . . 9
STANDARD PROCEDURE - FRONT FOG
LAMP UNIT ALIGNMENT - EXPORT . . . . . . . . 9
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
. . . . . . . . . . . . . . . . . . . . . . . . . 10
FRONT POSITION LAMP - EXPORT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
. . . . . . . . . . . . . . . . . . . . . . . . . 10
HEADLAMP
DIAGNOSIS AND TESTING - HEADLAMP
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
. . . . . . . . . . . . . . . . . . . . . . . . . 13
HEADLAMP - EXPORT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
. . . . . . . . . . . . . . . . . . . . . . . . . 13
HEADLAMP LEVELING MOTOR - EXPORT
DIAGNOSIS AND TESTING - HEADLAMP
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
. . . . . . . . . . . . . . . . . . . . . . . . . 15
HEADLAMP LEVELING SWITCH - EXPORT
. . . . . . . . . . . . . . . . . . . . . . . . . 15
DIAGNOSIS AND TESTING - HEADLAMP
HEADLAMP SWITCH
DIAGNOSIS AND TESTING - HEADLAMP
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DIAGNOSIS AND TESTING - HEADLAMP
SWITCH - EXPORT . . . . . . . . . . . . . . . . . . . . 16
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
. . . . . . . . . . . . . . . . . . . . . . . . . 17
HEADLAMP UNIT
UNIT ALIGNMENT . . . . . . . . . . . . . . . . . . . . . 17
UNIT ALIGNMENT - EXPORT . . . . . . . . . . . . . 17
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
. . . . . . . . . . . . . . . . . . . . . . . . . 20
HEADLAMP UNIT - EXPORT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
. . . . . . . . . . . . . . . . . . . . . . . . . 20
LICENSE LAMP
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
. . . . . . . . . . . . . . . . . . . . . . . . . 20
RS
LAMPS
8L - 1
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