Chrysler Town, Dodge Caravan. Manual - part 102

REMOVAL

When replacing the spark plugs and spark plug

cables, route the cables correctly and secure them in
the appropriate retainers. Failure to route the cables
properly can cause the radio to reproduce ignition
noise, cross ignition of the spark plugs or short cir-
cuit the cables to ground.

Always remove cables by grasping at the boot,

rotating the boot 1/2 turn, and pulling straight back
in a steady motion.

(1) Prior to removing the spark plug, spray com-

pressed air around the spark plug hole and the area
around the spark plug.

(2) Remove the spark plug using a quality socket

with a foam insert.

(3) Inspect the spark plug condition.

INSTALLATION

When replacing the spark plugs and spark plug

(1) Coat threads of spark plug with anti-seize. Be

sure not to get anti-seize ANTWHERE BUT ON
THE THREADS OF THE SPARK PLUG as
shown in (Fig. 13).

(2) To avoid cross threading, start the spark plug

into the cylinder head by hand.

(3) Tighten spark plugs to 17.5 N·m (13 ft. lbs.)

torque.

(4) Install spark plug cables over spark plugs. A

click will be heard and felt when the cable properly
attaches to the spark plug.

SPARK PLUG CABLE

DESCRIPTION

Spark Plug cables are sometimes referred to as

secondary ignition wires. The wires transfer electri-
cal current from the ignition coil pack to individual
spark plugs at each cylinder. The resistive spark plug
cables are of nonmetallic construction. The cables
provide suppression of radio frequency emissions
from the ignition system.

Check the spark plug cable connections for good

contact at the coil, and spark plugs. Terminals should
be fully seated. The insulators should be in good con-
dition and should fit tightly on the coil, and spark
plugs. Spark plug cables with insulators that are
cracked or torn must be replaced.

Clean Spark Plug cables with a cloth moistened

with a non-flammable solvent. Wipe the cables dry.
Check for brittle or cracked insulation. The spark
plug cables and spark plug boots are made from high
temperature materials.

REMOVAL - 2.0/2.4L

Failure to route the cables properly could cause the

radio to reproduce ignition noise, cross ignition of the
spark plugs or short circuit the cables to ground.

Remove spark plug cable from coil first.
Always remove the spark plug cable by grasping

the top of the spark plug insulator, turning the boot
1/2 turn and pulling straight up in a steady motion.

INSTALLATION - 2.0/2.4L

Failure to route the cables properly could cause the

radio to reproduce ignition noise, cross ignition of the
spark plugs or short circuit the cables to ground.
Install spark plug insulators over spark plugs.
Ensure the top of the spark plug insulator covers the
upper end of the spark plug tube, then connect the
other end to coil pack.

8I - 10

IGNITION CONTROL

SPARK PLUG (Continued)

INSTRUMENT CLUSTER

TABLE OF CONTENTS

page

INSTRUMENT CLUSTER

DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . . . 1

OPERATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

DIAGNOSIS AND TESTING

DIAGNOSIS AND TESTING - SELF-

DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . 2

DIAGNOSIS AND TESTING - CLUSTER

DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 10

CLUSTER LENS

REMOVAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . 10

INSTRUMENT CLUSTER

DESCRIPTION

The instrumentation gauges are contained in a

subdial assembly within the instrument cluster. The
individual gauges are not serviceable. If one of the
cluster gauges becomes faulty, the entire cluster
would require replacement.

The Mechanical Instrument Cluster (MIC) with a

tachometer is equipped with a electronic vacuum flu-
orescent transmission range indicator (PRND3L),
odometer, and trip odometer display.

The MIC without a tachometer is equipped with a

Light Emitting Diode (LED) transmission range indi-
cator (PRND3L) and a vacuum fluorescent odometer
display.

The MIC is equipped with the following warning

lamps.

• Lift Gate Ajar

• Low Fuel Level

• Low Windshield Washer Fluid Level

• Cruise

• Battery Voltage

• Fasten Seat Belt

• Door Ajar

• Coolant Temperature

• Anti-Lock Brake

• Brake

• Oil Pressure

• MIL (Malfunction Indicator Lamp)

• VTSS/SKIS Indicator

• Airbag

• Traction Control

• Autostick
The MIC without a tachometer also has the follow-

ing warning lamps:

• Turns Signals

• High Beam

WATER IN FUEL LAMP - EXPORT

The Water In Fuel Lamp is located in the message

center. When moisture is found within the fuel sys-
tem, the sensor sends a message via the PCI data
bus to the instrument cluster. The MIC illuminates
the bulb in the message center, 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

Refer to the vehicle Owner’s Manual for operation

instructions and conditions for the Instrument Clus-
ter Gauges.

WATER IN FUEL LAMP - EXPORT

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.

INSTRUMENT CLUSTER

8J - 1

DIAGNOSIS AND TESTING

DIAGNOSIS AND TESTING - SELF-DIAGNOSTICS

The instrument clusters are equipped with a self

diagnostic test feature to help identify electronic prob-
lems. Prior to any test, perform the Self-Diagnostic
Test. The self diagnostic system displays instrument
cluster stored fault codes in the odometer display,
sweeps the gauges to the calibration points, and bulb
checks the warning indicators. When the key is in the
ON position with the engine not running, the MIL will
remain illuminated for regulatory purposes.

To activate the Self-Diagnostic program:
(1) With the ignition switch in the OFF position,

depress the TRIP ODOMETER RESET button.

(2) Continue

hold

the

TRIP

ODOMETER

RESET button until Sof and a number (software ver-
sion number (i.e. Sof 3.2) appears in the odometer
window then release the button. If a fault code is
present, the cluster will display it in the odometer
display. When all fault codes have been displayed,
the cluster will display “end” in the odometer dis-
play. Refer to the INSTRUMENT CLUSTER DTC’S
table to determine what each trouble code means.

INSTRUMENT CLUSTER DTC’S

DTC

DESCRIPTION

100.0

LOOP-BACK FAILURE

100.1

ABS COMMUNICATION FAULT

100.2

BCM COMMUNICATION FAULT

100.3

EATX COMMUNICATION FAULT

100.4

FCM COMMUNICATION FAULT

100.5

ORC COMMUNICATION FAULT

100.6

SBEC/DEC/MCM COMMUNICATION
FAULT

200.0

AIRBAG LED SHORT

200.1

AIRBAG LED OPEN

200.2

ABS LED SHORT

200.3

ABS LED OPEN

200.6

EL INVERTER TIME-OUT

200.7

EATX MISMATCH

400.0

EEPROM READ/WRITE FAILURE

400.1

IMPROPER POWER DOWN
DETECTED

CALIBRATION TEST

The CLUSTER CALIBRATION table contains the

proper calibration points for each gauge. If the gauge
pointers are not calibrated, a problem exists in the
cluster. If any gauge is out of calibration, replace the
cluster.

CLUSTER CALIBRATION

SPEEDOMETER

CALIBRATION POINT

0 MPH (0 KM/H)

20 MPH (40 KM/H)

60 MPH (100 KM/H)

100 MPH (160 KM/H)

TACHOMETER

0 RPM

1000 RPM

3000 RPM

6000 RPM

FUEL GAUGE

EMPTY

1/4 FILLED

1/2 FILLED

FULL

TEMPERATURE

GAUGE

COLD

1/4

3/4

HOT

ODOMETER SEGMENT TEST

If a segment in the odometer does not illuminate

normally, a problem exists in the display.

ELECTRONIC TRANSMISSION RANGE INDICATOR
SEGMENT TEST

If a segment in the transmission range indicator

does not illuminate normally, a problem exists in the
display.

DIAGNOSIS AND TESTING - CLUSTER
DIAGNOSIS

CONDITIONS

Refer to the following tables for possible problems,

causes, and corrections.

• INSTRUMENT CLUSTER DIAGNOSIS

• SPEEDOMETER DIAGNOSIS

• TACHOMETER DIAGNOSIS

• FUEL GAUGE DIAGNOSIS

• TEMPERATURE GAUGE DIAGNOSIS

• ODOMETER DIAGNOSIS

• ELECTRONIC GEAR INDICATOR DISPLAY

DIAGNOSIS

NOTE: Always check the functionality of the cluster
by running the self test prior to troubleshooting.

8J - 2

INSTRUMENT CLUSTER

INSTRUMENT CLUSTER (Continued)

INSTRUMENT CLUSTER DIAGNOSIS

CONDITION

POSSIBLE CAUSES

CORRECTION

INSTRUMENT CLUSTER
INOPERATIVE. NO
RESPONSE FROM
INSTRUMENT CLUSTER.

NO PCI BUS MESSAGES
FROM THE BCM.

USE A DRB III

SCAN TOOL TO CHECK THE BCM.

IF OK, LOOK FOR ANOTHER POSSIBLE CAUSE
FOR CLUSTER FAILURE. IF NOT OK, REFER TO
THE PROPER BODY DIAGNOSTIC PROCEDURES
MANUAL.

SPREAD TERMINAL(S)
ON WIRING HARNESS
CLUSTER CONNECTOR.

REMOVE CLUSTER FROM INSTRUMENT PANEL
AND CHECK WIRING HARNESS CONNECTOR FOR
SPREAD TERMINAL. IF OK, LOOK FOR ANOTHER
POSSIBLE CAUSE FOR THE CLUSTER FAILURE. IF
NOT OK, REPAIR CONNECTOR.

BCM IS NOT RECEIVING
PROPER INPUT FROM
THE IGNITION SWITCH.

1. USE A DRB III

SCAN TOOL TO VERIFY IGNITION

SWITCH STATUS INTO THE BCM. IF NOT OK, GO
TO STEP (2). IF OK, LOOK AT ANOTHER POSSIBLE
CAUSE OF FAILURE.

2. CHECK IGNITION SWITCH FUNCTION AND
WIRING.

INTERNAL CLUSTER
FAILURE.

REPLACE CLUSTER.

WAKE UP CIRCUIT
FAULTY.

VERIFY CONTINUITY OF WAKE UP CIRCUIT FROM
BCM TO MIC. CIRCUIT SHALL BE LOW WHENEVER
BCM IS AWAKE.

POWER OR GROUND
MISSING.

IF NO RESPONSE FROM THE MIC, CHECK FOR
POWER AND GROUND AT THE MIC CONNECTOR.
REFER TO WIRING DIAGRAMS FOR CONNECTOR
CALL OUTS.

INSTRUMENT CLUSTER

8J - 3

INSTRUMENT CLUSTER (Continued)

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